KOMATSU PC80MR-3 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:F00003 & UP) KOMATSU PC80MR-3 – PDF DOWNLOAD

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KOMATSU PC80MR-3 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:F00003 & UP) KOMATSU PC80MR-3

KOMATSU PC80MR-3 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:F00003 & UP) KOMATSU PC80MR-3 – PDF DOWNLOAD:

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KOMATSU PC80MR-3 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:F00003 & UP) KOMATSU PC80MR-3

• This manual has been compiled by Komatsu Utility S.p.A. in order to supply customers with all the necessary information on the machine and on safety regulations, as well as 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, together with the spare parts catalogue, is an integral part of the machine and must accompany 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 consulted at any moment; it must be placed in the pocket behind the seat, where the registration documents and the logbook are usually kept.
• This manual must be given to the staff who have to use the machine and carry out the routine maintenance operations; they must read the contents carefully more than once, in such a way as to clearly understand what 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 or your Komatsu Dealer.
• The illustrations contained in this manual may represent machine configurations available on request. Komatsu machines are constantly improved in order to increase their efficiency and reliability; this manual sums up all the information regarding the most recent technology applied at the moment in which the machine is launched. For any further and/or updated information, contact your Komatsu Dealer.
• Punctual periodic annotations regarding the maintenance operations that have been carried out are important, since they provide a clear report on the situation and say exactly what has been done and what has to be done after the next maintenance interval. Therefore, it is advisable to consult both the hour meter and the maintenance plan frequently.
• Over the years Komatsu Dealers have gathered considerable experience in customer service. If more information is needed, do not hesitate to contact your Komatsu Dealer: he always knows how to get the best performance from the machine, he can recommend the equipment that is most suitable for specific needs and can provide the technical assistance necessary for any change that may be required to conform the machine to the safety standards and traffic rules. Furthermore, Komatsu Dealers also offer assistance for the supply of Komatsu genuine spare parts, which guarantee safety and interchangeability.
• The table included in this manual must be filled in with the machine data, which are also the data that must be communicated to the Dealer when requiring assistance and ordering spare parts.

TABLE OF CONTENTS:

KOMATSU PC80MR-3 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:F00003 & UP) KOMATSU PC80MR-3

1.1 FOREWORD........................................................................................................................................  3
1.2 INFORMATION ON SAFETY...........................................................................................................................  4
1.3 INTRODUCTION....................................................................................................................................  6
	1.3.1 INTENDED USE OF THE MACHINE...............................................................................................................  6
	1.3.2 IMPROPER OR UNAUTHORIZED USES.............................................................................................................  6
		1.3.2.1 MAIN CHARACTERISTICS................................................................................................................  6
	1.3.3 RUNNING-IN................................................................................................................................  7
	1.3.4 POSITIONS AND DIRECTIONS OF THE MACHINE...................................................................................................  8
1.4 PRODUCT IDENTIFICATION..........................................................................................................................  9
	1.4.1 MACHINE SERIAL NUMBER.....................................................................................................................  9
	1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)......................................................................  9
	1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE....................................................................................... 10
	1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER....................................................................................................... 10
	1.4.5 SWING REDUCTION GEAR SERIAL NUMBER........................................................................................................ 10
	1.4.6 CAB SERIAL NUMBER......................................................................................................................... 10
	1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS....................................................................................................... 11
1.5 KOMTRAX SYSTEM.................................................................................................................................. 12
	1.5.1 GENERAL PRECAUTIONS....................................................................................................................... 12
TABLE OF CONTENTS................................................................................................................................... 13
2.1 SAFETY, NOISE AND VIBRATION PLATES.............................................................................................................. 22
	2.1.1 POSITION OF THE SAFETY PLATES............................................................................................................. 22
	2.1.2 PICTOGRAMS AND RELEVANT MEANINGS.......................................................................................................... 23
	2.1.3 POSITION OF THE NOISE PLATES.............................................................................................................. 30
	2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED............................................................................................. 30
2.2 GENERAL PRECAUTIONS............................................................................................................................. 31
	2.2.1 SAFETY RULES.............................................................................................................................. 31
	2.2.2 HOW TO BEHAVE IN CASE OF ANOMALIES........................................................................................................ 31
	2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS.................................................................................................... 31
	2.2.4 FIRE EXTINGUISHERS AND FIRST AID KIT...................................................................................................... 32
	2.2.5 SAFETY DEVICES AND GUARDS................................................................................................................. 32
	2.2.6 CLEANING THE MACHINE...................................................................................................................... 32
	2.2.7 INSIDE OF THE CAB......................................................................................................................... 33
	2.2.8 LEAVING THE OPERATOR SEAT................................................................................................................. 33
	2.2.9 GETTING ON AND OFF THE MACHINE............................................................................................................ 34
	2.2.10 IT IS FORBIDDEN TO CLIMB ON THE EQUIPMENT................................................................................................ 34
	2.2.11 ARTICULATED PARTS........................................................................................................................ 34
	2.2.12 PREVENTING BURNS......................................................................................................................... 35
	2.2.13 PREVENTING FIRES DUE TO FUEL AND OIL..................................................................................................... 35
	2.2.14 HOW TO BEHAVE IN CASE OF FIRE............................................................................................................ 36
	2.2.15 DETERGENT FOR THE WINDOWS................................................................................................................ 36
	2.2.16 PROTECTION AGAINST FALLING OBJECTS, FLYING OBJECTS, FOREIGN BODIES....................................................................... 36
	2.2.17 PRECAUTIONS CONCERNING THE EQUIPMENT..................................................................................................... 36
	2.2.18 COMBINING THE WORK EQUIPMENT............................................................................................................. 36
	2.2.19 WORK LIGHT AND CAB LIGHTS................................................................................................................ 37
	2.2.20 CAB WINDOWS.............................................................................................................................. 37
	2.2.21 PRECAUTIONS CONCERNING THE CAB STRUCTURE................................................................................................. 37
	2.2.22 UNAUTHORIZED MODIFICATIONS............................................................................................................... 37
	2.2.23 SAFETY AT THE WORKPLACE.................................................................................................................. 37
	2.2.24 WORKING ON LOOSE GROUND.................................................................................................................. 37
	2.2.25 PREVENTING ELECTROCUTION................................................................................................................. 38
	2.2.26 VISIBILITY............................................................................................................................... 39
	2.2.27 ROOM VENTILATION......................................................................................................................... 39
	2.2.28 CHECKING THE SIGNALS OF THE SIGNALMAN AND THE FIXED SIGNS................................................................................ 39
	2.2.29 HAND SIGNALS............................................................................................................................. 40
	2.2.30 EMERGENCY EXIT........................................................................................................................... 45
	2.2.31 PREVENTING DAMAGE DUE TO ASBESTOS POWDER................................................................................................. 45
2.3 PRECAUTIONS FOR USE............................................................................................................................. 46
	2.3.1 BEFORE STARTING THE ENGINE................................................................................................................ 46
		2.3.1.1 CHECKS AND ADJUSTMENTS TO BE CARRIED OUT BEFORE STARTING THE ENGINE................................................................. 46
		2.3.1.2 PRECAUTIONS TO BE TAKEN DURING THE START PROCEDURE.................................................................................. 46
		2.3.1.3 PRECAUTIONS TO BE TAKEN IN COLD AREAS............................................................................................... 47
	2.3.2 PRECAUTIONS TO BE TAKEN WHEN WORKING...................................................................................................... 48
		2.3.2.1 CHECKS AFTER STARTING THE ENGINE.................................................................................................... 48
		2.3.2.2 PRECAUTIONS TO BE TAKEN WHEN CHANGING DIRECTION..................................................................................... 48
		2.3.2.3 PRECAUTIONS TO BE TAKEN DURING TRAVEL............................................................................................... 49
		2.3.2.4 MOVING ON SLOPES.................................................................................................................... 50
		2.3.2.5 WORKING ON SLOPES................................................................................................................... 51
		2.3.2.6 UNAUTHORIZED OPERATIONS............................................................................................................. 51
		2.3.2.7 WORKING ON ICY OR SNOW-COVERED SURFACES............................................................................................. 53
		2.3.2.8 PARKING THE MACHINE................................................................................................................. 53
	2.3.3 TRANSPORTING THE MACHINE.................................................................................................................. 54
		2.3.3.1 LOADING AND UNLOADING THE MACHINE................................................................................................... 54
		2.3.3.2 TRANSPORTING THE MACHINE............................................................................................................ 54
	2.3.4 BATTERY................................................................................................................................... 55
		2.3.4.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY..................................................................................... 55
		2.3.4.2 STARTING WITH BOOSTER CABLES........................................................................................................ 56
	2.3.5 REMOVAL................................................................................................................................... 57
		2.3.5.1 PRECAUTIONS FOR THE REMOVAL......................................................................................................... 57
2.4 PRECAUTIONS FOR MAINTENANCE..................................................................................................................... 58
	2.4.1 WARNING PLATES............................................................................................................................ 58
	2.4.2 KEEP THE WORK PLACE CLEAN AND ORDERLY..................................................................................................... 58
	2.4.3 APPOINT A SUPERVISOR WHEN WORKING WITH OTHER PEOPLE....................................................................................... 58
	2.4.4 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION............................................................... 59
	2.4.5 MAINTENANCE OPERATIONS TO BE CARRIED OUT WITH THE ENGINE RUNNING REQUIRE THE PRESENCE OF TWO OPERATORS.................................... 60
	2.4.6 TOOLS..................................................................................................................................... 60
	2.4.7 HYDRAULIC ACCUMULATOR..................................................................................................................... 60
	2.4.8 MAINTENANCE STAFF......................................................................................................................... 61
	2.4.9 EQUIPMENT................................................................................................................................. 61
	2.4.10 WORKING UNDER THE MACHINE................................................................................................................ 61
	2.4.11 NOISE.................................................................................................................................... 61
	2.4.12 PRECAUTIONS TO BE TAKEN WHEN USING THE HAMMER............................................................................................ 62
	2.4.13 REPAIR WELDS............................................................................................................................. 62
	2.4.14 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL....................................................................................... 62
	2.4.15 CHECKING THE COOLANT LEVEL IN THE RADIATOR............................................................................................... 63
	2.4.16 USING LAMPS.............................................................................................................................. 63
	2.4.17 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR..................................................................... 64
	2.4.18 PRECAUTIONS CONCERNING THE STARTER....................................................................................................... 64
	2.4.19 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE TRACK TENSION...................................................... 65
	2.4.20 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT.................................................................... 65
	2.4.21 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL.................................................................................. 66
	2.4.22 HANDLING HIGH-PRESSURE HOSES............................................................................................................. 66
	2.4.23 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE............................................................ 66
	2.4.24 COOLING FAN AND BELT..................................................................................................................... 67
	2.4.25 WASTE MATERIALS.......................................................................................................................... 67
	2.4.26 SERVICING THE AIR CONDITIONER............................................................................................................ 67
	2.4.27 COMPRESSED AIR........................................................................................................................... 67
	2.4.28 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY.............................................................................. 67
	2.4.29 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS...................................................................... 68
	2.4.30 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE HEES................................................................. 68
3.1 DESCRIPTION AND USE OF THE MACHINE.............................................................................................................. 70
	3.1.1 GENERAL VIEW OF THE MACHINE WITH MONOBOOM................................................................................................. 70
	3.1.2 GENERAL VIEW OF THE MACHINE WITH TWO-PIECE BOOM........................................................................................... 71
	3.1.3 CONTROLS AND INDICATORS................................................................................................................... 72
3.2 INSTRUMENTS AND CONTROLS........................................................................................................................ 73
	3.2.1 DASHBOARD................................................................................................................................. 73
		3.2.1.1 WARNING LIGHTS...................................................................................................................... 74
		3.2.1.2 EMERGENCY WARNING LIGHTS............................................................................................................ 76
		3.2.1.3 WARNING LIGHTS AND INDICATORS DISPLAY............................................................................................... 78
		3.2.1.4 SWITCHES............................................................................................................................ 82
	3.2.2 SWITCHES AND PUSH BUTTONS................................................................................................................. 84
	3.2.3 CONTROL LEVERS AND PEDALS................................................................................................................. 91
	3.2.4 CAB....................................................................................................................................... 96
		3.2.4.1 WINDSHIELD.......................................................................................................................... 97
		3.2.4.2 SLIDING DOOR........................................................................................................................101
		3.2.4.3 SIDE WINDOW.........................................................................................................................102
		3.2.4.4 EMERGENCY EXIT HAMMER...............................................................................................................104
	3.2.5 COVERS WITH LOCK..........................................................................................................................105
	3.2.6 ENGINE HOOD...............................................................................................................................106
	3.2.7 TANK COVER................................................................................................................................107
	3.2.8 FUSES AND RELAY...........................................................................................................................108
		3.2.8.1 CONTROL UNIT FUSES AND RELAYS.......................................................................................................108
		3.2.8.2 VENTILATION RELAYS..................................................................................................................111
		3.2.8.3 AIR CONDITIONER FUSE AND RELAY......................................................................................................112
		3.2.8.4 ENGINE LINE FUSES AND RELAYS........................................................................................................112
		3.2.8.5 MAIN FUSE...........................................................................................................................113
	3.2.9 CONTROLLER................................................................................................................................113
	3.2.10 VENTILATION AND HEATING..................................................................................................................114
		3.2.10.1 HEATING AND DEFROSTING CONTROL PANEL...............................................................................................114
	3.2.11 AIR CONDITIONER (if installed)...........................................................................................................117
		3.2.11.1 AIR CONDITIONER CONTROL PANEL......................................................................................................118
	3.2.12 TECHNICAL DOCUMENTATION COMPARTMENT......................................................................................................121
	3.2.13 TOOL BOX.................................................................................................................................121
	3.2.14 GREASING PUMP SUPPORT....................................................................................................................121
	3.2.15 ASHTRAY..................................................................................................................................122
	3.2.16 FIRE EXTINGUISHERS.......................................................................................................................122
	3.2.17 FIRST AID KIT............................................................................................................................122
3.3 USE OF THE MACHINE..............................................................................................................................123
	3.3.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE.......................................................................................123
		3.3.1.1 VISUAL CHECKS.......................................................................................................................123
	3.3.2 DAILY CHECKS..............................................................................................................................125
		3.3.2.1 CHECKING THE COOLANT LEVEL AND TOPPING UP...........................................................................................125
		3.3.2.2 CHECKING THE ENGINE OIL LEVEL AND TOPPING UP........................................................................................126
		3.3.2.3 CHECKING THE FUEL LEVEL AND REFUELLING..............................................................................................127
		3.3.2.4 CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP.........................................................................128
		3.3.2.5 AIR FILTER CLOGGING CHECK...........................................................................................................130
		3.3.2.6 CHECKING THE WATER SEPARATOR........................................................................................................130
		3.3.2.7 CHECK THE WIRING SYSTEMS............................................................................................................131
		3.3.2.8 HORN OPERATION CHECK................................................................................................................131
	3.3.3 ADJUSTMENTS...............................................................................................................................132
		3.3.3.1 ADJUSTING THE SEAT..................................................................................................................132
		3.3.3.2 REAR-VIEW MIRRORS...................................................................................................................133
	3.3.4 SEAT BELT.................................................................................................................................134
		3.3.4.1 FASTENING AND UNFASTENING THE SEAT BELT.............................................................................................134
		3.3.4.2 ADJUSTING THE SEAT BELT.............................................................................................................135
		3.3.4.3 RETRACTABLE SEAT BELT (if provided).................................................................................................136
	3.3.5 OPERATIONAL CHECKS........................................................................................................................137
	3.3.6 STARTING THE ENGINE.......................................................................................................................139
		3.3.6.1 STARTING THE ENGINE IN NORMAL OPERATING CONDITIONS..................................................................................139
		3.3.6.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES.......................................................................................141
	3.3.7 AFTER STARTING THE ENGINE.................................................................................................................144
		3.3.7.1 RUNNING-IN..........................................................................................................................144
		3.3.7.2 WARMING-UP PROCEDURE................................................................................................................145
	3.3.8 STOPPING THE ENGINE.......................................................................................................................147
	3.3.9 CHECKS TO BE CARRIED OUT AFTER STOPPING THE ENGINE........................................................................................147
	3.3.10 OPERATING THE MACHINE....................................................................................................................148
		3.3.10.1 HOW TO MOVE THE MACHINE............................................................................................................148
		3.3.10.2 MOVING THE MACHINE FORWARD.........................................................................................................149
		3.3.10.3 REVERSE............................................................................................................................150
		3.3.10.4 HOW TO STOP THE MACHINE............................................................................................................151
	3.3.11 STEERING THE MACHINE.....................................................................................................................152
		3.3.11.1 STEERING (CHANGING DIRECTION)......................................................................................................152
	3.3.12 SWINGING THE TURRET......................................................................................................................154
	3.3.13 WORK EQUIPMENT CONTROLS AND FUNCTIONS....................................................................................................155
	3.3.14 WORK MODE................................................................................................................................157
	3.3.15 UNAUTHORIZED OPERATIONS..................................................................................................................158
	3.3.16 IGENERAL INFORMATION ON THE OPERATION OF THE MACHINE.....................................................................................160
	3.3.17 MOVING ON SLOPES.........................................................................................................................162
	3.3.18 GETTING THE MACHINE OUT OF MUD...........................................................................................................164
	3.3.19 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR............................................................................165
	3.3.20 CHANGING THE BUCKET......................................................................................................................167
	3.3.21 PARKING THE MACHINE......................................................................................................................168
	3.3.22 CHECKS TO BE CARRIED OUT ON THE MACHINE AT THE END OF THE WORK DAY.......................................................................169
	3.3.23 LOCKING THE MACHINE......................................................................................................................169
	3.3.24 ROAD LINERS AND RUBBER TRACKS............................................................................................................170
		3.3.24.1 INFORMATION ON THE ROAD LINERS AND THE RUBBER TRACKS...............................................................................170
		3.3.24.2 WARRANTY ON THE ROAD LINERS AND THE RUBBER TRACKS..................................................................................170
		3.3.24.3 USING THE ROAD LINERS AND THE RUBBER TRACKS........................................................................................170
		3.3.24.4 HOW TO PRESERVE THE ROAD LINERS AND THE RUBBER TRACKS OVER TIME....................................................................171
3.4 TRANSPORTING THE MACHINE........................................................................................................................175
	3.4.1 TRANSPORT PROCEDURE.......................................................................................................................175
	3.4.2 LOADING AND UNLOADING THE MACHINE.........................................................................................................175
		3.4.2.1 LOADING THE MACHINE.................................................................................................................176
		3.4.2.2 HOW TO SECURE THE MACHINE...........................................................................................................178
		3.4.2.3 UNLOADING THE MACHINE...............................................................................................................179
	3.4.3 HOW TO LIFT THE MACHINE...................................................................................................................181
3.5 USING THE MACHINE IN COLD CLIMATES..............................................................................................................183
	3.5.1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON.........................................................................183
		3.5.1.1 FUEL AND LUBRICANTS.................................................................................................................183
		3.5.1.2 COOLANT.............................................................................................................................183
		3.5.1.3 BATTERY.............................................................................................................................184
	3.5.2 AT THE END OF THE WORK DAY................................................................................................................185
	3.5.3 AT THE END OF THE COLD SEASON.............................................................................................................185
3.6 LONG PERIODS OF INACTIVITY......................................................................................................................186
	3.6.1 BEFORE A PERIOD OF INACTIVITY.............................................................................................................186
	3.6.2 DURING A PERIOD OF INACTIVITY.............................................................................................................186
	3.6.3 AFTER A PERIOD OF INACTIVITY..............................................................................................................187
3.7 TROUBLESHOOTING.................................................................................................................................188
	3.7.1 IF FUEL RUNS OUT COMPLETELY...............................................................................................................188
	3.7.2 OCCURRENCES THAT ARE NOT FAILURES.........................................................................................................188
	3.7.3 REMOVING THE MACHINE......................................................................................................................188
	3.7.4 DEMANDING OPERATING CONDITIONS............................................................................................................189
	3.7.5 IF THE BATTERY IS DOWN....................................................................................................................189
	3.7.6 REMOVING AND INSTALLING THE BATTERY.......................................................................................................190
	3.7.7 CHARGING THE BATTERY......................................................................................................................191
	3.7.8 STARTING WITH BOOSTER CABLES..............................................................................................................192
		3.7.8.1 CONNECTING AND DISCONNECTING THE BOOSTER CABLES.....................................................................................192
		3.7.8.2 CONNECTING THE BOOSTER CABLES.......................................................................................................193
		3.7.8.3 STARTING THE ENGINE.................................................................................................................193
		3.7.8.4 REMOVING THE BOOSTER CABLES.........................................................................................................193
	3.7.9 LOWERING THE WORK EQUIPMENT WHEN THE ENGINE STOPS BECAUSE OF A FAILURE....................................................................194
	3.7.10 OTHER TROUBLES...........................................................................................................................195
		3.7.10.1 ELECTRICAL SYSTEM..................................................................................................................195
		3.7.10.2 FRAME..............................................................................................................................196
		3.7.10.3 ENGINE.............................................................................................................................197
		3.7.10.4 ELECTRONIC CONTROL SYSTEM..........................................................................................................199
4.1 GUIDE TO MAINTENANCE............................................................................................................................202
4.2 MAINTENANCE NOTES...............................................................................................................................204
	4.2.1 OIL, FUEL AND COOLANT.....................................................................................................................204
		4.2.1.1 OIL.................................................................................................................................204
		4.2.1.2 FUEL................................................................................................................................205
		4.2.1.3 COOLANT.............................................................................................................................205
		4.2.1.4 KOWA (KOMATSU OIL WEAR ANALYSIS)....................................................................................................206
		4.2.1.5 STORING OIL AND FUEL................................................................................................................207
		4.2.1.6 FILTERS.............................................................................................................................207
	4.2.2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM.........................................................................................208
	4.2.3 NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM..........................................................................................208
	4.2.4 MAINTENANCE NOTES REGARDING LUBRICATION...................................................................................................208
4.3 PARTS SUBJECT TO WEAR...........................................................................................................................209
	4.3.1 LIST OF THE PARTS SUBJECT TO WEAR.........................................................................................................209
4.4 FUEL, COOLANT AND LUBRICANTS....................................................................................................................210
	4.4.1 COOLANT...................................................................................................................................211
	4.4.2 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES.....................................................................................212
4.5 TIGHTENING TORQUES..............................................................................................................................213
	4.5.1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS...........................................................................................213
	4.5.2 STANDARD TIGHTENING TORQUES FOR HOSES WITH ORFS...........................................................................................214
4.6 LUBRICATION.....................................................................................................................................215
	4.6.1 LUBRICATION DIAGRAM.......................................................................................................................215
4.7 PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS..................................................................................................216
	4.7.1 SAFETY-RELATED PARTS......................................................................................................................217
4.8 MAINTENANCE PLAN................................................................................................................................218
	4.8.1 MAINTENANCE PLAN..........................................................................................................................218
	4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER.............................................................................221
4.9 MAINTENANCE PROCEDURES..........................................................................................................................222
	4.9.1 WHEN REQUIRED.............................................................................................................................222
		4.9.1.a CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE.............................................................................222
		4.9.1.b CLEANING THE WATER SEPARATOR FILTER.................................................................................................225
		4.9.1.c CHECKING THE TIGHTENING OF THE TRACKS...............................................................................................226
		4.9.1.d CHECKING AND ADJUSTING THE TRACK TENSION............................................................................................227
		4.9.1.e CHECKING THE ROAD LINERS OR THE RUBBER TRACKS.......................................................................................229
		4.9.1.f CHECKING AND ADJUSTING THE RUBBER TRACK TENSION.....................................................................................231
		4.9.1.g CHANGING THE ROAD LINERS............................................................................................................232
		4.9.1.h CHANGING THE RUBBER TRACKS..........................................................................................................233
		4.9.1.i REPLACING THE ROAD LINERS OR STEEL TRACKS WITH RUBBER TRACKS........................................................................236
		4.9.1.j ADJUSTING THE BUCKET CLEARANCE......................................................................................................237
		4.9.1.k CHECKING THE WINDSHIELD FLUID LEVEL AND TOPPING UP..................................................................................238
		4.9.1.l CHECKING, CLEANING AND LUBRICATING THE GUIDE OF THE CAB SLIDING DOOR................................................................239
		4.9.1.m WASHING THE FLOOR...................................................................................................................240
		4.9.1.n BLEEDING THE HYDRAULIC SYSTEM.......................................................................................................242
	4.9.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE.......................................................................................245
	4.9.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)..............245
	4.9.4 MAINTENANCE EVERY 50 HOURS OF OPERATION...................................................................................................245
		4.9.4.a COOLANT LEVEL CHECK IN THE RADIATOR.................................................................................................245
	4.9.5 MAINTENANCE EVERY 100 HOURS OF OPERATION..................................................................................................246
		4.9.5.a LUBRICATION.........................................................................................................................246
	4.9.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION........................................................................................246
	4.9.7 MAINTENANCE EVERY 250 HOURS OF OPERATION..................................................................................................247
		4.9.7.a LUBRICATION.........................................................................................................................247
		4.9.7.b CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR AND TOPPING UP...................................................................249
		4.9.7.c CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS AND TOPPING UP..................................................................249
		4.9.7.d BATTERY ELECTROLYTE LEVEL CHECK.....................................................................................................250
		4.9.7.e CHECKING AND ADJUSTING THE FAN BELT TENSION.........................................................................................251
		4.9.7.f CHECKING AND ADJUSTING THE AIR CONDITIONER COMPRESSOR BELT TENSION (if installed)...................................................252
		4.9.7.g DRAINING THE FUEL TANK..............................................................................................................253
	4.9.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used).............254
	4.9.9 MAINTENANCE EVERY 500 HOURS OF OPERATION..................................................................................................254
		4.9.9.a CHANGING THE FUEL FILTER CARTRIDGE..................................................................................................254
		4.9.9.b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE.........................................................................256
		4.9.9.c CHANGING THE HYDRAULIC OIL FILTER CARTRIDGE.........................................................................................258
		4.9.9.d CLEANING THE INSIDE AND OUTSIDE FILTERS OF THE AIR CONDITIONER......................................................................260
		4.9.9.e RADIATOR, EXCHANGER AND AIR CONDITIONER CONDENSER (if fitted) CHECK AND EXTERIOR CLEANING...........................................262
		4.9.9.f LUBRICATING THE SWING BALL- BEARING RING............................................................................................263
		4.9.9.g CHECKING THE GREASE LEVEL IN THE BALL-BEARING RING PINION AND TOPPING UP............................................................263
		4.9.9.h DRAINING THE HYDRAULIC OIL TANK (Only for machines in which synthetic biodegradable oil type HEES is used)..........................264
	4.9.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION................................................................................................265
		4.9.10.a CHANGING THE OIL IN THE SWING REDUCTION GEAR.......................................................................................265
		4.9.10.b CHANGING THE OIL IN THE FINAL REDUCTION GEARS......................................................................................266
	4.9.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION................................................................................................267
		4.9.11.a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER (Only for machines in which synthetic biodegradable oil HEES is used)....267
		4.9.11.b CHANGING THE COOLANT...............................................................................................................269
		4.9.11.c CHECKING THE ALTERNATOR AND THE STARTER............................................................................................271
		4.9.11.d CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE..................................................................................271
		4.9.11.e CHECKING THE A/C REFRIGERANT GAS QUANTITY ((only for machines with air conditioner)................................................271
	4.9.12 MAINTENANCE EVERY 4000 HOURS OF OPERATION................................................................................................272
		4.9.12.a CHANGING THE A/C FILTER DRIER (only for machines with air conditioner).............................................................272
		4.9.12.b CHECKING THE OPERATING CONDITIONS OF THE A/C COMPRESSOR (only for machines with air conditioner)...................................272
		4.9.12.c CHECKING THE WATER PUMP............................................................................................................272
	4.9.13 MAINTENANCE EVERY 5000 HOURS OF OPERATION................................................................................................273
		4.9.13.a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER..........................................................................273
5.1 TECHNICAL DATA..................................................................................................................................276
5.2 LIFTING CAPACITIES..............................................................................................................................278
	5.2.1 LIFTING CAPACITIES WITH MONOBOOM..........................................................................................................278
6.1 AUTHORIZED OPTIONAL EQUIPMENT...................................................................................................................284
	6.1.1 PRECAUTIONS REGARDING SAFETY..............................................................................................................284
	6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT.......................................................................................285
	6.1.3 AUTHORISED TOOLS CHARACTERISTICS..........................................................................................................286
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER.......................................................................................287
	6.2.1 DESCRIPTION AND CONTROL...................................................................................................................287
	6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED.....................................................................................288
	6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER.............................................................................................293
		6.2.3.1 INSTALLATION........................................................................................................................293
		6.2.3.2 REMOVING THE HAMMER.................................................................................................................294
	6.2.4 MAINTENANCE...............................................................................................................................294
6.3 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET SWING SYSTEM (second hydraulic line)...................................................295
6.4 ARRANGEMENT FOR THE INSTALLATION OF THE BUCKET QUICK COUPLING SYSTEM (Third hydraulic line).....................................................298
6.5 INSTALLING AND REMOVING THE ADDITIONAL COUNTERWEIGHT............................................................................................300

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