Komatsu PC16R-2 Hydraulic Excavator Index:

• 1.1 FOREWORD
• 1.2 INFORMATION ON SAFETY
• 1.3 INTRODUCTION
  • 1.3.1 INTENDED USE OF THE MACHINE
  • 1.3.2 IMPROPER OR UNAUTHORIZED USES
  • 1.3.3 MAIN CHARACTERISTICS
  • 1.3.4 RUNNING-IN
  • 1.3.5 POSITIONS AND DIRECTIONS OF THE MACHINE
• 1.4 PRODUCT IDENTIFICATION
  • 1.4.1 MACHINE SERIAL NUMBER
  • 1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
  • 1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
  • 1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER
  • 1.4.5 SWING REDUCTION GEAR SERIAL NUMBER
  • 1.4.6 SERIAL NUMBERS AND DEALER’S ADDRESS
• TABLE OF CONTENTS
• 2.1 SAFETY, NOISE AND VIBRATION PLATES
  • 2.1.1 POSITION OF THE SAFETY PLATES
  • 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS
  • 2.1.3 POSITION OF THE NOISE PLATES
  • 2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
• 2.2 GENERAL PRECAUTIONS
  • 2.2.1 GENERAL SAFETY RULES
  • 2.2.2 SAFETY DEVICES AND GUARDS
  • 2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS
  • 2.2.4 UNAUTHORIZED MODIFICATIONS
  • 2.2.5 LEAVING THE OPERATOR SEAT
  • 2.2.6 GETTING ON AND OFF THE MACHINE
  • 2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL
  • 2.2.8 PREVENTING BURNS
  • 2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER
  • 2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
  • 2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT
  • 2.2.12 PRECAUTIONS CONCERNING THE ROPS STRUCTURE
  • 2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT
• 2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE
  • 2.3.1 SAFETY AT THE WORK SITE
  • 2.3.2 FIRE PREVENTION
  • 2.3.3 PRECAUTIONS CONCERNING THE OPERATOR SEAT
  • 2.3.4 ROOM VENTILATION
  • 2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS
• 2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING
  • 2.4.1 STARTING THE ENGINE
  • 2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE
  • 2.4.3 HAND SIGNALS
  • 2.4.4 CHECKS FOR TRAVELLING IN REVERSE
  • 2.4.5 MOVING THE MACHINE
  • 2.4.6 MOVING ON SLOPES
  • 2.4.7 WORKING ON SLOPES
  • 2.4.8 UNAUTHORIZED OPERATIONS
  • 2.4.9 PREVENTING ELECTROCUTION
  • 2.4.10 VISIBILITY
  • 2.4.11 WORKING ON ICY OR SNOW-COVERED SURFACES
  • 2.4.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
  • 2.4.13 WORKING ON LOOSE GROUND
  • 2.4.14 PARKING THE MACHINE
• 2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES
  • 2.5.1 LOADING AND UNLOADING THE MACHINE
  • 2.5.2 TRANSPORTING THE MACHINE
• 2.6 BATTERY
  • 2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY
  • 2.6.2 STARTING WITH BOOSTER CABLES
• 2.7 PRECAUTIONS FOR THE REMOVAL OF THE MACHINE
• 2.8 PRECAUTIONS FOR MAINTENANCE
  • 2.8.1 WARNING PLATES
  • 2.8.2 TOOLS
  • 2.8.3 MAINTENANCE STAFF
  • 2.8.4 EQUIPMENT
  • 2.8.5 WORKING UNDER THE MACHINE
  • 2.8.6 CLEANING THE MACHINE
  • 2.8.7 USE OF THE ENGINE DURING MAINTENANCE
  • 2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY
  • 2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION
  • 2.8.10 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL
  • 2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR
  • 2.8.12 USING LAMPS
  • 2.8.13 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR
  • 2.8.14 PRECAUTIONS CONCERNING THE STARTER
  • 2.8.15 HANDLING HIGH-PRESSURE HOSES
  • 2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL
  • 2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE
  • 2.8.18 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE TRACK TENSION
  • 2.8.19 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT
  • 2.8.20 HYDRAULIC ACCUMULATOR
  • 2.8.21 COOLING FAN AND BELT
  • 2.8.22 WASTE MATERIALS
  • 2.8.23 COMPRESSED AIR
  • 2.8.24 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS
  • 2.8.25 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE HEES
• 3.1 MACHINE ILLUSTRATIONS
  • 3.1.1 OVERALL VIEW OF THE MACHINE
  • 3.1.2 CONTROLS AND GAUGES
• 3.2 INSTRUMENTS AND CONTROLS
  • 3.2.1 WARNING LIGHTS AND GAUGES
    • 3.2.1.1 EMERGENCY WARNING LIGHTS
    • 3.2.1.2 GAUGES
    • 3.2.1.3 WARNING LIGHTS
  • 3.2.2 SWITCHES AND PUSH BUTTONS
  • 3.2.3 CONTROL LEVERS AND PEDALS
  • 3.2.4 COVERSWITH LOCK
  • 3.2.5 ENGINE HOOD
  • 3.2.6 RADIATOR COVER
  • 3.2.7 BATTERY COVER
  • 3.2.8 TILTING THE CAB FLOOR
  • 3.2.9 FUSES
  • 3.2.10 MAIN FUSE
  • 3.2.11 TECHNICAL DOCUMENTATION COMPARTMENT
  • 3.2.12 TOOL BOX
• 3.3 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
  • 3.3.2 STARTING THE ENGINE
    • 3.3.2.1 STARTING WITH WARM ENGINE OR IN WARM CLIMATES
    • 3.3.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES
  • 3.3.3 AFTER STARTING THE ENGINE
    • 3.3.3.1 RUNNING IN A NEW MACHINE
    • 3.3.3.2 WARMING-UP OPERATIONS
  • 3.3.4 STOPPING THE ENGINE
  • 3.3.5 HOW TO MOVE THE MACHINE
    • 3.3.5.1 PRELIMINARY OPERATIONS TO BE CARRIED OUT BEFORE MOVING THE MACHINE
    • 3.3.5.2 MOVING THE MACHINE FORWARD
    • 3.3.5.3 MOVING THE MACHINE IN REVERSE
    • 3.3.5.4 STOPPING THE MACHINE
  • 3.3.6 STEERING THE MACHINE
    • 3.3.6.1 STEERING (CHANGING DIRECTION)
  • 3.3.7 SWINGING THE TURRET
  • 3.3.8 WORK EQUIPMENT CONTROLS AND FUNCTIONS
  • 3.3.9 UNAUTHORIZED OPERATIONS
  • 3.3.10 PRECAUTIONS FOR USE
  • 3.3.11 PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES
  • 3.3.12 GETTING THE MACHINE OUT OF MUD
  • 3.3.13 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR
  • 3.3.14 CHANGING THE BUCKET
  • 3.3.15 PARKING THE MACHINE
  • 3.3.16 CHECKING THE MACHINE EVERY DAY AFTER WORK
    • 3.3.16.1 BEFORE STOPPING THE ENGINE
    • 3.3.16.2 AFTER STOPPING THE ENGINE
  • 3.3.17 LOCKING THE MACHINE
  • 3.3.18 RUBBER TRACKS (Machines equipped with rubber tracks only)
    • 3.3.18.1 OPTIMAL USE OF THE RUBBER TRACKS
    • 3.3.18.2 WARRANTY ON RUBBER TRACKS
    • 3.3.18.3 USE OF THE RUBBER TRACKS
    • 3.3.18.4 HOW TO PRESERVE THE RUBBER TRACKS OVER TIME
• 3.4 TRANSPORTING THE MACHINE
  • 3.4.1 TRANSPORT PROCEDURE
  • 3.4.2 LOADING AND UNLOADING THE MACHINE
  • 3.4.3 LIFTING THE MACHINE
• 3.5 USING THE MACHINE IN THE COLD SEASON
  • 3.5.1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON
    • 3.5.1.1 FUEL AND LUBRICANTS
    • 3.5.1.2 COOLANT
    • 3.5.1.3 BATTERY
  • 3.5.2 PRECAUTIONS TO BE TAKEN EVERY DAY AT THE END OF WORK
  • 3.5.3 HOW TO PROCEED AT THE END OF THE COLD SEASON
• 3.6 LONG PERIODS OF INACTIVITY
  • 3.6.1 BEFORE A PERIOD OF INACTIVITY
  • 3.6.2 DURING A PERIOD OF INACTIVITY
  • 3.6.3 AFTER A PERIOD OF INACTIVITY
• 3.7 TROUBLESHOOTING
  • 3.7.1 IF FUEL RUNS OUT COMPLETELY
  • 3.7.2 OCCURRENCES THAT ARE NOT FAILURES
  • 3.7.3 REMOVING THE MACHINE
  • 3.7.4 PRECAUTIONS TO BE TAKEN WHEN WORKING IN PARTICULAR CONDITIONS
  • 3.7.5 IF THE BATTERY IS DOWN
    • 3.7.5.1 REMOVING AND INSTALLING THE BATTERY
    • 3.7.5.2 CHARGING THE BATTERY
    • 3.7.5.3 STARTING WITH BOOSTER CABLES
  • 3.7.6 OTHER TROUBLES
    • 3.7.6.1 ELECTRICAL CIRCUIT
    • 3.7.6.2 FRAME
    • 3.7.6.3 ENGINE
• 4.1 GUIDE TO MAINTENANCE
• 4.2 MAINTENANCE NOTES
  • 4.2.1 OIL, FUEL AND COOLANT
    • 4.2.1.1 OIL
    • 4.2.1.2 FUEL
    • 4.2.1.3 COOLANT
    • 4.2.1.4 KOWA (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
  • 4.2.4 MAINTENANCE NOTES REGARDING LUBRICATION
• 4.3 PARTS SUBJECT TO WEAR
  • 4.3.1 LIST OF THE PARTS SUBJECT TO WEAR
• 4.4 FUEL, COOLANT AND LUBRICANTS
  • 4.4.1 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES
• 4.5 TIGHTENING TORQUES
  • 4.5.1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS
  • 4.5.2 STANDARD TIGHTENING TORQUES FOR HOSES WITH ORFS
• 4.6 LUBRICATION
  • 4.6.1 LUBRICATION DIAGRAM
• 4.7 PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS
  • 4.7.1 SAFETY-RELATED PARTS
• 4.8 MAINTENANCE PLAN
  • 4.8.1 MAINTENANCE PLAN
  • 4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER
    • 4.8.2.a CHANGING THE HYDRAULIC OIL FILTER
    • 4.8.2.b CHANGING THE HYDRAULIC OIL
• 4.9 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
    • 4.9.1.f CHECKING THE RUBBER TRACKS
    • 4.9.1.g CHECKING AND ADJUSTING THE RUBBER TRACK TENSION
    • 4.9.1.h CHANGING THE RUBBER TRACKS
    • 4.9.1.i BLEEDING THE HYDRAULIC SYSTEM
  • 4.9.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE
  • 4.9.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)
  • 4.9.4 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)
  • 4.9.5 MAINTENANCE EVERY 500 HOURS OF OPERATION
    • 4.9.5.a LUBRICATION
    • 4.9.5.b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE
    • 4.9.5.c CHANGING THE FUEL FILTER CARTRIDGE
    • 4.9.5.d CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS
    • 4.9.5.e CHECKING AND CLEANING THE FINS OF THE RADIATOR AND OF THE EXCHANGER
    • 4.9.5.f CHECKING AND ADJUSTING THE FAN BELT TENSION
    • 4.9.5.g DRAINING THE HYDRAULIC OIL TANK (Only for machines in which synthetic biodegradable oil type HEES is used)
  • 4.9.6 MAINTENANCE EVERY 1000 HOURS OF OPERATION
    • 4.9.6.a CHANGING THE HYDRAULIC OIL FILTER
    • 4.9.6.b CHANGING THE OIL IN THE FINAL REDUCTION GEARS
    • 4.9.6.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE
  • 4.9.7 MAINTENANCE EVERY 2000 HOURS OF OPERATION
    • 4.9.7.a CHANGING THE OIL IN THE HYDRAULIC TANK AND CLEANING THE FILTER
    • 4.9.7.b CHANGING THE COOLANT
    • 4.9.7.c CHECKING THE ALTERNATOR AND THE STARTER
• 5.1 TECHNICAL DATA
• 5.2 LIFTING CAPACITIES
  • 5.2.1 LIFTING CAPACITIES
• 6.1 AUTHORIZED OPTIONAL EQUIPMENT
  • 6.1.1 PRECAUTIONS REGARDING SAFETY
  • 6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT
  • 6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT
    • 6.1.3.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT
• 6.2 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS
  • 6.2.1 POSITION OF THE DEVICES
  • 6.2.2 HYDRAULIC CIRCUIT
    • 6.2.2.1 INSTALLING AND CONNECTING THE EQUIPMENT
    • 6.2.2.2 MAINTENANCE
    • 6.2.2.3 BLEEDING
• 6.3 OPERATING THE EQUIPMENT
  • 6.3.1 LONG PERIODS OF INACTIVITY
• 6.4 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT
  • 6.4.1 HYDRAULIC BREAKER