CBLM Heavy Equipment

COMPETENCY BASED LEARNING MATERIAL
Sector:
CONSTRUCTION
Qualification:
HEO – (HYDRAULIC EXCAVATOR) NC II
Unit of Competency: PERFORM PRE AND POST OPERATION
PROCEDURES FOR HYDRAULIC EXCAVATOR
Module Title: PERFORMING PRE AND PPOST OPERATION
PROCEDURES FOR HYDRAULIC EXCAVATOR
RPASI RIVERVIEW POLYTECHNIC and ACADEMIC SCHOOL, INC.
Ibulao, Baguinge, Kiangan, Ifugao
RPASI Date Developed: Document No.

HEO - HYDRAULIC EXCAVATOR JANUARY 2019 Issued by:
NCII
Developed by:
PREFORM PRE AND POST Page 1 of
OPERATION PROCEDURES FOR 115
JULIO R. SANSANO Revision #
HYDRAULIC EXCAVATOR
01
HOW TO USE THIS COMPETENCY- BASED LEARNING MATERIALS
Welcome!
Competency based learning material for the module: PERFORMING PRE

AND POST OPERATION PROCEDURES FOR HYDRAULIC EXCAVATOR.
This module contains training materials and activities for you to accomplish.
This unit of competency “: PERFORM PRE AND POST OPERATION

PROCEDURES FOR HYDRAULIC EXCAVATOR” contains the knowledge,
skills and attitudes required for Heavy Equipment Operation (Hydraulic
Excavator) NCII.
You are required to go through a series of learning activities in order to

complete each learning outcome of the module. In each learning outcome are
Information Sheets, Self-checks and Job Sheets. Follow these activities on
your own pace. If you have questions, feel free to ask for the assistance of
your trainer/facilitator.
DIRECTION FOR USE OF THE CBLM
This module PERFORM PRE AND POST OPERATION PROCEDURES FOR

HYDRAULIC EXCAVATOR was prepared to help you achieve the required
competency: “”. This will be the source of information for you to acquire the
knowledge and skills in this particular module with minimum supervision or
help from your trainer. With the aid of this material, you will acquire the
competency independently and at your own pace.
Talk to your trainer and agree on how you will both organize the training of
this unit. Read the module carefully. It is divided into sections which covers all
the skills and knowledge you need to successfully complete this module.
Most probably, your trainer will also be your supervisor or manager. He/she is
there to support you and show you the correct way to do things. Always ask
for help.
Your trainer will tell you about the important things you need to consider when
you are completing activities and it is important that you listen and take notes.

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You will be given plenty of opportunity to ask questions and practice on the
job. Make sure you practice your new skills during regular work shifts. This
way you will improve both your speed and memory and also you’re confident.
RECOGNITION TO PRIOR LEARNING
You may already have some or most of the knowledge and skills covered in
this learners guide because you have been working for some time already or
completed training in this area.
If you can demonstrate to your trainer that you are competent in a particular
skill/s, talk to him about having them formally recognize so you don’t have to
do the same training again. If you have a qualification or Certificate of
Competency from previous trainings that are still current and relevant to the
unit/s of competency, show it to your trainer. If you are not sure of the
currency of your skill/s, discuss this with your trainer.
REMEMBER TO:
 Work through all the information and complete the activities in each
session.
 Read information sheets and complete self-check. Suggested
references are included to supplement the materials provided in this
module.
 Use the self-check and job sheets at the end of each section to test
your own progress.
 Talk to more experience workmates and ask for their guidance.
When you feel confident that you have sufficient practice, ask your instructor
to evaluate you. The result of your assessment will be recorded in your
Progress Chart and Accomplishment Chart.

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TRAINING REQUIREMENTS
(RIVERVIEW POLYTECHNIC AND ACADEMIC SCHOOL, INC.)
1. You must comply with the condition of trainees permit:

a. Basic competency Certificate
b. Training permits from the registrar
c. Student driving license permit (LTO)
2. You should carry with you your student driver’s license permit at all times
When driving.
3. You must not carry any passengers or animals during the training session
except for the instructor conducting the training.
4. For safety reasons you must wear appropriate footwear when driving-
thongs, bare feet, clogs (shoes thicker than 3cm.) or shoes without heel
support.
When you are learning to drive the instructor accompanying you is
required to:
1. Instruct you in the safe and efficient operation of the motor vehicle
2. Instruct you the correct application of the Philippines road rules
3. Be seated immediately alongside you at all times while you are driving.
This applies to parking practice (even in car parks) except if the training
session is conducted within the school compound.
4. Comply with the licensing and National Certificate requirements
You should also insure that they have the following characteristics:
• Patience and calm approach to your learning
• The ability to guide you in your practice.

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INSTRUCTION SHEETS:
Information Sheet – This will provide you with information (Concepts,
principles and other relevant information) needed in performing certain
activities.
Operation Sheet – This will guide you in performing single task, operation
process in a job.
Job Sheet – This is designed to guide you how to do the job that will
contribute to the attainment of the learning outcome.
Assignment Sheet – The assignment sheet is a guide used to enhance
(follow up) what you have learned in the information sheet or job sheet.
Worksheet – are the different forms that you need to fill up certain
activities that you performed.

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LIST OF COMPETENCIES
No. Unit of Competency Module Title Code
Performing Pre and

Perform pre- and
Post Operation
post-operation CON833301
1. Procedures for
procedures for
Hydraulic Excavator
Hydraulic Excavator
Operation
Perform basic
preventive Performing Basic
2. maintenance servicing Preventive Maintenance CON833302
for earth-moving for Hydraulic Excavator
equipment Operation
Performing productive
Perform productive operation Hydraulic
3. operation for hydraulic CON833303
Excavator
excavator

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MODULE CONTENT
UNIT OF COMPETENCY: Perform pre- and post-operation procedures for
Hydraulic Excavator
MODULE TITLE : Performing Pre and Post Operation
Procedures for Hydraulic Excavator Operation
CERTIFICATE LEVEL: NC II
NOMINAL DURATION: 24 hours
MODULE DESCRIPTOR: This module covers the knowledge, skills and

attitude required in performing productive operation for hydraulicExcavator.
LEARNING OUTCOMES:
At the end of this module you MUST be able to:
LO1. IDENTIFY HYDRAULIC EXCAVATOR TYPES/COMPONENTS
STRUCTURE
LO2. PERFORM VISUAL CHECK OF EQUIPMENT
LO3. PERFORM BLOWAF CHECK
LO4. CHECK HYDRAULIC EXCAVATOR SYSTEM FUNCTION
LO5. CHECK SAFETY DEVICES AND ACCESSORIES
LO6. PERFORM POST OPERATION PROCEDURES

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IDENTIFY HYDRAULIC EXCAVATOR
LEARNING OUTCOME #1 TYPES/COMPONENTS STRUCTURE
CONTENTS
1. Types and classifications of hydraulic excavator and uses
2. Components structure of hydraulic excavator and their function
ASSESSMENT CRITERIA:
1. Types of hydraulic excavator are identified
2. Hydraulic excavator components structure are identified and
functions are explained
CONDITION: Student/ trainee must be provided with the following:
1. Operations and maintenance manual
2. Unit of Equipment (Hydraulic Excavator)
3. Handouts/Instructional materials
Assessment method:
1. Written Test
2. Observation/Interview
3. Demonstration

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LEARNING EXPERIENCES
IDENTIFY HYDRAULIC EXCAVATOR TYPES/COMPONENTS STRUCTURE
Learning Activities Special Instructions

Read Information 1.1-1 If you have some problem on the content of the
Types and classifications of hydraulic information sheet don’t hesitate to approach your
excavator and uses facilitator.
If you feel that you are now knowledgeable on the
content of the information sheet 1.1-1, you can now
answer self-check provided in the module.
If you got 100% correct answer in this self-check,

Answer self-check 1.1-1 you can now move to the next information sheet. If
not, review the information sheet and go over the
self-check again.
If you have some problem on the content of the

information sheet don’t hesitate to approach your
Read Information 1.1-2
facilitator.
Components structure of hydraulic
excavator and their function If you feel that you are now knowledgeable on the
Answer self-check 1.1-2 If you got 100% correct answer in this self-check,
you can now move to the next information sheet. If
self-check again.

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INFORMATION SHEET 1.1-1
TYPES AND CLASSIFICATION HYDRAULIC EXCAVATOR AND USES
Learning Objectives:
After reading this information sheet, you must be able to identify the different
types of hydraulic excavator.
HYDRAULIC EXCAVATOR
An excavator is a machine that is used for construction sites. It is heavy duty

equipment that can progressively excavate various types of soils. There are
different types of excavators used for various applications such as
landscaping, material handling, construction, demolition and river dredging.
Excavator is the machine that can excavate the soil of various types forcefully
and then using hydraulic system a hydraulic force is generated and utilizing
this force bucket is pull back towards the machine. Bucket of excavator is
replaceable. If front bucket is exchange with some other attachments then
excavator can be used for multi-purpose. For example: pile diver, hydraulic
jack hammer etc…
Excavator comes in numerous sizes depending on bucket size, length of

boom, length of arm, and operation speed. Performance of excavator can be
measured from the production cycle. Production cycle is the time that an

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excavator took to load the bucket from source, swing, dump, return back and
then dig again. Therefore, faster the operation speed, the faster will be the
one complete cycle and hence production cycle will increase.
Excavators come in different sizes and shapes depending on their

utility. The different types of excavators are:
Crawler excavators
Crawlers are also called as compact excavators. Because of their high

horsepower, these excavators are used for mining and other heavy duty
purposes. Crawler excavator is heavy duty equipment used to lift up debris
and soil using hydraulic power mechanisms. It runs on a chain wheel system.
They are the best alternative when it comes to grading or landscaping hilly
areas. Their risk of sliding down the hill is minimal because of their versatile
framework.

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Wheel excavator
Wheel excavator runs on wheels and are used for excavation and loading of
dump trucks and most of the time it is only used for plain ground operations.
Because of wheel, it is not suitable for hilly areas due to low grip value to the
ground.
Backhoe

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Among all different types of excavators that are available, backhoe is the most
commonly used today? Its effectiveness is widely applicable in areas that may
not be specific to excavation only. A backhoe excavator has a bucket that
faces the driver. The bucket extracts soil by pulling it towards the driver before
lifting. Backhoe excavators are used to excavate soil in mining or construction
sites or unload waste in dumpsites. They are small in size as compared to the
other excavators but they serve various purposes.
Suction excavators
Suction excavators are also known as vacuum excavators. They come along
with a suction pipe that helps carry away loose soil and debris, cuts using
sharp teeth at the edge of the pipe. Before the excavation begins, a water jet
is used in order to loosen the ground. These types of excavators are used in
places that require careful and safe exploration of underground elements.

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Dragline excavators
A dragline excavator is heavy duty equipment that is slightly different and

much bigger in size. These types of excavators are used in large scale
applications. Dragline excavators can be further divided into standard mobile
draglines and on-site draglines. On-site draglines are large size excavators
that are assembled and built on site, while the standard ones are bigger than
the back hoe excavators but smaller than the on-sites. Draglines are too
heavy and can damage the roads so are transported in parts and assembled
on site.

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SELF-CHECK 1.1-1
ENUMERATION
1. Enumerate the different types of excavator and their uses.
a.
b.
c.
d.
e.

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COMPONENTS STRUCTURE OF HYDRAULIC EXCAVATOR AND THEIR
FUNCTION
After reading this information sheet, you must be able to identify the
components of hydraulic excavator.

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The figure above identifies the typical components of an excavator. Some
excavator may have additional attachments used to perform specific tasks.
The excavator should be inspected by the operator prior to being used. The
following list of items should be included in the pre-shift check.
• All safety devices: Horns, lights, guards and shields, fire extinguish, glass
and wipers.
• Engine and hydraulic fluid levels
• Boom, stick, and bucket
• Hydraulic leak
• All controls for proper function
A more thorough inspection should be conducted on a periodic basis.
Typically, this is done monthly, but depending on the amount of time the
machine is being used and under what conditions, more or less frequent
inspections may be necessary. The inspection check list shown here is an aid
in conducting the thorough inspection. The operator’s manual should be
consulted to identify any additional inspection requirements.
The frame of the excavator needs to be inspected for cracked welds and
loose bolts. This will require crawling under the machine to perform this
inspection. Often because of wet or muddy conditions, these inspections are
overlooked. As the machine gets older, the potential for failed welds or
fasteners increases.
An illustration of a typical rotation bearing is shown above. One half of the
bearing is attached to the frame and the other half is attached to the upper
structure. The only thing holding the two halves of the bearing together are
the ball bearings.
When digging and lifting with the excavator, this bearing experiences
tremendous loads and therefore needs to lubricate regularly. Excessive
bearing wear can be detected by first observing the relative location of the two
bearing halves with each other with the bucket off of the ground. Next, place
the bucket on the ground and slightly lift the tracks off the ground with the
boom. Again, observe the relative location of the two bearing halves. If the
bearing halves separate more than .060 of an inch, the manufacture should
be consulted to determine the amount of allowable play.
The tracks need to be checked for cracked or damaged pads. Also, the
condition of the grouser needs to be examined. The number of grousers per
pad is normally dependent on the surface on which the machine will be
working. For earth work, normally only one grouser would be needed. For

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working on pavement, the pad may have three grousers to prevent surface
damage when maneuvering the machine.
• Check for loose bolts attaching the pads to the track links and check the pins
connecting the pads together for wear or damage.
• Check the top and bottom rollers for wear and especially for flat spots.
• Check the operator’s or maintenance manual for the proper track
adjustment.
Inspect the drive sprocket for worn or cracked teeth.
A broken tooth on the sprocket will cause excessive wear to the pad sockets.
Check the drive seals for leaks.
The front idler needs to be checked for wear and flat spots. Depending on the
type of material the excavator has been working in, the perimeter of the idler
can be chipped or nicked which can result in wear to the pad sockets.
UPPER STRUCTURE
Engine Compartment
1. Inspect the engine for leaks. Keep the radiator free of dirt.
2. Check the oil level frequently.
3. Check the radiator for coolant.
4. Check the belts for proper tension and radiator hoses for cracks.
At the beginning of every shift the level of all fluids should be checked and
depending on the condition of the engine more often than that.
Check belts for proper tension and wear. A broken belt can result in a project
being shut down for several hours.
Check radiator and other hoses for cracks.
The engine compartment can become very dirty, especially the radiator.
Frequent cleaning may be necessary to kept dirt from building up in the
radiator and on the engine itself. Excessive dirt can cause the engine to run
hotter than normal which will reduce its life.
UPPER STRUCTURE
1. Check for proper hydraulic fluid level.
2. Inspect all lights to ensure proper working order.
3. Check the hydraulic system, pumps, hoses, lines and cylinders, for
leaks.

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Before operating the machine, the hydraulic fluid level needs to be checked.
The fluid level is normally checked with the stick and bucket fully retracted
and the boom down. Check the operator’s manual for specific instructions.
Check the hydraulic pump and compartment for leaking fluid and general
condition of the hoses and fittings.
Inspect all hydraulic hoses for leaking fluid. Where hoses bend over metal
edges, check the hoses for chaffing. Even though the edge may be smooth,
chaffing can still occur. Fluid weeping out of the compression flange on a
hose fitting needs to be investigated and the hose replaced as necessary.
.
CAB
1. Clean cab glass frequently.
2. Keep the cab floor clean & free of debris
3. Test all controls before using the machine.
Hydraulic cylinders need to be inspected for fluid leaks at the fittings and
where the cylinder rod comes out of the cylinder. All leaks need to be
corrected and any nicks in the cylinder rod need to be smoothed out to
prevent damage to the cylinder’s wiper seal.
All lights on the machine should be in working condition
The operator’s cab needs to be kept clean of dirt, grease and objects which
could interfere with the safe operation of the machine. It is recommended that
basic housekeeping items be kept on the machine to facilitate keeping it
clean. The glass in the machine needs to be free of cracks that would impair
the vision of the operator. Clean the glass regularly to increase visibility and to
avoid reflection in sunlight. The windshield wipers need to work and the blade
replaced periodically to avoid streaking.
All controls need to be properly labeled with their function and direction of
motion. Test each control before starting work to confirm they are in proper
working order.
The cab should have a fire extinguisher that has a current inspection label.
Hydraulic cylinders need to be inspected for fluid leaks at the fittings and
where the cylinder rod comes out of the cylinder. All leaks need to be
corrected and any nicks in the cylinder rod need to be smoothed out to
prevent damage to the cylinder’s wiper seal.
All lights on the machine should be in working condition.
BOOM AND STICK
Inspect the boom and stick for damage and wear. Grease regularly.
Inspect the boom and stick for dents and bends. Significant dents need to be
evaluated by a competent individual to determine if the structural strength has

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been compromised. This is especially critical when the excavator is being
used for lifting. All welded joints need to be inspected for cracks.
The hinge joints need to be greased regularly according to the manufacturer’s
recommendations.
After greasing, excessive grease should be wiped away with a rag. Keeping
these components free of excessive grease will reduce the buildup of grit
which can accelerate wear. Check the hydraulic hoses at the hinge points for
wear.
BUCKET
1. Check the locking pins that hold the teeth for damage.
2. Inspect the lifting points on the bucket and stick damage.
3. Check the ‘thumb’ for damage
4. Inspect the bucket linkages for damage & worn pins
5. Inspect the bucket for cracked welds, particularly where the hinge
gussets are attached.
Inspect bucket hinge pins and linkages for excessive wear, missing keeper
pins and other damage.
Make sure the pins or bolts used to attach the teeth to the bucket are in place
and not excessively worn.
Also, evaluate the wear on the teeth for planning the next change out.
If the excavator is fitted with a thumb, inspect the hinge pin and associated
linkages for wear and damage.
The frequency of greasing the bucket hinge pins is dependent on the weather
and the type of material being excavated. In sanding or powdery material it
may be necessary to grease these components two to three times a shift. The
fine material will have a tendency to work its way into the hinges and
accelerate wear. Frequent greasing will keep pushing this material out.
Buckets that will be digging below water need frequent greasing to keep it
fresh. At the end of the shift where the machine will sit overnight, grease all
these areas again to prevent corrosion. After greasing, exercise the bucket to
distribute the grease.
The structure of excavators can be divided into three parts: attachment, upper
frame and under carriage. Main working attachment contains stick cylinder,
boom, boom cylinder, stick, bucket cylinder, linkage, and bucket. As per the
types of bucket arrangement, there are two popular kinds, backhoe and face
shovel, and among them, backhoe is mostly common used.
The main parts of the upper structure include swing assembly, counterweight,
hydraulic pump, engine, main control valve, operation cab and swing platform.

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All movement and operation of a hydraulic excavator are completed through
the use of hydraulic fluid, with hydraulic cylinders and hydraulic motors. Due
to the linear actuation of hydraulic cylinders, their mode of operation is
fundamentally different from cable-operated excavators which use winches
and steel ropes to accomplish the movements.
The under carriage includes track, swivel joint, swing bearing, travel device,
idler wheel, carrier roller, sprocket wheel, track roller, and X-frame. According
to the types of ground contact, there are crawler excavator and wheeled
excavator, and according to the length of undercarriage, it has stander crawler
and long crawler.

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SELF-CHECK 1.1-2
ENUMERATION
1. Enumerate the components structure of hydraulic excavator.

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PERFORM VISUAL CHECK OF
LEARNING OUTCOME #2 EQUIPMENT
CONTENTS
1. Specification, limitations and classification of hydraulic excavator
based on operations and maintenance manual.
2. Controls, instruments, indicators function and application.
3. Equipment brand, model, parts, warning decals, jobsite and work
condition.
1. Hydraulic excavators are selected based on job requirements.
2. Operator serviceable (OS) parts are check in accordance with
equipment checklist and manufacturer’s procedures.
3. Performed walk-around check with the hydraulic excavator, with
engine stopped and keys removed based on standard
procedure.
3. PPE
4. Handouts/instructional materials
Assessment method:
1. Written Test

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PERFORM VISUAL CHECK OF EQUIPMENT

Specification, Limitations and information sheet don’t hesitate to approach your
classifications of hydraulic excavator facilitator.
based on operations and maintenance
manual If you feel that you are now knowledgeable on the

self-check again.
facilitator.
Read Information 1.2-2 If you feel that you are now knowledgeable on the
Controls, instruments, indicators functions content of the information sheet 1.2-2, you can now
and application answer self-check provided in the module.

Answer self-check 3.2-2 not, review the information sheet and go over the
self-check again.
facilitator.
Read Information 1.2-3 If you feel that you are now knowledgeable on the
Equipment brand, model parts, warning content of the information sheet 1.2-3, you can now
decals, jobsite and work conditions answer self-check provided in the module.
self-check again

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SPECIFICATION, LIMITATIONS AND CLASSIFICATIONS OF HYDRAULIC
EXCAVATOR BASED ON OPERATIONS AND MAINTENANCE MANUAL
After reading this information sheet, you must be able to know the operations
and maintenance manual of hydraulic excavator.
GUIDE TO MAINTENANCE
WARNING
1. Oils, filters, coolant, gaskets, electric cables, and batteries are
considered special waste and must be collected and disposed of
according to the anti-pollution regulations in force.
2. The combustible material of some components may become extremely
dangerous if it burns. For this reason, avoid any contact of burnt
material with your skin or eyes and do not inhale its fumes.
3. Do not carry out any inspection or maintenance operation not
prescribed in this manual.
4. Check the hour meter every day to verify if it is necessary to carry out
any maintenance operation.
5. Before opening the engine hood, engage all the safety locks and stop
the engine.
6. If it is necessary to check the hydraulic oil level, retract the bucket and
arm cylinders completely and lower the bucket teeth to the ground.
7. Carry out these operations on firm and level ground.
8. Use Komatsu genuine oils and greases; choose oils suitable for the
ambient temperature.
9. Use clean oils and greases. Keep the oil and grease containers clean
and prevent any foreign matter from getting into them.
10. Keep the machine thoroughly clean; this facilitates troubleshooting. In
particular, grease nozzles, breather holes, and the areas where fluid
levels are checked should be kept clean to prevent the infiltration of
impurities.
11. Draining water or oil, and changing filters soon after work is dangerous;
wait for the engine to cool down to a safe temperature of 40÷45°C.
12. If it is necessary to drain the oil when it is cold, warm it up to a suitable
temperature (approximately 20÷40°C) before draining it.
13. When changing oils or filters, check if metal particles are present. If
there are large quantities of metal particles, contact your Komatsu
Dealer.

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14. If the machine is provided with a fuel filter in the filler neck, do not
remove it while refueling.
15. Check and change the oil in a clean place and prevent any impurity
from getting into the tank.
16. Before carrying out any maintenance operation, hang a warning plate
to the ignition switch and the control levers to prevent anyone from
starting the engine.
17. When performing maintenance operations, always take the precautions
indicated in the safety plates applied to the machine.
Instructions for arc welding:

1 - Turn the ignition key to position OFF.
2 - Disconnect the battery (first the negative pole and then the positive pole).
3 - Disconnect the alternator.
4 - Do not apply more than 200V continuously.
5 - Connect the earth cable within 1 m from the point where the welding
operation must be carried out.
6 - Avoid placing gaskets and bearings between the welding area and the
earth cable. If the earth cable is connected near instruments, connectors, etc.,
these may not function correctly.
7 - Do not use the area around the work equipment pins or the hydraulic
cylinders as earth.
8 - Do not use flammable fluids to clean any parts of the machine.
9 - Keep naked flames away from these fluids and avoid smoking. When O
rings and gaskets are removed, clean the sealing surfaces thoroughly and
replace the O rings and gaskets with new ones. Fit the O rings and gaskets
correctly when reassembling.
10 - Avoid keeping loose objects or tools in your pockets: they may fall out
and drop into the machine, especially when you open covers and work on the
machine while bending over it.
11 - When working on rocky areas, make sure that the undercarriage is not
damaged and that there are no breakages, damages, worn parts, or loose or
damaged nuts or bolts.
12 - When washing the machine, do not direct the high-pressure water jet
onto the radiator.
13 - When washing the machine, protect the electric system connectors and
avoid wetting the ignition switch.

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14 - The fuel tank is made of plastic; therefore avoid using trichloroethylene to
clean it. Trichloroethylene reduces the resistance and duration of the tank.
15 - Before starting work on muddy ground, under rain or snow, on seashores
or river banks,, check the tightening of valves and caps. Wash the machine
immediately after work, in order to prevent its components from rusting
Make sure that there are no damages, missing or loose nuts or pins.
Lubricate the components more frequently than usual. Lubricate the pins of
the work equipment carefully every day, if during work they are immersed in
water.
When the work site is particularly dusty, proceed as follows:

1 - Check the air filter for clogging and clean it more frequently than usual.
2 - Clean the radiator frequently in order to prevent the fins from clogging.
3 - Change the diesel oil filter more frequently than usual.
4 - Clean the electrical components, especially the starter and the alternator,
to avoid any accumulation of dust.
5 - Do not mix oils of different brands. Do not top up with oils different from
those being used. If you cannot use the same oil, drain the tank and change
the oil completely.
MAINTENANCE NOTES
1. Use only Komatsu genuine spare parts.
2. Do not mix different types of oil.
3. Unless specified otherwise, the oils and the coolant used by Komatsu
to fill the tanks before the delivery of the machine are the following:
OIL, FUEL AND COOLANT
OIL
1. The oil used for the engine and the work equipment is subjected to
demanding conditions (high temperature, high pressure) and
deteriorates with use. Always use oil suitable for the characteristics and
temperatures indicated in the use and maintenance manual. Change
the oil after the prescribed interval, even if it is not dirty.
2. The engine oil must be selected very carefully, since it lubricates the
engine, which is the machine’s heart; the main maintenance operations
required for the engine oil are the following:
A. Daily check of the oil level;
B. Check of the degree of pollution of the oil;
C. Periodical change.
D. When changing the oil, change also the filters.
E. It is advisable to have the oil periodically analyzed in order to check the
conditions of the machine.

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ITEM / TANK / SYSTEM SPECIFICATIONS
• Engine oil SAE 10W-30
Specifications: API CF - CF2 - CD
• Hydraulic system oil SAE 10W
Specifications: API CD
• Biodegradable hydraulic system oil
(Only for machines in which synthetic biodegradable oil type HEES not of
plant origin is used)
SHELL NATURELLE HFX-32
• Travel reduction gears oil SAE 30
Specifications: API CD
• Fuel with ambient temperature over -10° C, use:
Diesel oil ASTM D975 N°2
With ambient temperature below -10°C, use:
Diesel oil ASTM D975 N°1
• Radiator Special permanent antifreeze, biodegradable, ethylene glycol
based with corrosion inhibitor and with no silicates, borates, nitrates,
phosphates and amines.
Red antifreeze suitable for aluminum radiators, diluted with water (50%) to
ensure protection down to -36°C.
FUEL
1. Always use fuel suitable for the engine. Other fuels with different
specifications may damage the engine or reduce its power.
2. Always refuel at the end of the workday.
3. When refueling, make sure that there is no water on the fuel drum
cover and take care not to draw condensate from the drum bottom.
4. If fuel runs out, or if the fuel filter has been replaced, it is necessary to
bleed the circuit.
COOLANT
1. The coolant serves to keep the engine at the correct temperature and
therefore to ensure optimal operating conditions; check the coolant
level in the expansion tank daily and top up when necessary.
2. The coolant containing antifreeze is flammable; do not use naked
flames near the coolant and do not smoke while topping up.
3. Use only red permanent ethylene glycol based antifreeze, with
corrosion inhibitors and antifoam products, suitable for aluminum
radiators. If pure, dilute with water (50%).

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4. The use of permanent antifreeze requires only the check of the level
and the periodical change of the fluid. It is not necessary to wash the
cooling circuit.
5. Use drinkable water and in any case soft water.
6. Do not use corrosion inhibitors containing soluble oil, since they
damage the rubber couplings.
7. In case of doubt regarding the applicable standards for the use of
coolant, contact your Komatsu Dealer, who will supply you with
exhaustive and precise information.
(KOMATSU OIL WEAR ANALYSIS)

This system requires that oil samples be periodically collected and analyzed.
This is a preventive maintenance service, which makes it possible to identify
faulty parts or worn machine components timely. It also allows many failures
to be prevented and machine downtime to be reduced.
Many years of experience and the availability of countless data and
information allow Komatsu to accurately determine the conditions of the
machine. This also allows us to locate troubles and suggest the most suitable
and fast repair solutions.
The customer immediately receives a report containing the results of the
analysis and suggestions for the operations to be carried out. This low-cost
service is very useful and allows customers to save money and avoid many
problems.
KOWA ANALYSIS STAGES

1. Analysis of metal particles
2. In this stage a ICP (Inductively Coupled Plasma) analyzer is used to
measure the density of the metal particles present in the oil.
3. Measurement of particle quantity
4. In this stage a PQI (Particle Quantifier Index) machine is used to
measure the quantity of large iron particles present in the oil.
5. Other analyses and measurements In this stage other aspects, such
as the percentage of water or fuel in the oil and the dynamic viscosity,
are analyzed.
OIL SAMPLING
1. Collection interval Every 500 hours: engine and other components
2. Precautions to be taken when sampling the oil
• Make sure that the oil is well mixed before sampling.

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• Carry out sampling regularly, at fixed intervals.
• Do not carry out sampling on rainy or windy days, when water or dust can
get into the oil.
STORING OIL AND FUEL
1. Keep oil and fuel indoors to prevent any water, dirt, or other impurities
from getting into them.
2. When storing drums for a long period, position them on one side, so
that the opening is lateral. This prevents moisture from being sucked in
through the drum filling opening. If drums have to be stored outside,
cover them with a waterproof sheet or take other measures to protect
them.
3. To prevent any change in quality during long-term storage, be sure to
use the fluids following the first in - first out (use the oldest oil or fuel
first) method.
FILTERS
1. Filters are very important components for safety. They prevent any
impurities from getting into the oil, fuel, or in the air circuits, thus
avoiding problems to important components of the machine.
Periodically change all the filters. For further information, see the
relevant Use and Maintenance manual. However, when working in
extreme conditions, it is necessary to change the filters more
frequently, depending on the type of oil and fuel used (sulphur content).
2. Do not attempt to clean the filters (type with cartridge) and reuse them.
Always change them with new filters.
3. When changing the oil filters, check if metal particles are present. If you
find large quantities of metal particles, contact your Komatsu Dealer.
4. Do not open the spare filter packages before using them.
5. Always use Komatsu original spare parts.
NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM
1. If the cables are wet or their insulating material is damaged, the
electrical system leaks and this may result in malfunctions of the
machine.
2. The maintenance operations required for the electrical system are the
following:
1 - Check of the alternator belt tension.
2 - Check of the alternator belt for damage or breakages.
3 - Check of the battery charge level.
3. Do not remove or eliminate any electric component installed on the
machine and do not install any electric component with characteristics
different from those specified and approved by Komatsu.
4. Keep the electric system dry.

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5. When working on the seashore or on river or lake banks, protect the
jack plugs from corrosion.
6. Do not connect any optional device to the fuses, ignition switch,
battery, relays, etc.
7. If any electric welding operation has to be carried out, disconnect the
battery and the alternator.
NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM
1. Be extremely careful when performing maintenance operations on the
hydraulic system, since soon after work the oil is very hot. The circuit is
pressurized not only during work, but also at the end of work.
2. The maintenance operations required for the hydraulic system are the
following:
1 - Daily check of the oil level in the tank.
2 - Periodical change of the oil filter.
3 - Periodical change of the oil and cleaning of the intake filter.
3. Always bleed the circuit after changing the oil filter or the oil.
4. When a component is removed from the circuit, check the gaskets and
O rings and change them if they are damaged.
5. When a cylinder or a component of the hydraulic circuit is removed,
after reassembly bleed the circuit by proceeding as follows:
1 - Start the engine and let it idle.
2 - Extend all the cylinders 4-5 times, stopping them at approx. 100 mm from
the end of stroke.
3 - Slowly make all the cylinders reach the end of stroke for 3-4 times.
MAINTENANCE NOTES REGARDING LUBRICATION
1. Lubrication makes the operations carried out with the machine and
work equipment smoother, whiles preventing wear and the noise that
may be produced if the joints are dry. Lubricate with grease or oil.
2. The maintenance operations required for the components that need
lubricating are the following:
1 - Check of the levels.
2 - Oil change.
3 - Injection of grease through the grease nipples.
3. Use only the specified lubricants, according to the ambient
temperature.
4. Always clean the grease nipples before injecting grease and remove
any excess grease after lubrication; this cleaning operation must be
performed with extreme care on the revolving parts. Maintain correct
lubricant levels, avoiding excessive or insufficient quantities.

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SELF-CHECK 1.2-1
ESSAY
1. Discuss and explain the importance of maintenance guide.

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INFORMATION SHEET 1.2.2
CONTROLS, INSTRUMENTS, INDICATORS FUNCTIONS AND
APPLICATION
After reading this information sheet, you must be able to know the controls,
instruments, indicators functions and application.
INSTRUMENTS AND CONTROLS

The following paragraphs describe the devices that are necessary for correct
operation of the machine.
To perform the required operations correctly and safely, it is important to
understand the equipment operating methods and the meaning of the
information displayed.
WARNING LIGHTS AND GAUGES

1. Emergency warning lights
2. Gauges
3. Warning lights
EMERGENCY WARNING LIGHTS

CAUTION
If a warning light does not go out or comes on when the engines is running,
stop the machine immediately and try to find the cause of the failure.
1. Engine oil pressure warning light

This warning light comes on, together with the acoustic alarm,
When the engine is not running and the starting circuit is operated, and goes
out as soon as the engine lubrication circuit is pressurized.
If it does not go out or comes on when the engine is running, stop the
machine immediately and try to find the cause of the failure,
2. Charge level warning light

This warning light comes on, together with the acoustic alarm, when the
starting circuit is energized and goes out when the engine exceeds the idling
speed; if this warning light remains on even when the engine is running at the
normal operating speed, this means that the alternator is not working and the
battery is not charged correctly.
IMPORTANT
If the warning light remains off when the ignition key is turned to position ON,
this means that the alternator is faulty or broken.

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GAUGES
1. Fuel gauge
It indicates the fuel level in the tank and functions only when the ignition key is
in position ON.
F: maximum level.
E: minimum level.
If the quantity of fuel in the tank is less than 3.3 liters, the indicator reaches
the red reserve area (A).
NOTE
If the indicator reaches the red reserve area (A) during use, stop the
machine and provide for refueling.
2. Hour meter
This instrument indicates the total number of operating hours of the engine.
The count is continuous and the hour number is increased by 0.1 when the
engine has worked for 0.1 hour (6 minutes), independently of the engine
speed. When the engine is running, the LED positioned on the hour meter
comes on, indicating that the count is proceeding.
If the engine is on, the hour meter keeps counting even if the machine is not
working. The reading of the hour meter must be used as reference for the
machine maintenance intervals.
WARNING LIGHTS
1. Engine preheating warning light
This warning light comes on when the ignition key is turned to the preheating
position (HEAT) to start the engine at low temperatures. It goes out
automatically after approximately 10 seconds, when the preheating process
has been completed.
2. Travel speed increase warning light

This warning light comes on when the travel speed selection switch is in high
speed position when the speed selection switch in low speed position, the
warning light is off.
NOTE
• When the machine travels at high speed on soft ground or up a slope and
the load increases, the low speed is automatically selected, but the travel
speed increase warning light remains on.

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3. Engine coolant temperature warning light
This warning light comes on when the engine coolant exceeds the maximum
temperature allowed; in this case, reduce the engine speed until the warning
light goes out. If this inconvenience occurs again, make sure that the radiator
is clean.
SWITCHES AND PUSH BUTTONS
1. Ignition switch
This is a four-position rotary switch and is used to switch the engine on and
off.
a. Position OFF
When the switch is in this position, the ignition key can be inserted and
removed. When the key is turned to this position, the power supply to the
electric circuit is interrupted and the engine stops.
b. Position ON
The load and light circuits are under voltage. Keep the key in this position
when the engine is on.
c. Position START
This is the ignition position. Keep the key in this position to make the starter
run. As soon as the engine starts, release the key, which will automatically
return to position ON.
Position HEAT (preheating)

When starting the engine in cold weather, turn the key to position HEAT for
approximately 10 seconds, until the corresponding warning light goes out.
Release the key, which will automatically return to position OFF. Start the
engine by rotating the key to position START.
IMPORTANT
If the engine has stopped due to lack of fuel, start it by proceeding as follows:
turn the ignition switch to position ON, wait for 15 seconds and then turn the
key to position START.
2. Horn
This button is positioned at the center of the right lever knob and serves to
send out a warning signal at the beginning of work and in case of danger.
3. Light switch
This is a two-position (ON-OFF) switch and is used to turn the lights on and to
light up the warning lights and gauges display.
Position ON (A):

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Lights on and warning lights and gauges display lit up
Position OFF (B):
Lights and display off.
4. Travel speed selection switch

WARNING
a. When loading or unloading the machine on/from a motor vehicle,
always travel at low speed. Never operate the travel speed selection
switch during the loading or unloading operation.
b. If the travel speed is switched over from high to low when the machine
is travelling, the machine may deviate to one side, even if it is travelling
straight. Stop the machine before changing speed. This is a two-
position switch and is used to change over from high to low speed or
vice versa.
High travel speed (A): When the switch is in this position, the high speed is
increase warning light on the display comes on.
Low travel speed (B): When the switch is in this position, the low speed is
selected and the warning light goes out.
NOTE
When the engine is started, the low speed is automatically selected.
When the machine travels on soft ground or up a slope at high speed and the
load increases, the low speed is automatically selected, but the speed
increase warning light remains on. When the load is reduced, the travel
system automatically changes over to high speed.
5. Blade/adjustable track gauge selection switch

WARNING
a. Use the narrow track gauge only when it is necessary to go through
narrow passages or when there is no other choice. For normal
applications and digging operations, always select the wide track
gauge.
b. Avoid adjusting the track gauge when the machine is working on a
slope: the machine may lose stability and overturn. Always adjust the
track gauge on level surfaces.
c. When the track gauge is narrowed completely, also the lateral stability
of the machine is reduced. In work sites where the machine runs the
risk of overturning, always widen the track gauge and pay the utmost
attention during travel.

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d. Before using the blade/adjustable track gauge lever, check the position
of the switch. This is a two-position switch and allows the operator to
choose between using the blade and adjusting the track gauge.
Adjustable track gauge (A): when the switch is in this position, it is possible to
adjust the track gauge.
Blade (B): When the switch is in this position, it is possible to use the blade.
For further details on how to use the blade and adjust the track gauge,
6. Power outlet (12V)

A power outlet is positioned on the front part of the machine for the
connection of a lamp for routine and maintenance operations.
It is a two-pole outlet and is in compliance with the ISO 4165- 1979 standard.
Power supplies 12 V.
CONTROL LEVERS AND PEDALS

1. Safety lever (control locking lever)
2. Left work equipment control lever
3. Right work equipment control lever
4. Accelerator lever
5. Blade/adjustable track gauge lever (if provided)
6. Travel levers (with pedal)
7. Boom swing control pedal locking device
8. Boom swing control pedal
9. Cab floor locking lever
10. Pedal locking device (for the optional equipment control pedal)
Safety lever (control locking lever)
WARNING
1. Before leaving the driver seat, lower the equipment to the ground and
shift the safety lever to the “locked” position (L). If the safety lever is not
in the “locked” position and the control levers are touched by mistake,
this may lead to serious injury.
2. If the safety lever is not in the “locked” position, the control levers may
move, causing accidents or serious injury. Always make sure that the
lever is in the “locked” position, as shown in the figure.
3. When shifting the safety lever, take care to avoid touching the
equipment control levers. This lever operates the safety device that
locks the work equipment, the swing and travel functions and the
attachments. When pulled upwards, it is in “locked” position (L). The
safety device is hydraulic, therefore even if the control levers and the
pedals move, the work equipment and the machine cannot be
operated.

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NOTE
If the safety lever on the right or left side is not in the “locked” position
(L), the engine cannot be started. Before operating the ignition switch,
always make sure that the safety lever is in the “locked” position. If the
engine stops while the safety lever is in “free” position (F), shift the
lever back to the “locked” position before operating the ignition switch.
(F): free
(L): locked
Work equipment control levers

WARNING
1. Before carrying out any maneuver with these levers, the operator must
seat in the work position and fasten the seat belt.
2. Before leaving the driver seat, lower the equipment to the ground, lock
the controls with the safety lever and stop the engine.
IMPORTANT
1. The horn push button is positioned on the right lever grip and must be
used to warn all the people in the vicinity before starting work and in
case of danger.
2. When the safety lever is in the “locked” position, all the movements are
inhibited
3. Safety lever (control locking lever).
The control lever (2) is positioned on the operator’s left and controls the arm
and the turret swing.
1. Swing function
(a) Swing to the right
(b) Swing to the left
2. Arm
(a) Fold
(b) Extend
N (Neutral): the turret and the arm are held in the position where they
stopped.
The control lever (3) is positioned on the operator’s right and controls the
boom and the bucket.
1. Boom

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(a) Lift
(b) Lower
2. Bucket
(a) Open
(b) Fold
N (Neutral): the boom and the bucket are held in the position where they
stopped.
Accelerator lever
This lever is used to control the engine speed and power.
(a) Minimum: push the lever completely forward.
(b) Maximum: pull the lever completely backward.
Use the accelerator with care, especially when the machine is under strain or
is working in difficult conditions. Avoiding useless accelerations means
reducing consumption and extending the service life of both the engine and
the machine.
Blade/adjustable track gauge lever

WARNING
1. Narrow the track gauge only when it is necessary to travel or to carry
out digging operations in small spaces. In any other condition, always
select the wide track gauge.
2. Avoid adjusting the track gauge when the machine is working on a
slope. This may affect the lateral stability of the machine.
3. Widen or narrow the track gauge with the machine resting on a firm
and level surface and the tracks slightly raised from the ground, in
order to avoid damaging the tracks and the hydraulic motors. This lever
is used to control the movements of the blade or to adjust the track
gauge, depending on the position of the switch
Blade
(a) Lower
(b) Lift
Adjustable track gauge
(a) Narrow track gauge
(b) Wide track gauge
NOTE

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1. When carrying out digging operations that require the blade to be used
for more than one hour without interruption, pay attention to the coolant
temperature, since this may increase excessively.
2. Before using the lever, check the position of the blade/ adjustable track
gauge switch.
Travel levers
WARNING
1. Before carrying out any maneuver with these levers, the operator must
2. Before moving the machine, make sure that the sprocket (A) is
positioned at the rear of the machine and that the safety locks are engaged; if
the turret is rotated by 180°, the controls are inverted
3. Use the travel control pedals only when the machine is moving. If a
pedal is inadvertently pressed when the machine is not moving or steering,
this may move suddenly and cause serious accidents.
4. When travelling or carrying out steering maneuvers, use the pedals with
the maximum care.
5. When leaving the operator seat, always rotate the pedals to the rest
position, in order to avoid pressing them by mistake.
These levers are used to operate the travel motors (right and left) and control
the forward and reverse travel according to the movements indicated.
(a) FORWARD: levers pushed forward
(b) REVERSE: levers pulled towards the operator
N (Neutral): machine at rest
NOTE
When it is necessary to use the travel pedals, the opening operation must be
carried out by the operator while correctly seated in driving position. After use,
always rotate the pedals to the rest position (closed).
IMPORTANT
When the safety lever is in the “locked” position, all the movements are
inhibited
Boom swing control pedal locking device

WARNING
Always shift the safety lever to position (L) when the boom swing is not
required, during travel and when parking the machine. If the control pedal is
inadvertently pressed, this may cause serious accidents.
This device is used to lock the movements of the boom swing control pedal
and has two positions.

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(F): free
(L): locked
Boom swing control pedal

This pedal controls the boom swing to the right and to the left, according to
the movements indicated below.
(a): swing to the right
(b): swing to the left
N (Neutral): boom at rest.
IMPORTANT
1. When the safety lever is in the “locked” position, all the movements are
inhibited
2. The boom swing is useful to displace the digging line beyond the track
outline; do not use this function during the work cycle.
Cab floor locking lever

WARNING
Always keep to the warnings when tilting or closing the cab floor. Any
operation carried out incorrectly may cause serious injury. Do not tilt or close
the cab floor on slopes or if there is a strong wind.
To tilt or close the cab floor, pull the lever to the “free” position (F).
After tilting or closing the cab floor, release the lever, which will automatically
return to the “locked” position (L).
(F): free
(L): locked
Pedal locking device

WARNING
Always lock the optional equipment control pedal when the use of this control
is not required, during travel and when parking the machine. If the control
pedal is inadvertently pressed, this may cause serious accidents.
The safety device is used to lock the optional equipment control pedal.
Optional equipment control pedal

The pedal controls oil delivery to and return from the optional equipment.
1. Upper part of the pedal (A) pressed: The oil flows to the right side of
the arm (hydraulic tank side).
2. Lower part of the pedal pressed (B): The oil flows to the left side of the
arm (operator seat side).

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COVERSWITH LOCK
Use the ignition key to open and close the covers with lock.
For details on the position of the covers with lock,
Introduce the key completely (6 mm from the point where the key narrows),
then turn it. If the key is turned when it is inserted only partially into the lock, it
may break.
OPENING AND CLOSING THE COVERS WITH LOCK

Opening
1 - Insert the key into the lock.
2 - Turn the key counterclockwise and open the cover.
Closing
1 - Close the cover and insert the key into the lock.
2 - Turn the key clockwise and extract it.
ENGINE HOOD
WARNING
1. Do not open the engine hood when the engine is running.
2. Do not use the machine without engine hood and do not start the
engine when the hood is open, unless this is expressly prescribed for
certain maintenance operations.
3. When carrying out an inspection or maintenance operation inside the
engine hood, always open it completely and make sure that it is kept
open by the opposite rod.
4. Non-compliance with these rules may lead to serious accidents.
IMPORTANT
1. If it is not necessary to open the cover, always keep it locked.
2. When the hood is locked, the handle (2) cannot move.
OPENING THE BATTERY COVER

1. Release the engine hood lock (1)
2. Pull the handle (2) of the engine hood (3) and open it completely. The cover
(2) is kept open by the opposite rod (3)
CLOSING THE COVER
1. Lift the rod (4) and partially close the hood (3) until the rod comes out of the
groove.
2. Close the hood completely and lock it.
RADIATOR COVER

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WARNING
When carrying out an inspection or maintenance operation inside the radiator
cover, always open it completely and make sure that it is kept open by the
opposite rod.
1. Release the radiator cover lock (1)
2. Pull the radiator cover (2) and open it completely. The cover
(2) is kept open by the opposite rod (3).
CLOSING THE COVER
3. Lift the rod (3) and close the cover (2) without exerting too much pressure.
When the rod comes out of the groove, close the cover completely and lock it.
BATTERY COVER
WARNING
When carrying out an inspection or maintenance operation inside the battery
cover, always open it completely and make sure that it is kept open by the
opposite rod.
OPENING THE BATTERY COVER
1. Release the battery cover lock (1)
2. Pull the battery cover (2) and open it completely. The cover
(2) Is kept open by the opposite rod (3).
CLOSING THE COVER
1. Pull the rod (3) and close the cover (2) without exerting too much pressure.
Remove the rod (3) from the groove and close the cover completely.
2. Lock the cover.
TILTING THE CAB FLOOR
WARNING
1. Always keep to the warnings when tilting or closing the cab floor. Any
operation carried out incorrectly may cause serious injury.
2. Do not tilt or close the cab floor on slopes or if there is a strong wind.
3. Do not get too near the cab floor tilting or closing area and do not enter
the cab when the cab floor is tilted.
4. Do not start the engine when the cab floor is tilted.
5. If there is something wrong in the locking function when the cab floor is
tilted,
Tilting the cab floor

1. Lower the blade.
2. Extend the bucket and arm cylinders completely, then lower the boom
slowly.
3. Shift the safety lever (1) to the “locked” position (L), then stop the engine.
4. Position blocks under the tracks in order to prevent the machine from
moving.

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5. Open the engine hood (2) completely and make sure that it is kept open by
the opposite rod
6. Loosen the fastening screws of the cab floor (3).
7. Raise the mat (4), pull the cab floor release lever (5) in the direction
indicated by the arrow and at the same time push the handle (6) upwards in
the direction indicated by the arrow
IMPORTANT
1. If the cab floor does not tilt, pull the handle (6) downwards and repeat
the procedure described above.
2. When tilting or closing the cab floor, be extremely careful, and keep
away from the area under the cab floor.
NOTE
1. The cab floor tilts thanks to the operation of a gas cylinder, so when the
ambient temperature is low, the operating effort increases.
2. After tilting the floor open, make sure that the locking pin (7) is inserted
in the groove (9) of the locking plate (8).
3. Insert the safety pin (10) into the hole (11) from the outside.
4. Turn until the coupling at the end of the safety pin (10) is completely
engaged with the pin (12).
NOTE
Make sure that the safety pin (10) is correctly engaged with the pin (12).
Closing the cab floor

IMPORTANT
Before closing the cab floor, check that there is no damage or anomaly
in the wiring or piping located in the compartment under the floor. If any
damage or anomaly is observed,
Remove the safety pin (10) and store it into the opposite hole
NOTE
1. If the safety pin (10) does not come out, try again by pushing the
handle (6) at the same time.
2. Pull the cab floor release lever (5) in the direction shown by the arrow
and at the same time pull the handle (6) downwards in the direction
indicated by the arrow (approximately 45°).
3. IMPORTANT
1. Lower the cab floor slowly and make sure that the wires and pipes
located under it are neither damaged nor twisted.

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2. When tilting or closing the cab floor, be extremely careful, and keep
away from the area under the cab floor.
3. Tighten the cab floor fastening screws (3) applying the required torque.
Tightening torque: 156.8 to 196 Nm
FUSES
IMPORTANT
1. When changing a fuse, make sure that the ignition key is in position
OFF.
2. If the fuses are oxidized, corroded or do not fit perfectly in their seat,
replace them only with new fuses having the same capacity. The fuses
protect the electrical equipment and wiring from burning out. If a fuse is
corroded, covered with white powder, or loose in the fuse holder,
change it. Replace the fuse with a new one having the same capacity.
POSITION COLOUR CAPACITY (A) CIRCUIT INVOLVED

F1 Red 10 Radio power supply
F2 Green 30 Engine stop solenoid valve power supply, engine stop timer,
safety relay, alternator excitation
F3 Red 10 Fuel pump, work light
F4 Yellow 20 High-low speed switch, PPC solenoid valve, display power
supply
F5 Light blue 15 Horn
F6 Light blue 15 Windshield wiper, overhead light, heating (for machine with
cab)
F7 Red 10 Optional equipment
F8 Red 10 Revolving light
F9 - - Free
F10 - - Free
F11 - - Free
MAIN FUSE
IMPORTANT
1. When changing a fuse, make sure that the ignition key is in position
OFF. If the starter does not run when the ignition switch is turned to
position ON, the fuse (1) may have blown. Open the cover on the left
side of the machine to check the fuse and change it if necessary. The
main fuse is positioned on the battery.
For further details on how to open and close the cover on the left side of the
machine,
NOTE

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The main fuse is the high-capacity fuse installed to protect the electric
components and the wiring.
TECHNICAL DOCUMENTATION COMPARTMENT

CAUTION
The use and maintenance manual is an integral part of the machine and must
accompany it even in case of resale.
The use and maintenance manual must be stored with care and always kept
on board the machine, so that it can be consulted at any moment; it must be
placed in the technical documentation compartment inside the seat support.
TOOL BOX
The tool box is positioned inside the seat support and can be reached by
opening the front panel.

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SELF-CHECK 1.2-2
ENUMERATION
1. Enumerate the control levers and pedals.

a.
b.
c.
d.
e.
f.
g.
h.
i.
j.

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EQUIPMENT BRAND, MODEL PARTS, WARNING DECALS, JOBSITE
AND WORK CONDITIONS
After reading this information sheet, you must be able to know the equipment
brand and model parts.
Warning Labels & Decals

- Warn employees of the potential for death or serious injury Post a
Warning Label any place there is a potentially hazardous situation.
Warning Labels are available in a variety of sizes from large too small.
Labels come in a wide variety of stock wording or order Custom
Warning Labels to warn of your specific hazard or danger.

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Protecting Yourself from Unsafe Working Conditions
Under federal and state laws, employers must provide a safe workplace. If
unsafe working conditions are present, a worker may report the violation to
the employer, to the federal and/or state Occupational Safety and Health
Administration (OSHA), and in some cases, the worker may refuse to work.
The following is a summary of OSHA protection and guidelines for dealing
with dangerous conditions in the workplace.
What is OSHA?
The Occupational Safety and Health Act is a federal statute that requires
employers to maintain a workplace that is free of dangerous health and safety
conditions that can cause illness, injury, or death. The Occupational Safety
and Health Administration, also referred to as OSHA, enforce the act and
establish safety standards.
The intent of OSHA is to protect workers (excluding independent contractors)

from:
 One-time injuries;
 Illnesses caused by unsafe health conditions in the workplace; and
 Recognized hazards that may cause death or serious injury.
To protect workers from unsafe working conditions, employers must abide by

workplace safety standards. Employers must:
 Provide a workplace free of health and safety hazards that can cause
death or serious injury;
 Post a OSHA job safety notice in the workplace;
 Keep a record of injuries, deaths, and exposure to hazardous material;
and
 Provide safety training if necessary.
Safety standards set by OSHA include provisions for the storage of hazardous
chemicals, equipment maintenance, fire protection, and protective clothing.
What to Do When a Safety Hazard Poses an Imminent Danger

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When unsafe working conditions place the life of a worker in imminent danger,
the worker should report the dangerous condition to OSHA. The worker also
has the right to refuse to work if:
 There is a reasonable and good faith belief that a condition in the

workplace poses an immediate and substantial risk of serious physical
injury or death;
 The employer will not fix the dangerous condition;
 The immediacy of the danger does not allow enough time to report the
condition to OSHA or the appropriate state agency; and
 The worker did not have a reasonable alternative.
The worker can refuse to return to work until the employer eliminates the
danger or investigates and determines that no imminent danger exists.
What to Do When a Safety Hazard Does Not Pose an Imminent Danger
If a dangerous condition does not create the risk of imminent danger, the
employee should inform the employer of the problem in writing. If the
employer fails to correct the condition, the worker can file a complaint with
OSHA or with the appropriate state occupational safety agency.
OSHA regulations and many state laws prohibit an employer from retaliating
against a worker that reports a violation. This means the employer may not
fire, demote, or reduce a worker's pay because the worker filed a complaint
about unsafe working conditions. A determination of employer retaliation by
OSHA can result in the reinstatement of the worker to their former position
and an order for compensation for lost wages.
Get a Free Initial Claim Review
If you are dealing with dangerous working conditions or have been injured on
the job you will benefit from the assistance of a legal professional. A lawyer
can help determine your rights and help you decide whether you need to sue
or will be better off negotiating with an employer. Contact an attorney for
a free initial claim review and let them help guide you to a better, safer
working environment.

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SELF-CHECK 1.2-3
ESSAY
1. Discuss and explain the importance of warning labels and decals.

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PERFORM BLOWAF CHECK
LEARNING OUTCOME #3
CONTENTS
1. Battery (condition and connections)
2. Lights (lighting system)
3. Oil (level)
4. Water (level)
5. Air (filter and connection)
6. Fuel (level and lines)
1. BLOWAF inspection are performed following equipment
checklist and with engine stopped
3. Pre-operation inspection checklist
4. Workplace situation
5. Fluids and lubricants (hydraulic oil, engine oil, brake fluid,
transmission gear oil, distilled water and grease.
Assessment method:
1. Written Test

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PERFORM BLOWAF CHECK

Battery (condition and connections) information sheet don’t hesitate to approach your
facilitator.

self-check again.

Lights (lighting system)
facilitator.
self-check again.
Oil (level) information sheet don’t hesitate to approach your
facilitator.

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self-check again
facilitator.
Water (level)

self-check again.
facilitator.
Air (filter and connection)

Answer self-check 1.3-5 not, review the information sheet and go over the
self-check again.
facilitator.
Fuel (level and lines)

self-check again

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INFORMATION SHEET 1.3-1 to 1.3-6
BLOWAF CHECK
After reading this information sheet, you must be able to know how to perform
BLOWAF check.
VISUAL CHECKS
Before starting the engine, look around the machine and under the machine to
check for loose nuts or bolts, oil, fuel or coolant leakages, and check the
conditions of the work equipment and the hydraulic system. Check also for
loose wires, excessive gaps, and accumulation of dust in places that reach
high temperatures.
WARNING
- When opening the engine hood, the radiator cover and the battery
cover to carry out inspection or maintenance operations, always open
them completely and secure them in the correct position with the
opposite retainer.
- Immediately remove any flammable materials that may have
accumulated around the battery, the exhaust silencer or other hot parts
of the engine. Any oil or fuel leakages may cause fires and damage the
machine. Always perform thorough checks and carry out the necessary
repairs; if any fault occurs repeatedly, contact your Komatsu Dealer.
- Make sure that the cab floor is properly fastened with the screws (1). If
it is not secured properly, it may cause serious injury. Carry out this
check with the machine parked on level ground. If the machine is
inclined, position it horizontally before carrying out the check.
Carry out the following inspection and cleaning operations every day before
starting the engine.
1. Check the work equipment, the cylinders, the articulations and the pipes for
damage, wear, excessive play. If any anomaly is observed, provide for the
necessary repairs.
2. Remove dirt and dust from around the engine, the battery, and the radiator.
Check that there is no dirt or dust accumulated around the engine or the
radiator. Check also that there is no flammable material (dry leaves, twigs,
etc.) accumulated around the exhaust silencer, the hot parts of the engine or
around the battery. Remove all dirt, dust, and flammable materials.
3. Make sure that there are no water or oil leakages around the engine.

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Make sure that there are no oil leakages from the engine or coolant leakages
from the cooling system. If any anomaly is observed, provide for the
necessary repairs.
4. Make sure that there are no oil leakages from the hydraulic system, the
hydraulic tank, pipes, and joints. Make sure that there are no oil leakages. If
any anomaly is observed, provide for the necessary repairs.
5. Check the components of the undercarriage.
Check the tracks, the sprocket, the idler roller, and the guards for damage,
wear, loose bolts, and make sure that there are no oil leakages from the
rollers, etc.
If any anomaly is observed, provide for the necessary repairs.
6. Check the handles that are used to reach the driver seat.
Make sure that there are no damaged or loose bolts, repair the damaged
parts and tighten any loose bolts.
7. Make sure that there are no faults in the gauges and the warning lights.
If any anomaly is observed, provide for the necessary repairs. Clean any dirty
Battery – is the main source of all electrical energy, as part of your car's/unit
regular maintenance. Most important, check battery voltage, clean the battery
of corrosion, especially the electrical posts.
CHECKING THE BATTERY CHARGE LEVEL

WARNING
- Check the charge level only with the engine at rest.
- To prevent gas explosions, do not use naked flames, do not smoke
and avoid producing sparks due to short circuits.
- The battery electrolyte is dangerous; in case of contact with the eyes or
skin, rinse with plenty of water and consults a doctor without delay. The
battery is maintenance-free.
IMPORTANT
- Make sure that the connection terminals are not oxidized; if necessary,
clean them and cover them with anti-oxidation grease.
The battery (1) can be reached after opening the battery cover
A sight gauge (2) shows, with different colours, the battery charge level
according to the table positioned beside the gauge itself:
- Green: optimal charge
- Gray: the battery needs recharging
- White: the battery must be replaced.
WARNING
REMOVING AND INSTALLING THE BATTERY

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- Before removing the battery, disconnect the earth cable (-). If a tool
touches the positive terminal and the frame of the machine at the same
time, sparks may be generated.
- When installing the battery, connect the earth cable (-) last.
- Install the battery correctly. During this operation, take care to prevent
the clamps from touching the terminals.
- When changing the battery, secure it with the clamp (1) and tighten the
fastening screw (2) with the required torque.
- Make sure that the cover is correctly positioned. If the cover is
damaged, change it immediately.
- If the battery terminals are oxidized, clean them carefully using a metal
brush.
Lights - (check all light if functioning)

CHECKING THE WIRING SYSTEM
WARNING
- If the fuses are corroded, oxidized or not perfectly held in their seat,
replace them only with fuses having the same capacity; before
changing a fuse, make sure that the ignition key is in position OFF.
- If the wirings show traces of short circuits, inform to your supervisor.
- Before checking the wiring, take all the necessary safety precautions.
- Always keep the battery surface clean and make sure that the charge
level warning light is always visible.
- Make sure that the fuses are not damaged, that fuses with the required
capacity are used, that there are no disconnected, broken, or short-
circuited wires; furthermore, check the terminals, and tighten any loose
ones.
- Check the wiring of the battery, the starter and the alternator carefully.
- In addition, remove any flammable material that may have
accumulated around the battery.
Oil – CHECKING THE ENGINE OIL LEVEL AND TOPPING UP

WARNING
- Soon after the machine has been stopped the engine is very hot and
may cause burns; let the engine cool down to 40-45°C before carrying
out any check.
CAUTION
- When carrying out an inspection or maintenance operation inside the
NOTE

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- If the machine is inclined, position it horizontally before carrying out the
check.
- If the engine has just been stopped, before checking the engine oil
level wait approximately 15 minutes, in order to allow the engine to cool
down.
1. Open the engine hood.
2. Remove the dipstick (G) and wipe it with a cloth.
3. Insert the dipstick (G) completely into the oil filler pipe, then remove it and
check the oil level.
4. The oil level must be included between the H and L marks; if the level is
near the L mark, top up through the filler neck (F), using oil suitable for the
ambient temperature, as indicated in the lubricant chart
5. If the oil level is above the H mark, drain the excess oil through the drain
plug (P), and check the oil level again.
6. If the oil level is correct, tighten the oil filler, and then close the engine
hood.
- The engine oil must be selected very carefully, since it lubricates the
engine, which is the machine’s heart; the main maintenance operations
required for the engine oil are the following:
A. Daily check of the oil level;
B. Check of the degree of pollution of the oil;
C. Periodical change.
D. When changing the oil, change also the filters.
Water - check water level in radiator and leaks.

CHECKING THE COOLANT LEVEL AND TOPPING UP
WARNING
- Do not remove the radiator cap, unless such operation is absolutely
necessary. Before checking the coolant level, wait for the engine to
cool down and check the expansion tank.
- Immediately after the engine has stopped, the coolant is very hot and
under pressure. Removing the cap in these conditions to check the
coolant level may cause a burn hazard. Wait for the temperature to
lower, and then turn the cap slowly to release the pressure before
removing it.
1. Open the radiator cover.
2. Make sure that the coolant level is included between the MIN. and
MAX. marks on the expansion tank (1). If the level is low, top up through the
filler neck of the tank (1), until reaching the MAX. Mark.
3. Put back the cap after topping up.

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4. If the expansion tank is empty, make sure that there are no leakages
and check the coolant level in the radiator. If necessary, add coolant in the
radiator and also in the expansion tank.
Air - check for air leak and filter

CHECKING THE AIR FILTER CLOGGING INDICATOR
- 1. Open the engine hood.
- 2. Check if the red piston is visible in the transparent portion of the filter
clogging indicator (1).
- 3. If the red piston is visible, clean or replace the filtering element
immediately.
- For further details on how to clean the filtering element,
- 4. After checking, cleaning or replacing the filtering element, press the
knob on the indicator (1), so that the red piston returns to its original
position.
Fuel - check fuel level and leak

CHECKING THE FUEL LEVEL AND REFUELLING
WARNING
- When refueling, avoid spilling fuel, since this may cause a fire hazard.
If fuel is spilled, wipe it up immediately.
- Fuel is highly flammable; do not use naked flames and do not smoke
when refueling. Hold the fuel gun constantly in contact with the filler.
1. Insert the key in the ignition switch (1) and turn it to position
ON.
2. Check the fuel level on the fuel gauge (2). If the fuel level is low, open the
engine hood (3) remove the cap and refuel through the filler (F). While
refueling, check the fuel level on the sight gauge (G).
3. Avoid filling the tank completely and leave enough space for the fuel to
expand.
4. After refueling, tighten the cap thoroughly and close the engine hood.

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SELF-CHECK 1.3-1-6
1. What is BLOWAF?
B–
L–
O–
W–
A–
F–

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CHECK HYDRAULIC EXCAVATOR
LEARNING OUTCOME #4 SYSTEM FUNCTIONS
CONTENTS
1. Safety start and warm up procedures
2. Familiarization on switches, gauges and systems monitor/indicators
3. Audio and air conditioning system
4. Electrical lighting and accessories
5. Familiarization on work equipment function
6. Familiarization on operator’s compartment
7. Familiarization on controls, levers and pedals
1. Walk-around and operation check is observed while engine is running
2. Systems function and operation are checked according to
manufacturer’s specifications
3. After-start/operation checklist
5. Fluids and lubricants (hydraulic oil, engine oil, brake fluid,
transmission gear oil, distilled water and grease.
Assessment method:
1. Direct observation
2. Written test/questioning

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CHECK HYDRAULIC EXCAVATOR SYSTEM AND FUNTIONS

Read Information 1.4-1 If you have some problem on the content
Safety start and warm up procedures of the information sheet don’t hesitate to
approach your facilitator.
If you feel that you are now knowledgeable
on the content of the information sheet
1.4-1, you can now answer self-check
provided in the module.
Answer self-check 1.4-1 If you got 100% correct answer in this self-
check, you can now move to the next
information sheet. If not, review the
information sheet and go over the self-
check again.

If you have some problem on the content
Familiarization on switches, gauges and
of the information sheet don’t hesitate to
system monitor/indicators
Answer self-check 1.4-2 If you got 100% correct answer in this self-
check again.
Read Information 1.4-3 If you have some problem on the content

Audio and air conditioning system of the information sheet don’t hesitate to

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Answer self-check 1.4-3
If you got 100% correct answer in this self-
Electrical lighting and accessories
check again

Read Information 1.4-5 information sheet. If not, review the
Familiarization on work equipment information sheet and go over the self-
function check again.
Answer self-check 1.4-5 If you feel that you are now knowledgeable

Familiarization on operator’s
compartment
check again.

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Read Information 1.4-7 check, you can now move to the next
Familiarization on controls, levers and information sheet. If not, review the
pedals information sheet and go over the self-
check again.

check again.

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SAFETY START AND WARM UP PROCEDURES
After reading this information sheet, you must be able to know the safety start
and warm up procedures
CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE

Carry out the checks listed below every day before starting the engine.
CHECKING THE COOLANT LEVEL AND TOPPING UP

WARNING
- Do not remove the radiator cap, unless such operation is absolutely
necessary. Before checking the coolant level, wait for the engine to
cool down and check the expansion tank.
- Immediately after the engine has stopped, the coolant is very hot and
under pressure. Removing the cap in these conditions to check the
coolant level may cause a burn hazard. Wait for the temperature to
lower, and then turn the cap slowly to release the pressure before
removing it.
2. Open the radiator cover.
2. Make sure that the coolant level is included between the MIN. and
MAX. marks on the expansion tank (1). If the level is low, top up through the
filler neck of the tank (1), until reaching the MAX. Mark.
3. Put back the cap after topping up.
4. If the expansion tank is empty, make sure that there are no leakages
and check the coolant level in the radiator. If necessary, add coolant in the
radiator and also in the expansion tank.
CHECKING THE ENGINE OIL LEVEL AND TOPPING UP

WARNING
- Soon after the machine has been stopped the engine is very hot and
may cause burns; let the engine cool down to 40-45°C before carrying
out any check.
CAUTION
- When carrying out an inspection or maintenance operation inside the
NOTE
- If the machine is inclined, position it horizontally before carrying out the
check.

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- If the engine has just been stopped, before checking the engine oil
level wait approximately 15 minutes, in order to allow the engine to cool
down.
2. Remove the dipstick (G) and wipe it with a cloth.
3. Insert the dipstick (G) completely into the oil filler pipe, then remove it and
check the oil level.
4. The oil level must be included between the H and L marks; if the level is
near the L mark, top up through the filler neck (F), using oil suitable for the
ambient temperature, as indicated in the lubricant chart
5. If the oil level is above the H mark, drain the excess oil through the drain
plug (P), and check the oil level again.
6. If the oil level is correct, tighten the oil filler, and then close the engine
hood.
CHECKING THE FUEL LEVEL AND REFUELLING

WARNING
- When refueling, avoid spilling fuel, since this may cause a fire hazard.
If fuel is spilled, wipe it up immediately.
- Fuel is highly flammable; do not use naked flames and do not smoke
when refueling. Hold the fuel gun constantly in contact with the filler.
1. Insert the key in the ignition switch (1) and turn it to position
ON.
2. Check the fuel level on the fuel gauge (2). If the fuel level is low, open the
engine hood (3) remove the cap and refuel through the filler (F). While
refueling, check the fuel level on the sight gauge (G).
3. Avoid filling the tank completely and leave enough space for the fuel to
expand.
4. After refueling, tighten the cap thoroughly and close the engine hood.
IMPORTANT
- It is advisable to refuel after work, in order to avoid the formation of
water condensate.
- If the breather hole (4) is clogged, the pressure in the tank will drop
and the fuel may not flow smoothly. Clean the breather hole (4)
frequently and make sure that it is not clogged.
-
CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP
WARNING

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- Carry out this check when the oil is cold, with the machine positioned
on level ground, bucket and arm cylinders retracted and bucket teeth
resting on the ground.
- Before topping up, stop the engine and eliminate the residual pressure
from the equipment circuits (by shifting the controls more than once)
and from the tank by slowly loosening the filling cap.
1. If the work equipment is not in the conditions shown in the diagram on the
right, start the engine and run it at high idling speed, retract the arm and
bucket cylinders completely and lower the boom until the bucket teeth touch
the ground. Stop the engine.
2. Make sure that the oil level is included between the H and L marks on the
sight gauge (G).
IMPORTANT
- Do not exceed the max. Level mark (H). This would damage the
hydraulic circuit and cause the oil to overflow.
- If too much oil is added and this exceeds the level (H) on the gauge,
turn the turret so that the drain plug (P) is positioned between the
tracks, stop the engine, wait for the hydraulic oil to cool down and drain
the excess oil through the drain plug (P).
3. If the oil does not reach the level (L), lift the mat (1), remove the cover
(2) and the cover on the filler neck (F), then top up through the filler
neck (F) using the oil recommended in the lubricant chart
NOTE
- The oil level varies according to its temperature. It is therefore
advisable to keep to the following indications:
- Before operation: near level (L) (Oil temperature ranging from 10°C to
30°C) Normal operation: near level (H) (Oil temperature ranging from
50°C to 80°C)
4. Extend the boom, arm and bucket cylinders completely, as shown in the
diagram on the right, and remove the filler cap.
Put back the cap and pressurize the tank, lowering the equipment to the
ground.
IMPORTANT
- If a constant or abnormal decrease in the oil level is observed,
thoroughly check the hydraulic circuit, the pistons and the pump for
leaks.
-

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CHECKING THE AIR FILTER CLOGGING INDICATOR
2. Check if the red piston is visible in the transparent portion of the filter
clogging indicator (1).
3. If the red piston is visible, clean or replace the filtering element
immediately.
For further details on how to clean the filtering element,
4. After checking, cleaning or replacing the filtering element, press the knob
on the indicator (1), so that the red piston returns to its original position.
Fuel is flammable; do not use naked flames and do not smoke while draining
the water separator.
- If fuel is spilled, wipe it up immediately.
- If the red ring (1) of the water separator is on the bottom of the casing
(2), this means that there is no water.
- If the ring (1) is floating, this means that there is water up to its lower
surface, therefore drain the water by proceeding as follows.
1 - Open the radiator cover and turn the lever (3)
2 - With a filter wrench, loosen the metal ring (4), remove the casing (2) and
eliminate the water contained inside it.
3 - Put back the casing (2) and tighten the metal ring (4).
4 - Turn the lever (3) to the “open” position (B).
5 - Drain any water or sediment from the fuel tank.
CHECKING THE WIRING SYSTEM

WARNING
- If the fuses are corroded, oxidized or not perfectly held in their seat,
replace them only with fuses having the same capacity; before
changing a fuse, make sure that the ignition key is in position OFF.
- If the wirings show traces of short circuits, inform to your supervisor.
- Before checking the wiring, take all the necessary safety precautions.
- Always keep the battery surface clean and make sure that the charge
level warning light is always visible.
- Make sure that the fuses are not damaged, that fuses with the required
capacity are used, that there are no disconnected, broken, or short-
circuited wires; furthermore, check the terminals, and tighten any loose
ones.
- Check the wiring of the battery, the starter and the alternator carefully.
- In addition, remove any flammable material that may have
accumulated around the battery.
-

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OPERATIONS TO BE CARRIED OUT BEFORE STARTING THE ENGINE
WARNING
- When starting the engine, make sure that the safety lever is in the
“locked” position.
- If the control levers are not locked and are inadvertently touched when
the engine is started, the work equipment may move suddenly and
cause serious accidents.
1. Make sure that the safety lever (1) is in the “locked” position (L).
NOTE
- If the safety lever is not in position (L), the engine cannot be started.
2. Check the position of each lever.
3. Turn the ignition key (2) to position ON and carry out the following checks.
1) Make sure that the following warning lights come on regularly:
• Battery charge level warning light (3)
• Engine oil pressure warning light (4)
• Engine coolant temperature warning light (5)
If a warning light or a gauge does not come on, this may be due to a faulty
fuse or bulb, or to an interruption in the
2) Press the light switch (6) and make sure that the work light functions
correctly. If it does not function, this may be due to a faulty bulb, or to an
interruption in the wirings, therefore it is advisable to contact a Komatsu
Dealer, who will provide for the necessary repairs.
3) Press the horn button (7) to make sure that the horn functions correctly.
STARTING THE ENGINE

STARTING WITH WARM ENGINE OR IN WARM CLIMATES
WARNING
- Before starting the engine, carefully read the instructions and
information regarding safety contained in this manual and make sure
that you know the controls. From the moment at which the engine is
started, the operator is directly responsible for any damage that may be
caused by wrong maneuvers and noncompliance with the safety
regulations and the rule of the road.
- Do not attempt to start the engine by causing a short circuit with the
terminals of the starter. This may cause serious injury or even fires.
- Start the engine only while seated with fastened seat belt.
- Before starting the engine, make sure that there is no one within the
operating range of the machine and sound the horn.
- Exhaust gas is toxic. When starting the engine in closed places, make
sure that there is sufficient ventilation.

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IMPORTANT
- Do not make the starter run for more than 20 seconds without
interruption. If the engine does not start, wait at least 2 minutes before
trying again.
1. Make sure that the safety lever (1) is in the “locked” position
(L). If the safety lever is in the “free” position (F), the engine cannot be started.
2. Pull the accelerator lever (2) midway between the idling position (A) and the
maximum speed position (B).
3. Turn the ignition key (3) to position START to start the engine.
4. As soon as the engine starts, release the key (3), which will automatically
STARTING WITH COLD ENGINE OR IN COLD CLIMATES

WARNING
- Before starting the engine, carefully read the instructions and
information regarding safety contained in this manual and make sure
that you know the controls. From the moment at which the engine is
started, the operator is directly responsible for any damage that may be
caused by wrong maneuvers and noncompliance with the safety
regulations and the rule of the road.
- Do not attempt to start the engine by causing a short circuit with the
terminals of the starter. This may cause serious injury or even fires.
- Start the engine only while seated with fastened seat belt.
- Before starting the engine, make sure that there is no one within the
operating range of the machine and sound the horn.
- Never use starting aid fluids, as they may cause explosions.
- Exhaust gas is toxic. When starting the engine in closed places, make
sure that there is sufficient ventilation.
IMPORTANT
- Do not make the starter run for more than 20 seconds without
interruption. If the engine does not start, wait at least 2 minutes before
trying again.
When starting the engine in cold climates, proceed as indicated below.
1. Make sure that the safety lever (1) is in the “locked” position
(L). If the safety lever is in the “free” position (F), the engine cannot be started.
2. Pull the accelerator lever (2) completely, from the idling position (A) to the
maximum speed position (B).
3. Turn the ignition key (3) to the preheating position (HEAT) and make sure
that the preheating warning light (4) comes on.

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After approximately 10 seconds, the warning light (4) goes out, indicating that
the preheating phase has been completed.
4. When the preheating warning light (4) goes out, turn the ignition key (3)
directly to position START to start the engine.
5. As soon as the engine starts, release the key (3), which will automatically

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SELF-CHECK 1.4-1
ESSAY
1. Why the engine needs to warm up before operation?

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FAMILIARIZATION ON SWICHES, GAUGES AND SYSTEM
MONITOR/INDICATORS
After reading this information sheet, you must be able to familiarization on
switches, gauges and systems monitor/indicators
CONTROLS AND GAUGES

Operator seat
Blade/adjustable track gauge selection switch (if provided)
Control locking lever (left)
Left work equipment control lever
Travel levers
Horn switch
Right work equipment control lever
Control locking lever (right)
Blade/adjustable track gauge control lever
Warning lights and gauges display
Accelerator lever
Ignition switch
Hour meter
Travel speed increase warning light
Engine coolant temperature warning light
Engine preheating warning light
Engine oil pressure warning light
Battery charge level warning light
Fuel gauge
Light switch
Travel speed selection switch (if provided)
INSTRUMENTS AND CONTROLS

- The following paragraphs describe the devices that are necessary for
correct operation of the machine.

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- To perform the required operations correctly and safely, it is important
to understand the equipment operating methods and the meaning of
the information displayed.
WARNING LIGHTS AND GAUGES

Emergency warning lights
Gauges
Warning lights
EMERGENCY WARNING LIGHTS

CAUTION
- If a warning light does not go out or comes on when the engine is
running, stops the machine immediately and tries to find the cause of
the failure.
1. Engine oil pressure warning light
engine is not running and the starting circuit is operated, and goes out as
soon as the engine lubrication circuit is pressurized.
If it does not go out or comes on when the engine is running, stop the
machine immediately and try to find the cause of the failure,
2. Charge level warning light
starting circuit is energized and goes out when the engine exceeds the idling
speed; if this warning light remains on even when the engine is running at the
normal operating speed, this means that the alternator is not working and the
battery is not charged correctly.
IMPORTANT
- If the warning light remains off when the ignition key is turned to
position ON, this means that the alternator is faulty or broken.
(1) Engine oil pressure warning light (2) Battery charge level warning light
GAUGES
1. Fuel gauge
It indicates the fuel level in the tank and functions only when the ignition key is
in position ON
F: maximum level.
E: minimum level.

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If the quantity of fuel in the tank is less than 3.3 liters, the indicator reaches
the red reserve area (A).
NOTE
- If the indicator reaches the red reserve area (A) during use, stop the
machine and provide for refueling.
2. Hour meter
- This instrument indicates the total number of operating hours of the engine.
The count is continuous and the hour number is increased by 0.1 when the
engine has worked for 0.1 hour (6 minutes), independently of the engine
speed. When the engine is running, the LED positioned on the hour meter
comes on, indicating that the count is proceeding.
If the engine is on, the hour meter keeps counting even if the machine is not
working. The reading of the hour meter must be used as reference for the
machine maintenance intervals.
(1) Fuel gauge (2) Hour meter
WARNING LIGHTS
1. Engine preheating warning light
This warning light comes on when the ignition key is turned to the preheating
position (HEAT) to start the engine at low temperatures. It goes out
automatically after approximately 10 seconds, when the preheating process
has been completed.
2. Travel speed increase warning light
This warning light comes on when the travel speed selection switch is in high
speed position
Travel speed selection switch (if provided)").
When the speed selection switch in low speed positioned, the warning light is
off.
NOTE
• When the machine travels at high speed on soft ground or up a slope and
the load increases, the low speed is automatically selected, but the travel
speed increase warning light remains on.
(2) Engine preheating warning light
(3) Travel speed increase warning light
(3)Engine coolant temperature warning light
3. Engine coolant temperature warning light
This warning light comes on when the engine coolant exceeds the maximum
temperature allowed; in this case, reduce the engine speed until the warning

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light goes out. If this inconvenience occurs again, make sure that the radiator
is clean.
SWITCHES AND PUSH BUTTONS

1. Ignition switch
This is a four-position rotary switch and is used to switch the engine on and
off.
Position OFF
When the switch is in this position, the ignition key can be inserted and
removed. When the key is turned to this position, the power supply to the
electric circuit is interrupted and the engine stops.
Position ON
The load and light circuits are under voltage. Keep the key in this position
when the engine is on.
Position START
This is the ignition position. Keep the key in this position to make the starter
run. As soon as the engine starts, release the key, which will automatically
Position HEAT (preheating)
When starting the engine in cold weather, turn the key to position HEAT for
approximately 10 seconds, until the corresponding warning light goes out.
Release the key, which will automatically return to position OFF. Start the
engine by rotating the key to position START.
IMPORTANT
- If the engine has stopped due to lack of fuel, start it by proceeding as
follows: turn the ignition switch to position ON, wait for 15 seconds and
then turn the key to position START.
Ignition switch
Horn
Light switch
Travel speed selection switch (if provided)
Blade/adjustable track gauge selection switch (if provided)
Power outlet
2. Horn
This button is positioned at the center of the right lever knob and serves to
send out a warning signal at the beginning of work and in case of danger.
3. Light switch
This is a two-position (ON-OFF) switch and is used to turn the lights on and to
light up the warning lights and gauges display.

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Position ON (A): Lights on and warning lights and gauges display lit up
Position OFF (B): Lights and display off.
4. Travel speed selection switch (if provided)
WARNING
- When loading or unloading the machine on/from a motor vehicle,
always travel at low speed. Never operate the travel speed selection
switch during the loading or unloading operation.
- If the travel speed is switched over from high to low when the machine
is travelling, the machine may deviate to one side, even if it is travelling
straight.
- Stop the machine before changing speed.
- This is a two-position switch and is used to change over from high to
low speed or vice versa.
- High travel speed (A): When the switch is in this position, the high
speed is selected and the speed increase warning light on the display
comes on. Low travel speed (B):
- When the switch is in this position, the low speed is selected and the
warning light goes out.
NOTE
- When the engine is started, the low speed is automatically selected.
- When the machine travels on soft ground or up a slope at high speed
and the load increases, the low speed is automatically selected, but the
speed increase warning light remains on. When the load is reduced,
the travel system automatically changes over to high speed.
5. Blade/adjustable track gauge selection switch (if provided)
WARNING
- Use the narrow track gauge only when it is necessary to go through
narrow passages or when there is no other choice.
- For normal applications and digging operations, always select the wide
track gauge.
- Avoid adjusting the track gauge when the machine is working on a
slope: the machine may lose stability and overturn. Always adjust the
track gauge on level surfaces.
- When the track gauge is narrowed completely, also the lateral stability
risk of overturning, always widen the track gauge and pay the utmost
attention during travel.
- Before using the blade/adjustable track gauge lever, check the position
of the switch.

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- This is a two-position switch and allows the operator to choose
between using the blade and adjusting the track gauge. Adjustable
track gauge (A): when the switch is in this position, it is possible to
adjust the track gauge.
Blade (B): When the switch is in this position, it is possible to use the
blade.
For further details on how to use the blade and adjust the track gauge,
(Blade/adjustable track gauge selection switch (if provided)").
6. Power outlet (12V)
A power outlet is positioned on the front part of the machine for the
connection of a lamp for routine and maintenance operations.
It is a two-pole outlet and is in compliance with the ISO 4165- 1979 standard.
Power supplies 12 V.

Accelerator lever
Blade/adjustable track gauge lever (if provided)
Travel levers (with pedal)
Pedal locking device (for the optional equipment control pedal)

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SELF-CHECK 1.4-2
ENUMERATION
1. Give at least 5 switches.

a.
b.
c.
d.
e.
2. Give at least 5 gauges.

a.
b.
c.
d.
e.

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AUDIO AND AIR CONDITIONING SYSTEM
After reading this information sheet, you must be able to know the audio and
air conditioning system
Audio - is sound within the acoustic range available to humans. ...

An audio card contains a special built-in processor and memory for
processing audio files and sending them to speakers in the computer.
An audio file is a record of captured sound that can be played back.
- Is a term used to describe any sound or noise that is within a range the
human ear is capable of hearing? Measured in hertz, the audio signal
on a computer is generated using a sound card and is heard through
speakers or headphones.
Car air con system - is turned on, the compressor pumps refrigerant vapor
under high pressure to the condenser. Condenser: The condenser is a device
used to change the high-pressure refrigerant vapor to a liquid. It is
mounted in front of the engine's radiator, and it looks very similar to a radiator.

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SELF-CHECK 1.4-3
ENUMERATION
1. Enumerate the components of air conditioning system.

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ELECTRICAL LIGHTING AND ACCESSORIES
After reading this information sheet, you must be able to identify electrical
lighting system

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SELF-CHECK 1.4-4
1. Discuss and explain the importance of the following
a. Battery light indicator –
b. temperature gauge –
c. oil pressure gauge –
d. fuel gauge –

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FAMILIARIZATION ON WORK EQUIPMENT FUNCTION
After reading this information sheet, you must be able to familiarize the work
equipment function.
WORK EQUIPMENT CONTROLS AND FUNCTIONS

The work equipment is controlled by means of the right and left work
equipment control levers. The left lever controls the arm and the turret swing,
while the right lever controls the boom and the bucket. When the levers are
released, they automatically return to the neutral position and the work
equipment remain in the position where they stopped.
The movements of the levers and the corresponding movements of the
equipment are shown in the diagrams below.
1.Arm control
- To operate the arm, shift the left control lever forward or backward.
2.Swing control
- To swing the turret, shift the left control lever to the left or to the right.
3.Boom control
- To operate the boom, shift the right control lever forward or backward.
4.Bucket control
- To operate the bucket, shift the right control lever to the left or to the
right.
5. Boom swing control
- To swing the boom, use the boom swing control pedal.
6. Blade control
- Select the use of the blade with the blade/adjustable track gauge
selection switch.
- To operate the blade, shift the lever positioned to the right of the
operator seat forward or backward.
7. Track gauge adjustment control (version with adjustable track gauge)
WARNING
- Select the narrow track gauge only when the machine must travel in
small spaces. For normal applications and digging operations, always
- Adjusting the track gauge on slopes is dangerous, since this may
affect the lateral stability of the machine. Therefore, it is advisable to
adjust the track gauge on level surfaces.

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- When the track gauge is narrowed completely, also the lateral stability
risk of overturning, widen the track gauge and pay the utmost attention
during travel.
- Before using the blade/adjustable track gauge lever, check the
position of the switch.
- Set the blade/adjustable track gauge switch to the track gauge
adjustment position.
- To adjust the track gauge, shift the lever positioned to the right of the
operator seat forward or backward.
IMPORTANT
- If there are obstacles that prevent the adjustment of the track gauge,
remove them or place the machine on a level surface, in order to be
able to find the correct position for the adjustment.
- If the tracks are dirty with mud, clean them thoroughly before adjusting
the track gauge.
- On machines with adjustable track gauge it is possible to modify the
blade width to adapt it to the track gauge; two blade configurations are
available.
A – Narrow blade
B – Wide blade
This operation must be carried out on a level surface, with the equipment
resting on the ground and after stopping the engine.
To modify the blade width, remove the pins (1) and the extensions (2).
Put back the extensions, inverting their position (the right one on the left side
and the left one on the right side
.

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SELF-CHECK 1.4-5
ENUMERATION
1. Give 5 work equipment controls
a.
b.
c.
d.
e.

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FAMILIARIZATION ON OPERATOR’S COMPARTMENT
After reading this information sheet, you must be able to familiarize the
operator’s compartment.
DOCUMENTATION COMPARTMENT
CAUTION
- The use and maintenance manual is an integral part of the machine
and must accompany it even in case of resale.
- The use and maintenance manual must be stored with care and always
kept on board the machine, so that it can be consulted at any moment;
it must be placed in the technical documentation compartment inside
the seat support.
TOOL BOX
The tool box is positioned inside the seat support and can be reached by
opening the front panel.
Operator Compartment
The operators compartment feature an all-weather seat with arm rests, a

brake pedal with integral parking brake, an accelerator pedal, a steering
wheel and hydraulic power steering control. The dash contains switches for
the horn and light operation, the key switch and the FNR switch. There is
even an optional power port available. Each machine now comes with a dash
mounted cup holder.
The operator’s compartment also provides for comfortable operation of the

hydraulic control valves, the water control rod, shaving depth hand wheel and
the snow breaker handle.

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SELF-CHECK 1.4-6
1. What is operator compartment?

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FAMILIARIZATION ON CONTROLS, LEVERS AND PEDALS
After reading this information sheet, you must be able to familiarize the
controls, levers and pedals.

Accelerator lever
Blade/adjustable track gauge lever (if provided)
Travel levers (with pedal)
Pedal locking device (for the optional equipment control pedal)
1. Safety lever (control locking lever)

WARNING
- Before leaving the driver seat, lower the equipment to the ground and
shift the safety lever to the “locked” position (L). If the safety lever is not
in the “locked” position and the control levers are touched by mistake,
this may lead to serious injury.
- If the safety lever is not in the “locked” position, the control levers may
move, causing accidents or serious injury. Always make sure that the
lever is in the “locked” position, as shown in the figure.
- When shifting the safety lever, take care to avoid touching the
equipment control levers. This lever operates the safety device that
locks the work equipment, the swing and travel functions and the
attachments. When pulled upwards, it is in “locked” position (L). The
safety device is hydraulic, therefore even if the control levers and the
pedals move, the work equipment and the machine cannot be
operated.
NOTE

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- If the safety lever on the right or left side is not in the “locked” position
(L), the engine cannot be started. Before operating the ignition switch,
always make sure that the safety lever is in the “locked” position. If the
engine stops while the safety lever is in “free” position (F), shift the
lever back to the “locked” position before operating the ignition switch.
(F): free
(L): locked
2. - 3. Work equipment control levers

WARNING
- Before carrying out any maneuvers with these levers, the operator
must seat in the work position and fasten the seat belt.
- Before leaving the driver seat, lower the equipment to the ground, lock
the controls with the safety lever and stop the engine.
IMPORTANT
- The horn push button is positioned on the right lever grip and must be
used to warn all the people in the vicinity before starting work and in
case of danger.
- When the safety lever is in the “locked” position, all the movements are
inhibited
- The control lever (2) is positioned on the operator’s left and controls the
arm and the turret swing.
Swing function
(a) Swing to the right
(b) Swing to the left
Arm
(c) Fold
(d) Extend
N (Neutral): the turret and the arm are held in the position where they
stopped.
The control lever (3) is positioned on the operator’s right and controls the
boom and the bucket.
Boom
(e) Lift
(f) Lower
Bucket
(g) Open
(h) Fold

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N (Neutral): the boom and the bucket are held in the position where they
stopped.
4. Accelerator lever
This lever is used to control the engine speed and power.
(a) Minimum: push the lever completely forward.
(b) Maximum: pull the lever completely backward.
Use the accelerator with care, especially when the machine is under strain or
is working in difficult conditions. Avoiding useless accelerations means
reducing consumption and extending the service life of both the engine and
the machine.
5. Blade/adjustable track gauge lever (if provided)

WARNING
- Narrow the track gauge only when it is necessary to travel or to carry
out digging operations in small spaces. In any other condition, always
- Avoid adjusting the track gauge when the machine is working on a
slope. This may affect the lateral stability of the machine.
- Widen or narrow the track gauge with the machine resting on a firm
and level surface and the tracks slightly raised from the ground, in
order to avoid damaging the tracks and the hydraulic motors.
This lever is used to control the movements of the blade or to adjust the track
gauge, depending on the position of the switch
5. Blade/adjustable track gauge selection switch (if provided)").

Blade
(a) Lower
(b) Lift
Adjustable track gauge
(a) Narrow track gauge
(b) Wide track gauge
NOTE
- When carrying out digging operations that require the blade to be used
for more than one hour without interruption, pay attention to the coolant
temperature, since this may increase excessively.
- Before using the lever, check the position of the blade/ adjustable track
gauge switch.
-
6. Travel levers

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WARNING
- Before carrying out any maneuver with these levers, the operator must
- Before moving the machine, make sure that the sprocket
(A) is positioned at the rear of the machine and that the safety locks are
engaged; if the turret is rotated by 180°, the controls are inverted MACHINE"
e
- Use the travel control pedals only when the machine is moving. If a pedal is
inadvertently pressed when the machine is not moving or steering, this may
move suddenly and cause serious accidents.
- When travelling or carrying out steering maneuvers, use the pedals with the
maximum care.
- When leaving the operator seat, always rotate the pedals to the rest
position, in order to avoid pressing them by mistake.
These levers are used to operate the travel motors (right and left) and control
the forward and reverse travel according to the movements indicated.
(a) FORWARD: levers pushed forward
(b) REVERSE: levers pulled towards the operator
N (Neutral): machine at rest.
NOTE
- When it is necessary to use the travel pedals, the opening operation
must be carried out by the operator while correctly seated in driving
position. After use, always rotate the pedals to the rest position
(closed).
IMPORTANT
inhibited
7. Boom swing control pedal locking device

WARNING
- Always shift the safety lever to position (L) when the boom swing is not
required, during travel and when parking the machine. If the control
pedal is inadvertently pressed, this may cause serious accidents.
This device is used to lock the movements of the boom swing control pedal
and has two positions.
(F): free
(L): locked
8. Boom swing control pedal

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- This pedal controls the boom swing to the right and to the left, according to
the movements indicated below.
(a): swing to the right
(b): swing to the left
N (Neutral): boom at rest.
IMPORTANT
inhibited
- The boom swing is useful to displace the digging line beyond the track
outline; do not use this function during the work cycle.
9. Cab floor locking lever

WARNING
- Always keep to the warnings when tilting or closing the cab floor. Any
operation carried out incorrectly may cause serious injury. Do not tilt or
close the cab floor on slopes or if there is a strong wind.
- To tilt or close the cab floor, pull the lever to the “free” position (F).
- After tilting or closing the cab floor, release the lever, which will
automatically return to the “locked” position (L).
(F): free
(L): locked
10. Pedal locking device (for the optional equipment control pedal)
WARNING
- Always lock the optional equipment control pedal when the use of this
control is not required, during travel and when parking the machine. If
the control pedal is inadvertently pressed, this may cause serious
accidents.
The safety device is used to lock the optional equipment control pedal.
11. Optional equipment control pedal

The pedal controls oil delivery to and return from the optional equipment.
- Upper part of the pedal (A) pressed: The oil flows to the right side of
the arm (hydraulic tank side).
- Lower part of the pedal pressed (B): The oil flows to the left side of the
arm (operator seat side).

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SELF-CHECK 1.4-7
ENUMERATION
1. Give at least 5 controls, 5 levers and 5 pedals

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CHECK SAFETY DEVICES AND
LEARNING OUTCOME #5 ACCESSORIES
CONTENTS
1. General precaution and safety procedures
2. Familiarization on safety levers and controls
1. Hydraulic excavator safety devices are checked for functionality according safety
regulation
2. Personal safety devices are checked in accordance with OHS procedures
a. Unit of Equipment (Hydraulic Excavator)
b. Post-operation checklist
Assessment method:

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CHECK SAFETY DEVICES AND ACCESSORIES

General precaution and safety information sheet don’t hesitate to approach your
procedures facilitator.
self-check again.

Familiarization on safety levers and
facilitator.
controls
self-check again.

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GENERAL PRECAUTION AND SAFETY PROCEDURES
After reading this information sheet, you must be able to know the safety
procedures.
GENERAL SAFETY RULES AND REGULATIONS IN THE WORKSHOP
1) never works alone in the workshop, work at least in pairs. This is so

because in case of industrial/workshop accident the other partner will be a
helper (Ecclesiastes 4:9-10) it’s all about Teamwork.
2) Think about what you are doing; think before you start a job and during the
entire time you are doing it. Remember that your own personal caution is of
more value to you than all the safeguards that can be set up.
3) Know where the main switch is. This stops processes immediately should
anything go wrong in the industry.
4) Smoking and carrying matches or naked flames by employees is prohibited

in and about the complex except in zone specifically designed for such
purposes. Safety section must see that “No smoking” signs are placed in and
about their area to warn the employee and visitors.
5) When work is being done which requires the wearing of a safety belt, the
supervisor in charge shall determine whether or not stand-by personnel are
required, and if necessary, will provide suitable personnel.
6) Any one working at or going to any plant area in the complex must wear a
safety cap and safety shoes.
7) Always use a safety belt when working at height such as on stacks or

columns where the danger of falling exists.
8) Do not tamper with or attempt to repair equipment or instruments which you

do not understand.

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9) Ability to communicate with the outside world, very important. This is
usually achieved by the installation of telephones. Important phone numbers
should include the following in Emergency cases;
a. Fire Service number
b. Ambulance number
c. Police number
d. NEPA/PHCN number
10) Defective tools are dangerous, do not use them. In fact never use a tool
except for its proper purpose.
11) Metal ladders may not be used for electrical work and must not be used
near electrical circuits or equipment.
12) Machines must be rendered inoperative by the removal of fuses or locking

out of moving parts. Replace guards before equipment is put back in
operation.
13) Provide a first Aid Box.
14) Protective valve caps must be placed on all cylinders (oxygen, acetylene,
ammonia, nitrogen, carbon dioxide, butane or propane, chlorine, etc.) at all
times when not in use or in transit.
15) Guards may not be removed from equipment while it is in operation and
equipment must never be operated with guards removed.
16) Goggles or shield must be used when working on emery wheels, using
wire brushes, chipping, etc; or any other circumstances where eye hazards
exist.
17) Only authorized employees from the Electrical section may operate switch
gear, apart from routine stopping and starting of motors and lighting.
18) When electrically-driven equipment is shut down for repairs, the electrical
circuits must be isolated before commence.

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19) All injuries must be reported immediately by completing the official
“Accident report form”. No employee who is feeling ill or suffering from after
effects of injuries or illness should be permitted to report to work, without the
doctor’s permission.
20) Make a close safety inspection of the work area before a job is
undertaken whether or not the related equipment is company owned,
operated or maintained.
21) Avoid carrying tools and materials which will prevent reasonably free use
of the hands in going up or coming down ladders or structures.
22) Employee must not be permitted to use any make shift apparatus of any
type which involves the use of compressed air, steam, gas, oil, gasoline or
electricity without the approval of his supervisor.
23) Before turning on electricity, steam, gas, or water, or setting in motion any
machinery, equipment, investigate to be sure that no one is in a position to be
injured.
24) Keep your hands off machinery that you are not operating or repairing.
25) Report all leaks of any nature and size at once. Be at alert for defective
and dangerous runways, railings, ladders, cables, switches, pressure gauges
and the absence of safeguards. If any unsafe act/practice/condition is seen, it
should be corrected or reported by the employee immediately.
26) All ropes should be tested before trusting your life to them.
27) Special care must be taken in the dismantling and erection of scaffolds
and handling tools and materials to and from scaffolds or other elevated work
levels. Warning signs should be placed at the ground level that would indicate
that work is being done overhead. Arrange tools and/or any materials on
scaffolds and other elevated places or work in such a position to prevent them
from falling and injuring people below.
28) Pressure must be released before repair work is started on lines, vessels,
pumps, etc.
29) The use of gasoline for cleaning purpose of any nature is prohibited. A
cleaning solvent should be used in cleaning orifice meters, instruments, and

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electrical motors.
30) All stairways, platforms and walk ways must be kept clear at all times.
31) Rubber gloves and eye protection material must be used in the handling
of acids, caustic, and bactericides.
32) The use of propane or other hydrocarbon product to shrink posts by

chilling is prohibited. When a shrinking agent is needed for shafts or pins, dry
ice, liquid nitrogen, or carbon dioxide may be used with adequate
precautions.
33) In areas where hydrogen sulphide, carbon dioxide, or other toxic gas is
encountered the supervisor will determine when, and under what conditions,
gas masks will be worn. Employees entering tanks, or other confined places
must have the approval of the supervisor, and he will determine the safety
precautions that must be taken.
34) Wear no loose hanging garments; wear smart fitting overalls if possible.
No dangling ear-rings, necklaces, chains, watches, etc. this is as things lie
long-ties may get into the machine and in the process of trying to free it, the
operator may find him/herself trapped in the machine.
35) Ensure that you wear prospective helmets, steel-capped boots, hand
gloves, goggles (shields) and other protective wears as the workshop
demands.
36) The female gender should also take note of all the above.

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SELF-CHECK 1.5-1
ENUMERATION
1. Give at least 5 general safety rules and regulations in the workshop.
a.
b.
c.
d.
e.

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FAMILIARIZATION ON SAFETY LEVERS AND CONTROLS
After reading this information sheet, you must be able to familiarize the safety
levers and controls.
SAFETY LEVERS AND CONTROLS
1. A safety lever system in a cab of an excavator, the system

comprising:
a fixed plate fixed in the cab, having a rotation axis; operator's

seat fixed on the fixed plate; a control box movably installed on
the rotation axis of the fixed plate as one body to descend or
ascend around the rotation axis, and having a control lever; a
safety lever protruded to the front side of the control box, and if
pulled upward by an operator, tilting the control box upward by
interlocking;
a tilting device, which is connected to one end of the safety lever,

operates with the control box as one body, is hinged at a hinge
axis and interlocks in an operational direction of the safety lever
around the axis for rotating the control box and then immobilizing
or fixing the control box when stopped; and a limit means
installed on one side of the control box for applying/short-
circuiting power to/from the control box by rotating at the same
angle as the tilted control box.
2. The safety lever system according to claim 1, wherein the

tilting device is comprised of: a rotating bracket connected to
one end of the safety lever, and is hinged at a hinge axis,
being extended; and a spring bracket hinged equally at the
hinge axis below the rotating bracket.
rotating bracket has an extended end of a designated length,
and to a guide pin in opposite direction of the end as one body.
tilting device further comprises a first cylinder rotatably
installed on the end of the rotating bracket.

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control box further comprises a rotation stopper for controlling
a rotation interval of the back and forth rotation of the end of
the rotation bracket.
tilting device further comprises an elastic body for elastically
supporting the spring bracket.
7. The safety lever system according to claim 1, wherein the fixed
plate further comprises a fixed axis that is suspended by a
suspension end of the spring bracket for fixing the control box.
tilting device further comprises a second cylinder connected to
the control box and the fixed plate for limiting a tilting distance
thereof.
suspension end of the spring bracket is protrusively formed on
a position as opposed to the extended end of the rotating
bracket, and when tilted, is suspended by the fixed axis for
fixing the control box.
suspension end comprises a suspension groove where the
fixed axis is inserted.
spring bracket comprises a guide groove for guiding the
inserted guide pin, and a groove for operation for guiding the
fixed axis.
spring bracket further comprises a guide surface for guiding
the fixed axis to the groove for operation during restoration.
13. The safety lever system according to claim 1, wherein the limit
means is comprised of: a limit holder fixed on the rotation axis
of the fixed plate; and a limit switch being turned on/off along
the limit holder according to a tilting angle of the control box.
limit holder has a guide for adjusting an operating depth of the
limit switch.
limit switch moves along the guide and the operating depth
thereof is adjustable.

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SELF-CHECK 1.5-2
ESSAY
1. Discuss and explain the importance in familiarization of safety levers.

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PERFORM POST-OPERATION
LEARNING OUTCOME #6 PROCEDURES
CONTENTS
1. Proper shutdown and post operation procedures
2. Safe parking procedures and practices
3. Vandalism prevention
1. Post operation check is performed based on standard procedures
2. Accomplished daily equipment record/report (DETR) in line with company
3. Post-operation checklist
Assessment method:

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PERFORM POST-OPERATION PROCEDURES

Proper shutdown and post operation information sheet don’t hesitate to approach your
procedures facilitator.
self-check again.
Safe parking procedures and practices
facilitator.
self-check again.
facilitator.
Vandalism prevention
self-check again.

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PROPER SHUTDOWN AND POST OPERATION PROCEDURES
After reading this information sheet, you must be able to know the proper
shutdown and post operation procedures.
Machine shut-down
1. Park machine on smooth, level area
2. Ground all hydraulic implements
3. Move Hydraulic lock lever into the LOCKED position
4. Allow engine to run at LOW IDLE for 5 minutes
5. Turn the key start switch to OFF and remove key Turn battery
disconnect switch to OFF
6. Dismount machine using 3-point contact
7. Conduct post-operation walk around inspection

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SELF-CHECK 1.6-1
ENUMERATION
1. Give at least 5 proper shutdown of the machine.
a.
b.
c.
d.
e.

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SAFE PARKING PROCEDURE AND PRACTICES
After reading this information sheet, you must be able to know the proper
parking procedures/techniques.
Proper parking technique is important to protect yourself, your machine, and

those around you.
First, reduce your engine speed as you approach your parking location.
Ensure that your parking location is on level ground.
Lower your blade and extend the stick and bucket, lowering the boom until
your bucket is resting on the ground.
In freezing conditions be sure to park the machine on boards to prevent the

tracks from freezing to the ground.
Next, raise the hydraulic control console to disengage the hydraulic control
system.
Be sure to run the engine for 5 minutes at low idle to avoid engine
overheating.
Now you can shut down the machine.
Move the controls to relieve any working pressure.
Now you’re ready to exit the cab using three points of contact.
Now the machine is parked safely and ready to go back to work again soon.
As always, consult your operation and maintenance manual for more

information.
That was today’s Quick Tip, thanks for watching.

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SELF-CHECK 1.6-2
ENUMERATION
1. Give 5 proper parking procedures/techniques.
a.
b.
c.
d.
e.

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VALDALISM PREVENTION
After reading this information sheet, you must be able to know the
Vandalism - is an "action involving deliberate destruction of or damage to

public or private property." The term includes property damage, such as
graffiti and defacement directed towards any property without permission of
the owner.
Vandalism Prevention
- Educate the public, especially young people about the costs
of vandalism. Clean up vandalism as soon as it happens -- replace
signs, repair playground equipment, paint over graffiti. If you see
anyone committing vandalism, report it to the police, school
authorities, or someone who can take action.

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SELF-CHECK 1.6-3
1. What is vandalism?

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COMPETENCY BASED LEARNING MATERIAL

RPASI Date Developed: Document No.

Competency based learning material for the module: PERFORMING PRE

This unit of competency “: PERFORM PRE AND POST OPERATION

You are required to go through a series of learning activities in order to

DIRECTION FOR USE OF THE CBLM

This module PERFORM PRE AND POST OPERATION PROCEDURES FOR

RPASI Date Developed: Document No.

RECOGNITION TO PRIOR LEARNING

RPASI Date Developed: Document No.

1. You must comply with the condition of trainees permit:

b. Training permits from the registrar

c. Student driving license permit (LTO)

2. Instruct you the correct application of the Philippines road rules

4. Comply with the licensing and National Certificate requirements

• The ability to guide you in your practice.

RPASI Date Developed: Document No.

RPASI Date Developed: Document No.

No. Unit of Competency Module Title Code

Performing Pre and

RPASI Date Developed: Document No.

NOMINAL DURATION: 24 hours

MODULE DESCRIPTOR: This module covers the knowledge, skills and

RPASI Date Developed: Document No.

RPASI Date Developed: Document No.

IDENTIFY HYDRAULIC EXCAVATOR TYPES/COMPONENTS STRUCTURE

Learning Activities Special Instructions

If you got 100% correct answer in this self-check,

If you have some problem on the content of the

RPASI Date Developed: Document No.

An excavator is a machine that is used for construction sites. It is heavy duty

Excavator comes in numerous sizes depending on bucket size, length of

RPASI Date Developed: Document No.

Excavators come in different sizes and shapes depending on their

Crawlers are also called as compact excavators. Because of their high

RPASI Date Developed: Document No.

RPASI Date Developed: Document No.

RPASI Date Developed: Document No.

A dragline excavator is heavy duty equipment that is slightly different and

RPASI Date Developed: Document No.

1. Enumerate the different types of excavator and their uses.

RPASI Date Developed: Document No.

RPASI Date Developed: Document No.

RPASI Date Developed: Document No.

RPASI Date Developed: Document No.

RPASI Date Developed: Document No.

RPASI Date Developed: Document No.

RPASI Date Developed: Document No.

1. Enumerate the components structure of hydraulic excavator.

RPASI Date Developed: Document No.

RPASI Date Developed: Document No.

PERFORM VISUAL CHECK OF EQUIPMENT

Learning Activities Special Instructions

If you got 100% correct answer in this self-check,

If you got 100% correct answer in this self-check,

RPASI Date Developed: Document No.

RPASI Date Developed: Document No.

Instructions for arc welding:

RPASI Date Developed: Document No.

When the work site is particularly dusty, proceed as follows:

RPASI Date Developed: Document No.

RPASI Date Developed: Document No.

(KOMATSU OIL WEAR ANALYSIS)