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Komatsu PC16R-3HS User Manual

Komatsu PC16R-3HS
288 pages
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Operation & Maintenance
Manual
WEAM012405
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.
WARNING
PC16R-3HS
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PC16R-3 F60241 and up
PC16R-3
PC16R-3HS F72480 and up
ORIGINAL INSTRUCTIONS

Table of Contents

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Komatsu PC16R-3HS Specifications

General IconGeneral
BrandKomatsu
ModelPC16R-3HS
CategoryExcavators
LanguageEnglish

Summary

Komatsu Operation & Maintenance Manual

1.2 Information on Safety

2.1 Safety, Noise, and Vibration Plates

2.1.1 Position of Safety Plates

Describes the importance and location of safety plates on the machine.

2.1.2 Pictograms and Relevant Meanings

Explains the meaning of various pictograms used on machine safety labels.

2.2 General Precautions for Safe Operation

2.2.1 General Safety Rules

Emphasizes using only trained staff and following all safety rules.

2.2.2 Handling Anomalies

Instructs on reporting and handling machine anomalies or malfunctions.

2.2.3 Safety Devices and Guards Maintenance

Stresses the importance of maintaining safety devices and guards in good condition.

2.2.4 Clothing and Personal Protection Items

Details necessary personal protective equipment (PPE) and appropriate attire.

2.2.12 Fire Prevention: Fuel and Oil

Details precautions to prevent fires related to fuel and oil handling.

2.2.14 Fire Prevention: Flammable Material Accumulation

Instructs to remove flammable materials from the engine area to prevent fires.

2.2.16 Fire Response Procedure

Provides steps to take in the event of a fire on the machine.

2.2.22 ROPS Cautions

Explains the function of ROPS (Rollover Protection System) and precautions.

2.3 Precautions Before Starting the Engine

2.3.1 Work Site Safety

Covers checks for ground conditions, utilities, and work area safety before starting.

2.3.2 Fire Prevention Measures

Details steps to prevent fires, including removing flammables and checking for leaks.

2.4 Precautions During Operation

2.4.1 Engine Starting Procedure

Details pre-start checks, seat belt use, and horn signaling.

2.4.6 Moving on Slopes Safely

Details safe practices for operating on slopes, including speed and direction.

2.4.7 Working on Slopes Precautions

Advises against turret swing on slopes and suggests creating platforms.

2.4.8 Unauthorized Operations Warning

Highlights risks associated with machine overturns or ground collapse.

2.4.9 Preventing Electrocution

Warns about the extreme danger of overhead electric lines and minimum safety distances.

2.4.14 Parking the Machine Safely

Details the procedure for safely parking the machine on level ground or slopes.

2.6 Battery Safety Precautions

2.6.1 Preventing Battery Hazards

Details hazards associated with battery acid, hydrogen gas, and handling precautions.

2.6.2 Starting with Booster Cables

Provides instructions and safety precautions for jump-starting the machine.

2.8 Precautions for Maintenance

2.8.3 Machine Stability During Maintenance

Emphasizes ensuring machine stability during dismantling or assembly.

2.8.6 Working Under the Machine Safety

Details crucial safety steps for working beneath the machine.

2.8.9 Periodical Change of Safety-Critical Parts

Highlights the importance of periodic replacement of safety-critical parts.

2.8.10 Stability During Maintenance

Reinforces the need for machine stability during maintenance procedures.

2.8.11 Stop Engine Before Maintenance

Stresses stopping the engine before any maintenance or inspection.

2.8.12 Battery Main Switch Precautions

Lists specific situations requiring the battery main switch to be turned OFF.

2.8.13 Refueling and Oil Adding Rules

Provides critical safety rules for refueling and adding oil to prevent fires.

2.8.16 Battery and Alternator Handling

Covers safety measures when working with the battery and alternator.

2.8.19 Handling High-Pressure Oil

Details dangers of high-pressure oil leaks and protective measures.

2.8.20 Maintenance at High Temps and Pressure

Warns about risks associated with hot components and pressurized systems during maintenance.

2.8.23 Hydraulic Accumulator Safety

Highlights explosion risks from hydraulic accumulators and necessary precautions.

3.2 Instruments and Controls

3.2.1 Warning Lights and Gauges

Explains the function and meaning of warning lights and gauges on the instrument panel.

3.2.3 Control Levers and Pedals Overview

Provides an overview of control levers and pedals for machine operation.

1. Safety Lever Function

Explains the safety lever's function in locking work equipment and preventing accidental movement.

2. & 3. Work Equipment Control Levers

Details the left and right control levers for arm, turret, boom, and bucket.

6. Travel Levers Operation

Explains the operation of travel levers for forward, reverse, and steering.

3.3 Using the Machine and Related Controls

3.3.1 Before Starting the Engine: Visual Checks

Covers essential visual checks before starting the engine.

3.3.1.1 Visual Checks Guide

Lists daily inspection points for work equipment, engine, undercarriage, etc.

3.3.1.2 Checks Before Starting Engine

Details daily checks for coolant, oil, fuel, filters, and wiring systems.

3.3.2 Starting the Engine

Provides instructions for starting the engine in warm conditions.

3.3.2.1 Starting in Warm Climates

Outlines the steps for starting the engine under normal temperature conditions.

3.3.2.2 Starting in Cold Climates

Details specific procedures and precautions for starting the engine in cold weather.

3.3.3 After Starting the Engine

Covers post-start procedures and warnings.

3.3.4 Stopping the Engine Safely

Provides instructions for safely shutting down the engine.

3.3.5 How to Move the Machine

Provides guidance on basic machine movement, including pre-movement checks.

3.3.5.1 Preliminary Operations Before Moving

Lists essential steps before moving the machine, including accelerator and safety lever.

3.3.5.2 Moving the Machine Forward

Details how to move the machine forward using travel levers and speed selection.

3.3.5.3 Moving the Machine in Reverse

Explains how to move the machine in reverse, including sprocket position.

3.3.5.4 Stopping the Machine

Provides instructions for safely stopping the machine's movement.

3.3.6 Steering the Machine

Explains how to steer the machine using travel levers.

3.3.6.1 Steering (Changing Direction)

Explains how to steer the machine using travel levers, including counter-rotations.

3.3.7 Swinging the Turret

Provides instructions for safely swinging the machine's turret.

3.3.8 Work Equipment Controls and Functions

Details the operation of arm, swing, boom, and bucket controls.

3.3.9 Unauthorized Operations Warnings

Warns against using turret swing force for compacting or breaking.

Unauthorized Travel Force Use

Prohibits using travel force for digging operations, which can damage the machine.

Dropping Force of Bucket Prohibitions

Prohibits using bucket dropping force as a pickaxe or breaker.

Gravity Force Usage Prohibition

Discourages using machine's gravity for digging operations.

3.3.11 Precautions When Traveling on Slopes

Details safe practices for operating on slopes, including speed and direction.

3.3.12 Getting Machine Out of Mud

Provides steps for extracting the machine when one track is stuck in mud.

3.3.15 Parking the Machine Safely

Details the procedure for safely parking the machine on level ground or slopes.

3.3.16.2 Checks After Stopping Engine

Details checks after stopping the engine, including leakages and cleaning.

3.4 Transporting the Machine

3.4.2 Loading and Unloading the Machine Safely

Details safety precautions and procedures for loading and unloading.

Securing the Machine for Transport

Explains how to secure the machine for transport using anchorage points and tie-downs.

3.4.3 Lifting the Machine Safely

4.1 Guide to Maintenance

4.2 Maintenance Notes

4.2.1 Oil, Fuel, and Coolant Specifications

Provides specifications for engine oil, hydraulic oil, fuel, and coolant.

4.4 Fuel, Coolant, and Lubricants

4.5 Tightening Torques

4.6 Lubrication Procedures

4.7 Periodical Change of Safety-Related Components

4.7.1 List of Safety-Related Parts

Lists safety-related components requiring periodic inspection and change.

4.8 Maintenance Plan

4.8.1 Maintenance Schedule Overview

Details maintenance tasks based on operating hours and required intervals.

When Required Maintenance Tasks

Lists maintenance tasks to be performed as needed.

Checks Before Starting the Engine

Details checks to perform daily before starting the engine.

Maintenance Every 500 Hours

Details tasks for 500-hour maintenance intervals.

Maintenance Every 1000 Hours

Lists tasks for 1000-hour maintenance intervals.

Maintenance Every 2000 Hours

Outlines tasks for 2000-hour maintenance intervals.

4.9 Maintenance Procedures

4.9.1 When Required Procedures

Lists procedures for tasks like air filter checks, battery checks, and fuel draining.

4.9.1.a Air Filter Cartridge Check, Cleaning, or Change

Provides detailed steps for checking, cleaning, or replacing the air filter cartridge.

4.9.1.g Rubber Track Tension Check and Adjustment

Provides procedures for checking and adjusting rubber track tension.

4.9.1.m Bleeding the Hydraulic System

Explains the procedure for bleeding the hydraulic system after maintenance.

4.9.2 Checks Before Starting the Engine

Lists essential checks before starting the engine, including fluid levels and systems.

4.9.6 Maintenance Every 500 Hours

Covers tasks for 500-hour intervals, including oil and filter changes.

4.9.6.a Engine Oil and Filter Change

Provides detailed steps for changing engine oil and filter.

4.9.6.b Fuel Filter Change and Bleeding

Details the procedure for changing the fuel filter and bleeding the circuit.

4.9.7 Maintenance Every 1000 Hours

Outlines tasks for 1000-hour maintenance intervals.

4.9.8 Maintenance Every 2000 Hours

Outlines tasks for 2000-hour maintenance intervals.

6.1 General Precautions for Safety with Attachments

6.1.1 Precautions When Selecting Attachments

Advises consulting the distributor for proper attachment selection and safety checks.

6.1.3 Precautions When Removing or Installing Attachments

Details safety precautions for removing or installing attachments.

6.1.4 Precautions When Using Attachments

Covers safety measures when using attachments, especially heavy ones or on angles.

6.3 Attachment Guide

6.4 Machine Configuration for Attachment Installation

6.5 Preparation for Equipment Installation (Proportional Controls)

6.5.2 Work Equipment Control Levers

Explains the work equipment control levers and associated safety precautions.

6.5.5 Using the Equipment

Provides guidance on operating attachments like the hammer.

6.5.5.1 When Using Hammer

Provides precautions and operating instructions for using a hydraulic hammer.

6.6 Hydraulic Quick Coupler (Single-Effect)

6.6.2 Functioning of Hydraulic Quick Coupler

Explains how to unlock and lock the bucket or accessory using the quick coupler.

6.7 Operating the Equipment

Using the Hydraulic Breaker

Guides on operating the hydraulic breaker using the equipment control pedal.

Hydraulic Breaker Precautions for Use

Lists precautions for using the breaker, including selection valve and accelerator settings.

6.8 Precautions When Using Optional Equipment

6.8.1 Hydraulic Breaker Applications

Details main applications and precautions for using a hydraulic breaker.

Hydraulic Breaker Wrong Usage

Lists incorrect operations to avoid for long machine life and safety.

Cylinder Full Extension Warning

Prohibits fully extending cylinders to lift the machine due to potential damage.

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