Komatsu PC16R-2 Hydraulic Excavator Operation and Maintenance Manual (WEAM007800)
On a small excavator like the Komatsu PC16R-2, usually working on tight sites, utilities, or landscaping, this Operation and Maintenance Manual is what I lean on to keep it earning without surprise breakdowns. It walks you through how to operate the machine correctly and then lay out a steady maintenance rhythm so pins, tracks, and hydraulics don’t get hammered early. If, for example, the boom starts moving a bit jerky or the machine feels weak on the controls, this is the book I use to verify basic checks, rule out simple operator or maintenance issues, and decide what needs a closer look.
Applications & Use Cases
- Plan routine services so filters, belts, and wear items are inspected before they cause downtime.
- Set up a maintenance log that follows Komatsu’s general service timing for this exact model.
- Trace early wear signs on undercarriage, work equipment, and hydraulics with guided inspection points.
- Verify correct operating practices for different ground conditions to reduce stress on the machine.
- Prepare the machine for storage or seasonal use, so it starts the next job without surprises.
FAQ
Q: Can I keep this manual on a tablet in the cab?
A: Yes, it’s handy to have a digital copy for quick checks, but keep it protected from dust and vibration.
Q: Is it worth printing certain pages?
A: I’d print the daily/weekly check pages and keep them in a binder so operators can tick them off on site.
Safety Note
Always follow the manual’s safety instructions before inspecting, adjusting, or working under any raised component.
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
- 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
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