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MAINTENANCE PROCEDURES

228

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”.

a - CHANGE THE HYDRAULIC OIL AND CLEAN THE INTAKE FILTER

For further details, see paragraph “EVERY 2000 HOURS”.

WEAM012405

Foreword 1.1 Foreword3
Information on Safety4
Introduction7
- Intended Use of the Machine7
- Demolition Work7
- Improper or Unauthorized Uses7
- Main Characteristics8
- Running-In8
- Positions and Directions of the Machine9
Product Identification10
- Machine Serial Number10
- Machine Identification Plate and Product Identification Number (Pin)10
  - MACHINE SERIAL NUMBER PLATE (According Directive 2006/42/EC)11
- Engine Serial Number and Exhaust Gas Emission Plate12
- Travel Reduction Gear Serial Number12
- Swing Reduction Gear Serial Number13
- Cab Serial Number13
- DECLARATION of CONFORMITY (for Machines Placed on the Market as from 29 December 2009)14
Komtrax System15
- General Precautions15
- Table of Contents17
Safety and Accident Prevention25
Safety, Noise and Vibration Plates26
- Position of the Safety Plates26
- Pictograms and Relevant Meanings27
- Position of the Noise Plates on Machines with Canopy37
- Position of the Noise Plates on Machines with Cab38
- Vibrations to Which the Operator Is Subjected39
General Precautions41
- General Safety Rules41
- How to Behave in Case of Anomalies41
- Safety Devices and Guards41
- Clothing and Personal Protection Items41
- Unauthorized Modifications42
- Leaving the Operator Seat42
- Emergency Exit43
- Getting on and off the Machine44
- Is Forbidden to Climb on the Equipment45
- Articulated Parts45
- Lifting of Personnel Prohibited45
- Preventing Fires Due to Fuel and Oil45
- Preventing Burns46
- Preventing Fires Caused by Accumulated Inflammable Material46
- Fires Caused by Electrical Wiring46
- How to Behave in Case of Fire46
- Detergent for the Windows46
- Asbestos Dust Hazard Prevention47
- Preventing Damage Caused by the Work Equipment47
- Fire Extinguishers and First Aid Kit47
- Falling Objects, Flying Objects and Intruding Objects Prevention48
- Cautions Related to Rops49
  - ROPS (Canopy Specification)49
  - ROPS (Cab Specification)49
- Precautions Concerning the Equipment49
Precautions to be Taken before Starting the Engine50
- Safety at the Work Site50
- Fire Prevention50
- Precautions Concerning the Operator Seat50
- Room Ventilation51
- Precautions to be Taken for the Lights51
- Cab Windows51
- Cleaning the Windows and Checking the Windshield Wiper Blades51
Precautions to be Taken When Working52
- Starting the Engine52
- Check the Direction before Starting the Machine52
- Hand Signals53
- Checks for Travelling in Reverse58
- Moving the Machine58
- Moving on Slopes59
- Working on Slopes60
- Unauthorized Operations60
- Preventing Electrocution62
- Visibility63
- Working on Icy or Snow-Covered Surfaces63
- Preventing Damage Caused by the Work Equipment63
- Working on Loose Ground63
- Parking the Machine64
Transporting the Machine on Motor Vehicles65
- Loading and Unloading the Machine65
- Transporting the Machine65
Battery66
- Preventing Risks that May be Due to the Battery66
- Starting with Booster Cables67
Precautions for the Removal of the Machine68
Precautions for Maintenance69
- Warning Plates69
- Tools69
- Stability69
- Maintenance Staff69
- Equipment70
- Working under the Machine70
- Cleaning the Machine70
- Use of the Engine During Maintenance71
- Periodical Change of the Parts that Are Critical for Safety71
- Stability71
- Stop the Engine before Carrying out any Maintenance Operation or72
  - Inspection72
- Battery Main Switch Precautions72
- Rules to be Followed When Refuelling or Adding Oil73
- Checking the Coolant Level in the Radiator73
- Using Lamps73
- Precautions to be Taken When Handling the Battery and the  Alternator74
- Precautions Concerning the Starter74
- Handling High-Pressure Hoses74
- Precautions to be Taken When Handling High-Pressure Oil75
  - High Pressure75
- Precautions to be Taken When Using High-Pressure Grease to76
  - Adjust the Track Tension76
- Do Not Remove the Shock Absorbing Spring from the Shock76
  - Absorber Unit76
- Hydraulic Accumulator76
- Cooling Fan and Belt77
- Chemical Hazard77
- Waste Materials77
- Compressed Air77
  - Elastomers78
- Precautions to be Taken When Using Synthetic Biodegradable Oil78
  - Type Hees78
- Final Disposal of the Machine78
The Machine and Its Operations79
Machine Illustrations80
- Overall View of the Machine80
- Controls and Gauges81
Instruments and Controls82
- Warning Lights and Gauges82
- Switches and Push Buttons87
- Control Levers and Pedals92
- CAB (if Provided)100
- Coverswith Lock105
- Engine Hood106
- Radiator Cover107
- Battery Cover108
- TILTING the CAB FLOOR (Machines with Canopy)109
- TILTING the CAB FLOOR (Machines with Cab)112
- Fuses116
- Main Fuse117
- Technical Documentation Compartment117
- Tool Box117
Use of the Machine and Related Controls118
- Before Starting the Engine118
- Starting the Engine130
  - Starting with Warm Engine or in Warm Climates130
  - Starting with Cold Engine or in Cold Climates132
- After Starting the Engine134
  - Running in a New Machine134
  - Warming-Up Operations135
- Stopping the Engine137
- How to Move the Machine138
- Steering the Machine142
  - Steering (Changing Direction)142
- Swinging the Turret144
- Work Equipment Controls and Functions145
- Unauthorized Operations148
- Precautions for Use150
- Precautions to be Taken When Travelling on Slopes152
- Getting the Machine out of Mud154
- Operations that Can be Performed with the Hydraulic Excavator155
- Changing the Bucket157
- Parking the Machine158
- Checking the Machine Every Day after Work160
  - Before Stopping the Engine160
  - After Stopping the Engine160
- Locking the Machine160
- RUBBER TRACKS (Machines Equipped with Rubber Tracks Only)161
Transporting the Machine166
- Transport Procedure166
- Loading and Unloading the Machine166
- Lifting the Machine173
Using the Machine in the Cold Season176
- Precautions to be Taken When Using the Machine in the Cold Season176
- Ventilation and Heating178
- Precautions to be Taken Every Day at the End of Work179
- How to Proceed at the End of the Cold Season179
Long Periods of Inactivity180
- Before a Period of Inactivity180
- During a Period of Inactivity180
- After a Period of Inactivity181
- Recommendations for Machines Equipped with Komtrax System During Long Periods of Inactivity181
- Ambient Temperature Range for Operation and Long Term Storage181
Troubleshooting182
- If Fuel Runs out Completely182
- Occurrences that Are Not Failures182
- Removing the Machine182
- Precautions to be Taken When Working in Particular Conditions183
- If the Battery Is down183
- Other Troubles187
Maintenance191
Guide to Maintenance192
Maintenance Notes194
- Oil, Fuel and Coolant194
- Notes on the Maintenance of the Electrical System198
- Notes on the Maintenance of the Hydraulic System198
- Maintenance Notes Regarding Lubrication198
Parts Subject to Wear199
- List of the Parts Subject to Wear199
Fuel, Coolant and Lubricants200
- Coolant201
- Approved Synthetic Biodegradable Lubricants Type Hees202
Tightening Torques203
- Standard Tightening Torques for Screws and Nuts203
- Standard Tightening Torques for Hoses with Orfs204
Lubrication205
- Lubrication Diagram205
Periodical Change of Safety-Related Components206
- Safety-Related Parts207
Maintenance Plan208
- Maintenance Intervals in Case of Use of the Hydraulic Breaker210
Maintenance Procedures211
- When Required211
- Checks to be Carried out before Starting the Engine227
- MAINTENANCE after the FIRST 50 HOURS of OPERATION (Only for Machines in Which Synthetic Biodegradable Oil Type HEES Is Used)227
- Maintenance after the First 50 Hours of Operation227
- Maintenance Every 100 Hours of Operation228
  - Lubrication228
- MAINTENANCE after the FIRST 500 HOURS of OPERATION (Only for Machines in Which Synthetic Biodegradable Oil Type HEES Is Used)230
- Maintenance after the First 500 Hours of Operation230
- Maintenance Every 500 Hours of Operation231
- Maintenance Every 1000 Hours of Operation236
Type HEES Is Used)")239
THE HYDRAULIC OIL TANK (Only for Machines in Which Synthetic Biodegradable Oil239
- Maintenance Every 2000 Hours of Operation239
End of Service Life243
Technical Specifications246
Lifting Capacities248
Authorized Optional Equipment253
General Precautions for Safety254
- Precautions When Selecting254
- Read the Instruction Manual Thoroughly254
- Precautions When Removing or Installing254
- Precautions When Using255
Specifications256
- Arm-Pin Information256
Attachment Guide257
- Combinations of Work Equipment257
- Attachment Configuration257
Machine Configuration for the Installation of Attachments259
- Position of the Devices259
- Hydraulic Circuit261
PREPARATION for EQUIPMENT INSTALLATION (Only for Machines with Proportional Controls)263
- Position of the Devices263
- Work Equipment Control Levers268
- Lifting Capacities Tables269
- Hydraulic Circuit271
- Using the Equipment273
  - When Using Hammer273
- Long Periods of Inactivity274
- Specifications274
- Programming the Control Unit275
Hydraulic Quick Coupler (Single-Effect)276
- Position of the Devices277
- Functioning278
Operating the Equipment280
- Long Periods of Inactivity281
Precautions to be Taken When Using Optional Equipment282
- Hydraulic Breaker282

Brand	Komatsu
Model	PC16R-3
Category	Excavators
Language	English

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