Komatsu PC110R-1 Maintenance Manual
WEAM000402
Operation & Maintenance
Manual
PC110R-1
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PC110R-1 2265010001 and up
WARNING
Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or maintaining this machine.
This manual should be kept inside the cab for reference and periodically reviewed by all personnel who
will come into contact with the machine.
FOREWORD
CAUTION
1.1 FOREWORD
• This manual has been carried out by Komatsu Utility in order to supply their customers with all the necessary in-
formation on the machine and the safety regulations related to it, together with the use and maintenance instructions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine
efficient over time.
• The operation manual, to gether wi th the spare parts cata logue, is an integral part of the machine a nd must ac-
company it, even when it is resold, until its final disposal.
• The manual must be handled with the greatest care and always kept on board the machine, so that it can be con-
sulted at any moment; it must be placed in the appropriate compartment behind the seat, where also the ownership documents and the logbook are usually kept.
• This manual must be given to the p ersons who have to use the m achin e and ca rry out th e routine m aintena nce
operations; they mus t read th e contents c arefully m ore than once, in such a wa y as to c learly u nderstand wh at
are the correct operating conditions and the dangerous conditions that must be avoided.
In case of loss or damage, request a new copy to Komatsu Utility or your Komatsu Utility Dealer.
• The illustrations contained in this manual may represent machine configurations available on request.
The machines are c onstantly upgra ded in order to i ncrease their efficiency and re liability; this m anual sums u p
all the information regardi ng the sta te of techn ical pro gress at th e moment i n which th e machine is launc hed on
the market.
Consult your Komatsu Utility Dealer for any updated information.
• Punctual periodic annotations regarding the maintenance operations that have been carried out are important to
have a clear prospect of the situation and to know exactly what has been done and what has to be done after the
next maintenance in terva l. Therefo re, i t is advisa ble t o con sult either th e H our mete r and the m ainten ance plan
frequently.
• Over the years Komatsu Utility Dealers have gathered considerable experience in customer service.
If more information is needed , do not hesitate to contact your Kom atsu Utility Dealer: he alway s knows how to
get the best performance from the machine, he can s uggest the use of the equ ipment that is most suit able for
specific needs and can provide the tec hnical assistance ne ce ss ary for a ny ch ang e th at m ay be re qui red to conform the machine to the safety standards and traffic rules.
Furthermore, Komatsu Utility Dealers also ensure their assistance for the supply of Komatsu Utility genuine
spare parts, which alone guarantee safety and interchangeability.
• The table included in this manual must be filled in with the machine data, which are the data that must always be
indicated to the Dealer when requiring assistance and ordering spare parts.
• Improper operation and maintenance of this machine may be hazardous and cause serious injuries and
even death.
• Operators and maintenance personnel must carefully read this manual before us ing the machine or per-
forming maintenance operations.
• Some actions involved in the operation and mainten ance of t he machine may cause serious injuries or
even death, if they are not performed in compliance with the instructions given herein.
• The procedures and precautions described in this manual are valid for application to the machine only
when it is used correctly.
If the machine is used for any purpose or in any way other than those described herein, the operator
shall be responsible for his own safety and for the safety of any other person involved.
1
INFORMATION ON SAFETY
IMPORTANT
☞
1.2 INFORMATION ON SAFETY
Many accidents are c aused by insufficient knowledge of an d failure to comply with the safety regulations prescribed for the maintenance operations that must be performed on the machine.
In order to avoid accidents, before starting work and before carrying out any maintenance operation, carefully read
and be sure to under stand a ll the infor mation a nd warnings contain ed in thi s manual a nd given on the pl ates applied onto the machine.
To identify the messages rega rding safet y that ar e inclu ded in this manual and wri tten on the mac hine plates, th e
following words have been used.
DANGER
CAUTION
Komatsu Utility can not r e aso nab ly predict every circums tan ce that mi ght inv ol ve a p oten tia l h az ar d du ring the operation or maintenan ce of the m achine; for this reas on, the sa fety mess ages in cluded in th is manua l and a pplied
onto the machine may not include all possible safety precautions.
If all the procedures and operations prescribed for this machine are kept to, you can be sure that the operator and
the persons in the vicinity will work in total safety, with no risk of damaging the machine. In case of doubt regarding
the safety measures necessary for some procedures, contact Komatsu Utility or your local Dealer.
• This word is used in the safety warnings in the manual and on the plates when
the situation is dangerous and it may possibly result in serious injuries or even
death.
These messages describe the safety precautions to be taken in order to avoid
any risk. Non-compliance with these instructions may also result in serious damage to the machine.
• This word is used in the safety warnings in the manua l and on the pla tes to signal
risks that may cause moderate damage or injuries.
The message can be used even to indicate the risk of damage to the machine only.
• This word is used wh en preca u tions ar e ind ic ated , wh ic h mu st b e taken to a void
actions that may shorten the life of the machine.
DANGER
• Before starting any maintenan ce operation, position the machine on a firm and level sur face, lower the
equipment to the ground, engage the safety locks of the equipment and of the controls and stop the engine.
DANGER
• To make the information clearer, some illustrations in this manual represent the machine without safety
guards. Do not use the machine without guards and do not start the engine when the engine protection
casing is open, if this is not expressly prescribed for some specific maintenance operations.
2
INFORMATION ON SAFETY
DANGER
DANGER
DANGER
• It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu Utility cannot
be held liable for any damage to persons, property or the machine, if this has been tampered with by
modifying the standard setting of the hydraulic system.
• Before carrying out any e lectrical welding, disco nnect the battery and the al ternator (See “2.8.13 PR E-
CAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR”).
• Install only authorized additional equipment (See “6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIP-
MENT”).
3
INTRODUCTION
IMPORTANT
1.3 INTRODUCTION
1.3.1 INTENDED USES
The Komatsu Utility MACHINES described in this manual have been designed and constructed to be used by duly
trained personnel mainly for EXCAVATION and EARTH-MOVING OPERATIONS.
If provided with suitable safety devices, they can be used with authorized optional equipment having the characteristics illustrated at point “6.1 AUTHORIZED OPTIONAL EQUIPMENT”.
1.3.2 IMPROPER OR UNAUTHORIZED USE
CAUTION
• This paragraph describes some of the improper or unauthorized uses of the machine; since it is impos-
sible to predict all the possible improper uses, if the machine happens to be used for particular applications, contact your Komatsu Utility Dealer before carrying out the work.
• The instructions regarding the authorized optional equipment are given in the relevant operation and
maintenance manuals; if the equipment is supplied by Komatsu Utility, these publications are enclosed
to this manual.
• The instructions regarding the assembly of the authorized equipment, the controls requiring special ar-
rangements on the machine and the hydraulic couplings necessary for the operation of the equipment
are grouped in the final section of this manual.
Komatsu Utility MACHINES are constructed exclusively for the handling, excavation and treatment of inert materials; therefore, the following uses are absolutely forbidden:
• USE OF THE MACHINE BY MINORS OR INEXPERIENCED PERSONS.
• USE OF THE MACHINE FOR LIFTING PERSONS OR OBJECTS.
• TRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS.
• USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.
• USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.
4
INTRODUCTION
1.3.3 MAIN CHARACTERISTICS
• Simple and easy operation.
• Hydrostatic transmission obtained through two variable displacement motors that operate epicyclic reduction
gears equipped with hydraulic brakes with negative control.
• Upper structure rotation achieved through an axial piston hydraulic motor acting on an epicyclic reduction gear.
• Lubrication of the ball-bearing ring toothing and of the pinion in grease bath.
• Main equipment servo levers ensuring also combined movements that can be modulated proportionally and con-
tinually.
• Boom swing and travel controls with s ervo assiste d pedals that ens ure proportiona l and continu ous modulate d
movements.
• Travel speed increase by means of a button.
• Servo controls also for the two-piece boom and the blade.
• Complete series of instruments visible from the operating position.
• Lever accelerator.
• Easy maintenance with simplified intervals.
1.3.4 RUNNING-IN
Every machine is scrupulously adjusted and tested before delivery.
A new machine, however, must be used carefully for the first 100 hours, in order to ensure proper running-in of the
various components.
If the machine is subjected to excessive work load at the beginning of operation, its potential yield and its functionality will be untimely reduced.
Every new machine must be used carefully, paying special attention to the following indications:
• After the start, let the engine idle for 5 minutes, in such a way as to warm it up gradually before actual operation.
• Avoid operating the machine with the limit loads allowed or at high speed.
• Avoid abrupt starts or accelerations, useless sudden decelerations and abrupt reversals.
• After the first 250 hours, carry out the following operations, in addition to those to be performed every 250 hours:
1 - Change the oil in the travel reduction gears.
2 - Change the oil in the swing reduction gear.
3 - Change the hydraulic circuit oil filter.
4 - Check and adjust the engine valve clearance.
SYNTHETIC BIODEGRADABLE OIL TYPE HEES
On machines in whi ch the s ynthetic bi odegrad able oil ty pe HEES is used, th e following o peration s are to be performed besides the standard maintenance operations:
• After the first 50 hours of operation, change the hydraulic circuit drain filter.
• After the first 500 hours of operation, change the hydraulic circuit oil.
IMPORTANT
• When changing the oil filters (cartridges), check their innner part to make sure that there are no depos-
its.
If considerable deposits are observed, find out what may have caused them before starting the machine.
• The number of operating hours is indicated by the Hour meter.
5
PRODUCT IDENTIFICATION
1.4 PRODUCT IDENTIFICATION
The Komatsu Utility EXCA VATOR 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 indicated
to the Dealer when requiring assistance and ordering spare parts.
1.4.1 MACHINE SERIAL NUMBER
The machine serial num ber is stamped on the front right par t of
the main frame.
RYA14760
1.4.2 MACHINE IDENTIFICATION PLATE
The Komatsu Utility EXCAVATORS described in this manual are
provided with the CE mark, which certifies that they are in compliance with the CE harmonized standards.
The plate with the mar k is applie d onto the fro nt wall of the main
frame, on the right side.
RYA14770
6
PRODUCT IDENTIFICATION
MODELLO - MODEL
TYP - MODELE
MATRICOLA N˚ - SERIAL N˚
FABR. NR. - SERIE NR.
ANNO - YEAR
BAUJAHR - ANNEE
MASSA TOTALE MAX - TOTAL MAX WEIGHT
ZUL. GESAMTGEWICHT - POIDS TOTAL MAX
POTENZA MOTORE - ENGINE POWER
LEISTUNG - PUISSANCE MOTEUR
MASSA MAX ASSE ANT. - MAX WEIGHT FRONT AXLE
ZUL. ACHSLAST VORN - POIDS MAX ESSIEU AV
MASSA MAX ASSE POST. - MAX WEIGHT REAR AXLE
ZUL. ACHSLAST HINTEN - POIDS MAX ESSIEU AR
MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A.
36025 NOVENTA VICENTINA (VI) ITALY
MODEL
SERIAL N
YEAR
TOTAL MAX WEIGHT
ENGINE POWER
MAX WEIGHT FRONT AXLE
MAX WEIGHT REAR AXLE
MANUFACTURED BY KOMATSU UTILITY EUROPE S.p.A.
36025 NOVENTA VICENTINA (VI) ITALY
kg
kw
kg
kg
21D-98-12580
RWA34270
kg
kw
kg
kg
1.4.3 NGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
The engine serial number is st amped on the plate positioned on
the upper side of the tappet cover.
The exhaust gas emis sion plate is applied to the front s ide of the
tappet cover.
RWA18500
RWAA9550
7
PRODUCT IDENTIFICATION
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER
The serial number of the travel red uction gear is stamped on the
plate positioned on the outer side of the reduction gear cover.
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER
The serial number of the swi ng reducti on gear is stamped on the
plate positioned on the side of the reduction gear body.
RWA18210
1.4.6 CAB SERIAL NUMBER
The cab serial number is sta mped on the plat e positioned on the
right side of the front base cross member.
RWAA11980
RWA09430
8
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS
Machine n. Model
Engine n.
Travel reduction gear n.
Swing reduction gear n.
Cab n.
Dealer:
PRODUCT IDENTIFICATION
Address
Person to contact:
NOTES:
Tel.
9
CONTENTS
Page
CONTENTS
1.1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 INFORMATION ON SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.1 INTENDED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.2 IMPROPER OR UNAUTHORIZED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.3 MAIN CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.4 RUNNING-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 PRODUCT IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.1 MACHINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.2 MACHINE IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.3 NGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE . . . . . . . . . . . . . . . . . . 7
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4.6 CAB SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SAFETY AND ACCIDENT PREVENTION
2.1 SAFETY, NOISE AND VIBRATION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.1 POSITION OF THE SAFETY PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1.3 POSITION OF THE NOISE PLATES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2 GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.1 GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.2 SAFETY DEVICES AND GUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.4 UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.5 LEAVING THE OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.6 GETTING ON AND OFF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2.8 PREVENTING BURNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT. . . . . . . . . . . . . . . . . . . . . 29
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.1 SAFETY ON THE WORK SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.2 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB. . . . . . . . . . . . . . . . . . . . . . . 30
2.3.4 ROOM VENTILATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING
THE WINDSHIELD WIPER BLADES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10
CONTENTS
Page
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4.1 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE. . . . . . . . . . . . . . . . . . . . . . 32
2.4.3 CHECKS FOR TRAVELLING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4.4 MOVING THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.4.5 MOVING ON SLOPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.4.6 WORKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4.7 UNAUTHORIZED OPERATIONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4.8 PREVENTING ELECTROCUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4.9 VISIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . 37
2.4.12 WORKING ON LOOSE GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4.13 PARKING THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.5.1 LOADING AND UNLOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.5.2 SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.6 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.6.2 STARTING WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.8.1 WARNING PLATES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.8.2 TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.8.3 PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.8.4 EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.8.5 WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.8.6 KEEPING THE MACHINE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.8.7 USE OF THE ENGINE DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY . . . . . . . . . . 44
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION
OR INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.8.10 RULES FOR REFUELLING AND ADDING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.8.12 USING LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR . . . . . . . . . . . . . 46
2.8.14 PRECAUTIONS CONCERNING THE STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . 47
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMSE . . . 47
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES
AND PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.8.18 COOLING FAN AND FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.8.19 WASTE MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.8.20 PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADABLE OIL
TYPE HEES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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DESCRIPTION AND USE OF THE MACHINE
3.1 SAFETY LOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.1.1 MACHINE LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.2 GENERAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.2.1 FRONT GENERAL VIEW (MONOBOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.2.2 FRONT GENERAL VIEW (TWO-PIECE BOOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.2.3 CAB INSIDE GENERAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.3 INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3.1 INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3.2 WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3.3 SWITCHES AND PUSH BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3.4 ELECTRICAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.3.5 MACHINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.4 FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4.1 CENTRAL UNIT FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4.1.1 CENTRAL UNIT FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.4.1.2 CENTRAL UNIT RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.4.2 ENGINE LINE FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.4.2.1 ENGINE LINE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.4.2.2 ENGINE LINE RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.4.3 FUSES AND RELAYS OF THE AIR CONDITIONING SYSTEM (if provided) . . . . . . . . . . . . 82
3.5 GUARDS AND DRIVER’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.5.1 ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.5.2 SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.5.3 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.5.4 VENTILATION AND HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.5.5 AIR CONDITIONER (if provided) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.5.6 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.5.7 SAFETY BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.5.8 EMERGENCY EXIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.5.9 TECHNICAL DOCUMENTATION CASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.5.10 FIRE EXTINGUISHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.5.11 FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.6 USE OF THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.6.1 CHECKS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.6.1.1 VISUAL CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.6.1.2 DAILY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.6.1.3 OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.6.2 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES . . . . . . . . . 97
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES . . . . . . . . . . . . . . . . 98
3.6.3 WARMING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.6.4 HEATING THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.6.5 HOW TO MOVE THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.6.5.1 STEERING (CHANGING DIRECTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.6.5.2 MOVING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.6.5.3 MAXIMUM IMMERSION DEPTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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3.7 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.7.1 PARKING ON LEVEL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.7.2 PARKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.8 STOPPING THE ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.9.1 LOADING AND UNLOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.9.2 TRANSPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.10.1 FUEL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.10.2 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.10.3 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.10.4 OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.12 USING THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.12.1 ORGANIZING THE WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.12.2 POSITIONING THE BUCKET ACCORDING TO THE WORK TO BE CARRIED OUT. . . . . . 112
3.12.3 POSITIONING THE MACHINE FOR DIGGING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . 113
3.12.4 DIGGING METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.12.5 CHANGING THE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.13 LONG PERIODS OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.13.1 BEFORE THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.13.2 DURING THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.13.3 AFTER THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.14 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.14.1 HOW TO REMOVE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.14.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.14.3 IF THE BATTERY IS DEPLETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.14.3.1 STARTING WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.14.4 OTHER TROUBLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.14.4.1 ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.14.4.2 HYDRAULIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.14.4.3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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MAINTENANCE
4.1 GUIDE TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.2 MAINTENANCE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2.1 NOTES REGARDING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2.1.1 ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2.1.2 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2.1.3 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.2.4 NOTES REGARDING LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING . . . . . . . . . . . . . . 131
4.3 FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS. . . . . . . . . . . . . . . 134
4.4 DRIVING TORQUES FOR SCREWS AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.4.1 STANDARD DRIVING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.4.2 SPECIFIC DRIVING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.5 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.5.1 LUBRICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY . . . . . . . . . . . . . . . 137
4.6.1 CRITICAL PARTS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.7 MAINTENANCE PLAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.7.1 WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE . . . 145
4.7.1.b CHECKING AND CLEANING THE CAB AIR FILTER . . . . . . . . . . . . . . . . . . . . . . 147
4.7.1.c CHECKING AND CLEANING THE AIR RECIRCULATION FILTER
(only for machines equipped with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.7.1.d CLEANING THE WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.7.1.e CHECKING THE STEEL TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.7.1.f CHECKING THE SHOE FASTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER . . . . . . . 153
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.7.2.b CHANGING THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.7.3 CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.7.3.a VARIOUS CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.7.3.b CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.7.3.c CHECKING THE FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.7.3.d CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . 156
4.7.3.f DRAINING THE WATER SEPARATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.7.4.a LUBRICATING THE JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION
(Only for machines in which the synthetic biodegradable oil type HEES is used) . . . . . . . . . 161
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4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.7.6.a CHECKING THE RADIATOR FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.7.6.b LUBRICATING THE SWING JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.7.6.c CHECKING THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.7.7 MAINTENANCE EVERY 100 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.7.7.a LUBRICATING THE BALL-BEARING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.7.8 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . 164
4.7.9 MAINTENANCE EVERY 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.7.9.a ADJUSTING THE FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.7.9.b ADJUSTING THE TENSION OF THE A/C COMPRESSOR BELT
(only for machines equipped with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.7.9.c CHECKING THE BATTERY ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . . 166
4.7.9.d CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS . . . . . . . . . 166
4.7.9.e CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR . . . . . . . . . . . 167
4.7.10 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION
(Only for machines in which the synthetic biodegradable oil type HEES is used) . . . . . . . . . 168
4.7.11 MAINTENANCE EVERY 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL FILTER . . . . . . . . . . . . . . . . . . . . . 168
4.7.11.b CHANGING THE SERVO CONTROL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.7.11.c CHANGING THE ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.7.11.d CHANGING THE ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.7.11.e CHANGING THE FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.7.11.f DRAINING THE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.7.11.g CLEANING THE OUTSIDE OF THE RADIATORS . . . . . . . . . . . . . . . . . . . . . . . . 174
4.7.11.h CLEANING THE OUTSIDE OF THE A/C CONDENSER
(only for machines equipped with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . 175
4.7.11.j CHECKING THE BALL-BEARING RING PINION LUBRICANT LEVEL . . . . . . . . 176
4.7.11.k DRAINING THE HYDRAULIC OIL TANK (Only for machines in which
the synthetic biodegradable oil type HEES is used) . . . . . . . . . . . . . . . . . . . . . . . 176
4.7.12 MAINTENANCE EVERY 1000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
4.7.12.a CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE . . . . . . . . . . 178
4.7.13 MAINTENANCE EVERY 2000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.7.13.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS . . . . . . . . . . . . . . . 179
4.7.13.b CHANGING THE OIL IN THE SWING REDUCTION GEAR . . . . . . . . . . . . . . . . . 180
4.7.13.c CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION
FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
4.7.13.d CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.7.13.e CHANGING THE BALL-BEARING RING PINION LUBRICANT . . . . . . . . . . . . . 185
4.7.13.f CHECKING THE ALTERNATOR AND THE STARTER . . . . . . . . . . . . . . . . . . . . 185
4.7.13.g CHECKING THE A/C COOLING GAS QUANTITY
(only for machines equipped with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.7.14 MAINTENANCE EVERY 4000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.7.14.a CHANGING THE A/C DEHYDRATOR FILTER
(only for machines equipped with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.7.14.b CHECKING THE CORRECT OPERATION OF THE A/C COMPRESSOR
(only for machines equipped with air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . 187
15
CONTENTS
Page
TECHNICAL DATA
5.1 TECHNICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5.1.1 STANDARD OVERALL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5.1.2 TECHNICAL CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5.1.3 LIFTING CAPACITIES
(Only for machines with overload alarm device) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.1.3.1 LIFTING CAPACITY TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.1.3.2 LIFTING CAPACITY WITH MONOBOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5.1.3.3 LIFTING CAPACITY WITH TWO-PIECE BOOM . . . . . . . . . . . . . . . . . . . . . . . . . 195
AUTHORIZED OPTIONAL EQUIPMENT
6.1 AUTHORIZED OPTIONAL EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
6.1.1 PRECAUTIONS REGARDING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT . . . . . . . . . . . . . . . . 199
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER . . . . . . . . . . . . . . . 201
6.2.1 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED. . . . . . . . . . . . . . . 201
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER . . . . . . . . . . . . . . . . . . . . . . . 205
6.2.3.1 INSTALLING THE HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6.2.3.2 REMOVING THE HAMMER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6.2.4 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6.3 CLAMSHELL BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6.3.1 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6.3.2 INSTALLING THE CLAMSHELL BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
6.3.3 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
16
SAFETY AND
ACCIDENT PREVENTION
17
SAFETY, NOISE AND VIBRATION PLATES
2.1 SAFETY, NOISE AND VIBRATION PLATES
2.1.1 POSITION OF THE SAFETY PLATES
• The safety plates must alway s be le gi ble and i n goo d co ndi ti ons ; for thi s reas on , if th ey are dir ty with dus t, oil or
grease, it is necessary to clean them with a solution made of water and detergent.
Do not use fuel, petrol or solvents.
• If the plates are damaged, ask for new ones to Komatsu Utility or to your Komatsu Utility Dealer.
• In case of replacemen t of a co mponent provided with a sa fety plate , ma ke su re that thi s p late is ap pli ed als o o n
the new piece.
• The machine can be provided with other plates in addition to those indicated below; keep also to the instructions
given in the additional plates, in any case.
18
RYA14780
SAFETY, NOISE AND VIBRATION PLATES
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS
The warning and danger plates applied onto the machine are accompanied or represented by pictograms.
The personnel in charge with th e ope ra tio n and mai nten ance of th e mac hi ne m us t know the sym bol s con tai ned i n
the pictograms perfectly; the following description illustrates what they look like and their respective meanings.
DANGER IN THE WORK AREA
• Do not approach or stand within the equipment operating radius
when the boom and the bucket are raised.
RWA00020
DO NOT OPEN THE HOOD
• Do not open or remove the hood while the engine is running.
CONSULT THE MANUAL
• Carefully read the co ntents of the manual bef ore using th e ma-
chine or performing maintenance operations.
RWA00010
RWA00030
19
SAFETY, NOISE AND VIBRATION PLATES
SAFETY DISTANCE
• Do not get near or stand within the machine working area.
FILLING THE HYDRAULIC SYSTEM WITH
OIL
RWA18280
(Only for machines in which the synthetic biodegradable oil
type HEES is used)
HYDRAULIC OIL TOPPING UP
REFUELLING
BIO-OIL
RWA00050
D
RWA00040
RWA34380
ENGINE LUBRICATING OIL FILTER
20
RWA00080
FUEL FILTER
ENGINE AIR SUCTION FILTER
ENGINE COOLANT PRESSURE
SAFETY, NOISE AND VIBRATION PLATES
D
RWA00060
RWA00090
HYDRAULIC OIL LEVEL
HYDRAULIC OIL FILTER
H
L
RWA00110
RYA12880
RWA00070
ELECTRIC OUTLET
RWA00120
12 V
21
SAFETY, NOISE AND VIBRATION PLATES
ANCHORAGE POINT
EMERGENCY EXIT
DO NOT LIFT MORE THAN 1000 KG
(Only for machine without overload warning device)
RWA00200
RWA00190
22
> 1000 Kg
RYA12890
2.1.3 POSITION OF THE NOISE PLATES
• The noise plates must always be legible and in good conditions;
for this reason, if they are dirt y wit h d ust, oil or grea se , it is n ecessary to clean the m with a solution ma de of water and deter gent.
Do not use fuel, petrol or solvents.
• If the plates are damaged, ask for new one s to Komatsu Utility
or to your Komatsu Utility Dealer.
• In case of replacement of a compon ent provided with a noise
plate, make sure that this plate is applied also on the new piece.
NOISE OUTSIDE THE CAB
• This value indicates the noise le vel outside the machine and re-
fers to the noise perceived by the persons who are in the vicinity
of the work area.
SAFETY, NOISE AND VIBRATION PLATES
RYA14790
NOISE INSIDE THE CAB
• This value indic ates the maxi mum noise lev el perceive d by the
operator’s ears inside the cab when this is completely closed.
10
3
2000/14/EC
7
6
ISO 6396
dB
dB
RYA12910
RYA14800
23
SAFETY, NOISE AND VIBRATION PLATES
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
• According to the results of the tests carried out to determine the vibrations transmitted to the operator by the ma-
chine, the upper limbs ar e su bjected to vi brations lower t han 2.5 m/sq. sec., while the seate d par t of the body is
subjected to vibrations lower than 0.5 m/sq.sec.
24
GENERAL PRECAUTIONS
2.2 GENERAL PRECAUTIONS
2.2.1 GENERAL SAFETY RULES
• Only trained and authorized personnel can use the machine and perform maintenance operations.
• Follow all the safety ru les, pr ec au tion s a nd in str u cti ons whe n us ing the ma ch ine or per for ming maintenance op-
erations.
• When working with other op erators or whe n the work site is of ten occupied by othe r operators, m ake 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.
2.2.2 SAFETY DEVICES AND GUARDS
• Make sure that all th e guards and covers ar e in the correct positio n. Have guards and co vers changed or re-
paired if damaged. Neither use the machine without guards, nor remove the guards when the engine is running.
• Always use the proper safety devices to lock the machine when parking and fasten the safety belt.
• For the safety devices, see “3.1 SAFETY LOCKS”.
• For the safety belt, see “3.5.6 SAFETY BELT”.
• Do not remove the safety devices and always keep them in good operating conditions.
• Improper use of the safety devices may result in serious injuries or even death.
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS
• Do not wear large or l oose clothes, rings and w atches and do
not approach the machine with lo ose long hair, since they can
get entagled in the moving parts of the machine and cause serious injuries and damage.
Avoid also wearing clothes dirty with oil or fuel , since they are
flammable.
• Wear a hard hat, goggles, safety shoes, mask, gloves and
headphones when operating the machine or performing maintenance operations.
• Always wear safety goggles, a hard hat and heavy gloves if your
job involves scattering metal chips or minute materials; these
precautions are particular ly useful when driving the equipment
connection pins with a hamm er and whe n blowing co mpressed
air into the air filter and the radiator to clean them.
During these operations, make also sure that no one is standing
or working near the machine without the necessary protections.
• When working for 8 ho ur s with a noise level exc ee din g 90 dB A,
it is necessary to use headphones or ear plugs and to be particularly careful, especially at the end of the work shift.
RWA00960
25
GENERAL PRECAUTIONS
r
2.2.4 UNAUTHORIZED MODIFICATIONS
• Any modification made without the authorization of Komatsu Utility can involve hazards.
• Before making a modification, consult your Komatsu Utility Dealer. Komatsu Utility declines any responsibility for
injuries or damage caused by unautho ri z ed modific ations.
2.2.5 LEAVING THE OPERATOR’S SEAT
• When leaving the operator’s seat, even if temporarily, make sure
that the machine i s in a safe position. (Se e “2.4.13 PARKING
THE MACHINE”).
• Before leaving the operator’s seat, carry out the following opera-
tions in the sequence indicated below:
1 - Rest the equipment onto the ground.
2 - Connect the safety devices of the boom swing control and
engage the upper structure rotation safety pin.
3 - Lock the equipment control by shifting the safety device leve
to the lock position.
4 - Stop the engine (See “3.8 STOPPING THE ENGINE”).
If you have to go so far a way that you will not be able to s ee the
machine, extract the ignition key.
RWA20720
26
RWA18590
RYA12930
2.2.6 GETTING ON AND OFF THE MACHINE
• Do not jump on or off the machine, either when it is at rest and
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.
• Never hold or rest on the control levers.
• Either when getting on and when getting off the machine, al-
ways maintain three points of contact (holding or resting points),
in order to avoid losing your balance and falling down.
• Tighten the handle connection screws if they are loose and
clean the handles and tracks if they are dirty with oil or grease.
Carefully clean the cab floor if it is dirty with oil, grease, mud or
rubble.
GENERAL PRECAUTIONS
RYA16180
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL
Fuel, oil and some types of antifreeze can be easily ignited if they
get in contact with a flame. Fuel is particularly flammable and
therefore extremely hazardous.
• Keep any naked flame away from flammable fluids.
• Stop the engine and do not smoke when refuelling.
• To p up with fuel and oil only after stopping the engine and in
well ventilated areas.
• Top up with fuel and oil in a well delimited area and do not allow
unauthorized persons to approach.
• When refuelling, hold th e fuel gun firmly and keep it constantl y
in contact with the filler until you hav e fi nishe d, in orde r to avoid
sparks due to static electricity.
• After topping up, tighten the safety caps of the fuel and oil tanks
securely.
RWA18670
RWA00970
• Do not fill the tank completely , in order to leave room for the fuel
to expand.
• In case some fuel is spilled, wipe it up immediately.
RWA00980
27
GENERAL PRECAUTIONS
2.2.8 PREVENTING BURNS
• If the engine coolant, the engine oil and the hydraulic oil are hot,
use heavy cloths a nd wear gloves, heavy clothing and safety
goggles before carrying out any check or touching the hot parts.
• Before checking the coo lant level, stop the engine and let the
fluid cool down.
If a check is necessary du e to the overheating of the engine,
slowly loosen the radiato r cap to releas e any residual p ressure
before removing it. The hot fluid that spurts out may cause serious burns.
• Before checking the engine oil and hydraulic circuit oi l levels,
stop the engine and let the oil cool down. The hot oil that can be
sprayed out of the tank may cause serious burns.
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER
RWA00990
• Asbestos powder can be hazardous to your health if it is in-
haled.
• If you handle materials containi ng asbestos fibers, keep to the
instructions given below:
1 - Do n ot use compressed air, but only aspirators to clean the
machine and make sure that the room in which you are
working is properly ventilated.
2 - Use low-pressure water to kee p down the dust when cl ean-
ing.
3 - If there is danger that there m ay be asbestos powder in the
air, operate the machine with the wind to your bac k when ev er possible.
4 - Even if the cab provides suitable protection, use an ap-
proved and homologated respira tor.
5 - The powder gathered during the cleaning operations must
be dampened and put in a sealed and marked container, so
that it can be safely d ispos ed of ac co rding to the regulations
in force.
RWA01000
RWA01010
28
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