Komatsu Excavator PC05, PC07, PC10, PC15, PC20 Repair Service Manuals
Catalog:
Model:
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Excavator PC05, PC07, PC10, PC15, PC20, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Excavator PC05, PC07, PC10, PC10, PC15, PC15, PC20 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEBM020M0604 - Hydraulic Excavator PC05-6, PC07-1, PC10-6, PC15-2 Shop Manual.pdf
SEBM020P0703 - Hydraulic Excavator PC10-7, PC15-3, PC20-7 Shop Manual.pdf
EEPB000800 - Hydraulic Excavator PC05-6F Parts Book.pdf
SEAM020MB600 - Hydraulic Excavator PC05-6, PC10-6, PC15-2 Operation & Maintenance Manual.pdf
WEAM007700 - Hydraulic Excavator GALEO PC14R-2 Operation & Maintenance Manual.pdf
WEAM007800 - Hydraulic Excavator GALEO PC16R-2 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 613 pages
File Format: PDF
Language: English
MAIN SECTIONS
EEPB000800 - Hydraulic Excavator PC05-6F Parts Book...2
SEAM020MB600 - Hydraulic Excavator PC05-6, PC10-6, PC15-2 Operation & Maintenance Manual...159
COVER...159
FOREWORD...160
BREAKING IN YOUR NEW MACHINE...161
CONTENTS...162
GENERAL LOCATIONS AND SPECIFICATIONS...163
INSTRUMENTS AND CONTROLS...165
OIL FILLER AND LEVEL GAUGE POSITIONS...181
CHECK BEFORE STARTING...183
OPERATING YOUR MACHINE...187
REPLACEMENT OF BUCKET...209
METHOD OF LIFTING THE MACHINE...211
COLD WEATHER OPERATION...214
PERIODIC MAINTENANCE...217
MAINTENANCE TABLE...218
INITIAL 50 HOURS SERVICE...221
EVERY 50 HOURS SERVICE...221
EVERY 100 HOURS SERVICE...224
INITIAL 250 HOURS SERVICE...226
EVERY 250 HOURS SERVICE...227
EVERY 500 HOURS SERVICE...238
EVERY 2000 HOURS SERVICE...242
WHEN REQUIRED...244
HANDLING RUBBER SHOES...251
SERVICE METER...256
MACHINE AND ENGINE SERIAL NUMBERS...257
FUEL,COOLANT AND LUBRICANTS...258
SAFETY AND OPERATION...260
CONTENTS...261
SAFETY HINTS...262
HANDLING OF BATTERY...275
TRANSPORTATION...278
PRECAUTIONS FOR MAINTENANCE...279
STORAGE...286
COOLANT AND LUBRICANTS...287
SEBM020M0604 - Hydraulic Excavator PC05-6, PC07-1, PC10-6, PC15-2 Shop Manual...289
COVER...289
CONTENTS...290
10 STRUCTURE AND FUNCTION...304
RADIATOR...305
POWER TRAIN...308
SWING CIRCLE...312
TRACK FRAME AND RECOIL SPRING...314
HYDRAULIC PIPING...316
HYDRAULIC CIRCUIT DIAGRAM...321
HYDRAULIC TANK...330
HYDRAULIC PUMP...332
7-SPOOL CONTROL VALVE...336
8-SPOOL CONTROL VALVE...338
1-SPOOL CONTROL VALVE...340
5-SPOOL CONTROL VALVE...341
6-SPOOL CONTROL VALVE...343
2-SPOOL CONTROL VALVE...345
SWING-BOOM SWING SELECTOR VALVE...346
SWING MOTOR...347
TRAVEL MOTOR...349
CENTER SWIVEL JOINT...353
HYDRAULIC CYLINDER...355
VALVE CONTROL...365
WORK EQUIPMENT...370
ELECTRIC CIRCUIT DIAGRAM...372
20 TESTING AND ADJUSTING...375
TABLE OF JUDGEMENT STANDARD VALUE...376
TESTING AND ADJUSTING TOOL LIST...410
ADJUSTING VALVE CLEARANCE (PC05-6,PC07-1)...411
ADJUSTING VALVE CLEARANCE (PC10-6,PC15-2)...412
MEASURING COMPRESSION PRESSURE (PC05-6,PC07-1)...413
MEASURING COMPRESSION PRESSURE (PC10-6,PC15-2)...414
TESTING AND ADJUSTING FUEL INJECTION TIMING (PC05-6,PC07-1)...415
TESTING AND ADJUSTING FUEL INJECTION TIMING (PC10-6,PC15-2)...416
TESTING AND ADJUSTING HYDRAULIC PRESSURE (PC05-6,PC07-1)...417
TESTING AND ADJUSTING HYDRAULIC PRESSURE (PC10-6,PC15-2)...418
30 DISASSEMBLY AND ASSEMBLY...419
RADIATOR (PC05-6,PC07-1)...420
REMOVAL...420
INSTALLATION...420
RADIATOR (PC10-6,PC15-2)...422
REMOVAL...422
INSTALLATION...422
ENGINE (PC05-6 SERIAL NO:11301-11700)...424
REMOVAL...424
INSTALLATION...426
ENGINE (PC05-6 SERIAL NO:11701 AND UP,PC07-1)...428
REMOVAL...428
INSTALLATION...430
ENGINE (PC10-6,PC15-2)...434
REMOVAL...434
INSTALLATION...436
SWING CIRCLE (PC05-6,PC07-1)...438
REMOVAL...438
INSTALLATION...442
SWING CIRCLE (PC10-6,PC15-2)...446
REMOVAL...446
INSTALLATION...450
HYDRAULIC PUMP (PC05-6,PC07-1)...454
REMOVAL...454
INSTALLATION...454
HYDRAULIC PUMP (PC10-6,PC15-2)...454
REMOVAL...454
INSTALLATION...454
7-SPOOL CONTROL VALVE...456
REMOVAL...456
INSTALLATION...458
8-SPOOL CONTROL VALVE...460
REMOVAL...460
INSTALLATION...462
2-SPOOL CONTROL VALVE...464
REMOVAL...464
INSTALLATION...464
6-SPOOL CONTROL VALVE...466
REMOVAL...466
INSTALLATION...466
CONTROL VALVE...468
DISASSEMBLY...468
ASSEMBLY...468
SWING MOTOR (PC05-6,PC07-1)...470
REMOVAL...470
INSTALLATION...470
SWING MOTOR (PC10-6,PC15-2)...470
REMOVAL...470
INSTALLATION...470
TRAVEL MOTOR...472
REMOVAL...472
INSTALLATION...472
DISASSEMBLY...474
ASSEMBLY...480
CENTER SWIVEL JOINT (PC05-6,PC07-1)...486
REMOVAL...486
INSTALLATION...486
DISASSEMBLY...490
ASSEMBLY...490
WORK EQUIPMENT...492
REMOVAL...492
INSTALLATION...492
BLADE...492
REMOVAL...492
INSTALLATION...492
40 MAINTENANCE STANDARD...494
SWING CIRCLE...495
TRACK FRAME AND RECOIL SPRING...497
IDLER...499
TRACK ROLLER...505
TRACK SHOE...508
HYDRAULIC PUMP...511
7-SPOOL CONTROL VALVE...514
8-SPOOL CONTROL VALVE...516
1-SPOOL CONTROL VALVE...517
5-SPOOL CONTROL VALVE...518
6-SPOOL CONTROL VALVE...519
2-SPOOL CONTROL VALVE...520
TRAVEL MOTOR BRAKE VALVE...521
HYDRAULIC CYLINDER...522
WORK EQUIPMENT...527
SEBM020P0703 - Hydraulic Excavator PC10-7, PC15-3, PC20-7 Shop Manual...537
COVER...537
CONTENTS...538
10 STRUCTURE AND FUNCTION...553
POWER TRAIN...554
SWING CIRCLE...556
SWING MACHINERY...558
TRACK FRAME AND RECOIL SPRING...559
HYDRAULIC PIPING...563
HYDRAULIC CIRCUIT DIAGRAM...565
HYDRAULIC TANK AND FUEL TANK...568
HYDRAULIC PUMP...569
7-SPOOL CONTROL VALVE...570
2-SPOOL CONTROL VALVE...572
SWING MOTOR...574
CENTER SWIVEL JOINT...577
TRAVEL MOTOR ...578
HYDRAULIC CYLINDER...579
VALVE CONTROL...585
WORK EQUIPMENT...586
ELECTRICAL CIRCUIT DIAGRAM...587
MONITOR SYSTEM...589
20 TESTING AND ADJUSTING...594
TABLE OF JUDGEMENT STANDARD VALUE...595
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...611
TOOL FOR TESTING, ADJUSTING AND TROUBLESHOOTING...613
ADJUSTING VALVE CLEARANCE...614
MEASURING COMPRESSION PRESSURE...615
ADJUSTING FUEL INJECTION TIMING...616
ADJUSTING FUEL CONTROL LEVER...617
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...618
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...621
BLEEDING AIR...622
TROUBLESHOOTING...623
POINTS TO REMEMBER WHEN TROUBLESHOOTING...624
SEQUENCE OF EVENTS IN TROUBLESHOOTING...625
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...626
CHECKS BEFORE TROUBLESHOOTING...633
ELECTRICAL CIRCUIT DIAGRAM...634
POSITION OF CONNECTORS FOR TROUBLESHOOTING...636
CONNECTION TABLE FOR CONNECTOR...638
HANDLING CONNECTORS...645
METHOD OF USING TROUBLESHOOTING CHARTS...646
TROUBLESHOOTING OF ELECTRICAL SYSTEM (C MODE)...648
C-1. THIS ENGINE DOES NOT STOP WHEN THE STARTING SWITCH IS TURNED OFF...649
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...650
H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL SWING ARE ALL SLOW ALL WORK EQUIPMENT, TRAVEL, SWING LACK POWER...651
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IN EXTREMELY SLOW...651
H-3 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)...652
H-4 CONTROL LEVER IS HEAVY...652
H-5 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW EXCESSIVE HYDRAULIC DRIFT...653
H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER ...653
H-7 EXCESSIVE TIME LAG...653
H-8 WHEN MACHINE IS TRAVELING . IT DEVIATES NATURALLY TO ONE SIDE...654
a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE...654
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE...654
H-9 TRAVEL LACKS POWER (OR SPEED IS SLOW)...656
H-10 MACHINE DOES NOT MOVE (ONE SIDE ONLY)...656
H-11 DOES NOT SWING...657
H-12 SWING SPEED IS SLOW OR ACCELERATION IS POOR...659
H-13 EXCESSIVE OVERRUN WHEN STOPPING SWING...659
H-14 EXCESSIVE SHOCK WHEN STOPPING SWING...660
H-15 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...661
H-16 EXCESSIVE HYDRAULIC DRIFT OF SWING...662
H-17 EXCESSIVE HYDRAULIC OF BOOM SWING...663
TABLE OF FAILURE MODES AND CAUSES...664
TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)...666
P-1 MONITOR PANEL DOES NOT WORK...667
P-2 MONITOR PANEL CAUTION AND GAUGE LAMPS DO NOT LIGHT UP FOR 3 SECONDS AFTER STARTING SWITCHES TURNED ON, OR ALL LAMPS STAY LIGHTED UP...668
a) DO NOT LIGHT UP FOR 3 SECONDS...668
b) ALL LAMPS STAY LIGHTED UP...668
P-3 (OIL PRESSURE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)...669
P-4 (CHARGE CAUTION LAMP) DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED)...670
P-5 (PREHEATING PILOT LAMP) DOES NOT LIGHT UP WHEN PREHEATING...671
P-6 (ENGINE OIL LEVEL CAUTION LAMP) LIGHTS UP WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) (ENGINE OIL LEVEL IS NORMAL)...671
P-7 (ENGINE OIL PRESSURE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)...672
P-8 (CHARGE CAUTION LAMP) LIGHTS UP WHEN ENGINE IS RUNNING...673
P-9 ABNORMALITY IN COOLANT TEMPERATURE GAUGE DISPLAY...674
a) AFTER ENGINE IS STARTED, GAUGE STAYS AT LOWEST LEVEL AND DOES NOT MOVE...674
b) AFTER ENGINE IS STARTED, LEVEL RISES IMMEDIATELY ENTERS TED RANGE EVEN WHEN ENGINE IS NOT OVERHEATING...674
P-10 ABNORMALITY IN FUEL GAUGE DISPLAY...675
a) ALL SEGMENTS OF FUEL GAUGE GO OUT...675
b) FUEL LEVEL HAS GONE DOWN, BUT FUEL GAUGE STILL GIVES FULL DISPLAY, AND DOES NOT GO DOWN...675
c) FUEL GAUGE DOES NOT GIVE FULL DISPLAY EVEN WHEN FUEL TANK IS FILLED...676
P-11 WHEN STARTING SWITCH IS TURNED ON, BUZZER DOES NOT SOUND FOR 1 SECOND...676
P-12 ABNORMALITY IN SERVICE METER DISPLAY...677
a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS RUNNING...677
b) SERVICE METER PILOT LAMP DOES NOT FLASH...677
P-13 NIGHT LIGHTING DOES NOT LIGHT UP ...678
a) WHEN LAMP SWITCH IS AT POSITION 1OR POSITION 2, INTERNAL LIGHTING OF MONITOR (GAUGE PORTION) DOES NOT LIGHT UP...678
b) WHEN LAMP SWITCH IS AT POSITION 2, WORKING LAMP DOES NOT LIGHT UP...678
P-14 HEATER DOES NOT WORK WHEN HEATER SWITCH IS OPERATED (MACHINES WITH CAB SPECIFICATION)...679
30 DISASSEMBLY AND ASSEMBLY...680
METHOD OF USING MANUAL...682
PRECAUTIONS WHEN CARRYING OUT OPERATION...683
SPECIAL TOOL LIST...685
STARTING MOTOR...686
REMOVAL...686
INSTALLATION...686
ALTERNATOR...687
REMOVAL...687
INSTALLATION...687
FUEL INJECTION PUMP...688
REMOVAL...688
INSTALLATION...688
NOZZLE HOLDER...689
REMOVAL...689
INSTALLATION...689
WATER PUMP...690
REMOVAL...690
INSTALLATION...690
THERMOSTAT...692
REMOVAL...692
INSTALLATION...692
ENGINE FRONT SEAL...693
REMOVAL...693
INSTALLATION...693
ENGINE REAR SEAL...694
REMOVAL...694
INSTALLATION...694
CYLINDER HEAD...695
REMOVAL...695
INSTALLATION...696
RADIATOR AND OIL COOLER...699
REMOVAL...699
INSTALLATION...699
ENGINE AND HYDRAULIC PUMP...701
REMOVAL...701
INSTALLATION...702
DAMPER...703
REMOVAL...703
INSTALLATION...703
CENTER SWIVEL JOINT...704
REMOVAL...704
INSTALLATION...704
DISASSEMBLY...706
ASSEMBLY...706
TRAVEL MOTOR...707
REMOVAL...707
INSTALLATION...707
DISASSEMBLY...708
ASSEMBLY...713
SPROCKET...719
REMOVAL...719
INSTALLATION...719
SWING MOTOR AND SWING MACHINERY...720
REMOVAL...720
INSTALLATION...720
SWING MOTOR ...722
DISASSEMBLY...722
ASSEMBLY...724
SWING MACHINERY...728
DISASSEMBLY...728
ASSEMBLY...730
REVOLVING FRAME...732
REMOVAL...732
INSTALLATION...733
SWING CIRCLE...736
REMOVAL...736
INSTALLATION...736
IDLER AND RECOIL SPRING...737
REMOVAL...737
INSTALLATION...737
RECOIL SPRING...738
DISASSEMBLY...738
ASSEMBLY...739
TRACK ROLLER...740
REMOVAL...740
INSTALLATION...740
CARRIER ROLLER...741
REMOVAL...741
INSTALLATION...741
RUBBER SHOE...742
REMOVAL...742
INSTALLATION...742
HYDRAULIC PUMP...743
REMOVAL...743
INSTALLATION...743
7-SPOOL CONTROL VALVE...744
REMOVAL...744
INSTALLATION...744
2-SPOOL CONTROL VALVE...746
REMOVAL...746
INSTALLATION...746
7-SPOOL CONTROL VALVE...748
DISASSEMBLY...748
ASSEMBLY...750
2-SPOOL CONTROL VALVE...752
DISASSEMBLY...752
ASSEMBLY...753
BOOM CYLINDER...754
REMOVAL...754
INSTALLATION...754
ARM CYLINDER...755
REMOVAL...755
INSTALLATION...755
BUCKET CYLINDER...756
REMOVAL...756
INSTALLATION...756
SWING CYLINDER ...757
REMOVAL...757
INSTALLATION...757
BLADE CYLINDER...758
REMOVAL...758
INSTALLATION...758
HYDRAULIC CYLINDER...759
DISASSEMBLY...759
ASSEMBLY...761
WORK EQUIPMENT...763
REMOVAL...763
INSTALLATION...763
BUCKET...764
REMOVAL...764
INSTALLATION...764
ARM...765
REMOVAL...765
INSTALLATION...765
BOOM...766
REMOVAL...766
INSTALLATION...766
BLADE...767
REMOVAL...767
INSTALLATION...767
40 MAINTENANCE STANDARD...769
SWING CIRCLE...770
SWING MACHINERY...772
TRACK FRAME AND RECOIL SPRING...773
IDLER...775
CARRIER ROLLER...776
TRACK ROLLER...778
TRACK SHOE...780
HYDRAULIC PUMP...781
7-SPOOL CONTROL VALVE...782
2-SPOOL CONTROL VALVE...785
SWING MOTOR...787
TRAVEL MOTOR...788
CENTER SWIVEL JOINT...789
HYDRAULIC CYLINDER...790
WORK EQUIPMENT...793
WEAM007700 - Hydraulic Excavator GALEO PC14R-2 Operation & Maintenance Manual...801
1.1 FOREWORD...803
1.2 INFORMATION ON SAFETY...804
1.3 INTRODUCTION...806
1.3.1 INTENDED USE OF THE MACHINE...806
1.3.2 IMPROPER OR UNAUTHORIZED USES...806
1.3.3 MAIN CHARACTERISTICS...806
1.3.4 RUNNING-IN...807
1.3.5 POSITIONS AND DIRECTIONS OF THE MACHINE...807
1.4 PRODUCT IDENTIFICATION...808
1.4.1 MACHINE SERIAL NUMBER...808
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)...808
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE...809
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER...809
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER...810
1.4.6 SERIAL NUMBERS AND DEALER’S ADDRESS...811
TABLE OF CONTENTS...812
2.1 SAFETY, NOISE AND VIBRATION PLATES...820
2.1.1 POSITION OF THE SAFETY PLATES...820
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...821
2.1.3 POSITION OF THE NOISE PLATES...826
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...826
2.2 GENERAL PRECAUTIONS...827
2.2.1 GENERAL SAFETY RULES...827
2.2.2 SAFETY DEVICES AND GUARDS...827
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...827
2.2.4 UNAUTHORIZED MODIFICATIONS...828
2.2.5 LEAVING THE OPERATOR SEAT...828
2.2.6 GETTING ON AND OFF THE MACHINE...829
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL...830
2.2.8 PREVENTING BURNS...830
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...831
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...831
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT...832
2.2.12 PRECAUTIONS CONCERNING THE ROPS STRUCTURE...832
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT...832
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...833
2.3.1 SAFETY AT THE WORK SITE...833
2.3.2 FIRE PREVENTION...833
2.3.3 PRECAUTIONS CONCERNING THE OPERATOR SEAT...833
2.3.4 ROOM VENTILATION...834
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS...834
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING...835
2.4.1 STARTING THE ENGINE...835
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE...835
2.4.3 HAND SIGNALS...836
2.4.4 CHECKS FOR TRAVELLING IN REVERSE...841
2.4.5 MOVING THE MACHINE...841
2.4.6 MOVING ON SLOPES...842
2.4.7 WORKING ON SLOPES...843
2.4.8 UNAUTHORIZED OPERATIONS...843
2.4.9 PREVENTING ELECTROCUTION...845
2.4.10 VISIBILITY...845
2.4.11 WORKING ON ICY OR SNOW-COVERED SURFACES...845
2.4.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...846
2.4.13 WORKING ON LOOSE GROUND...846
2.4.14 PARKING THE MACHINE...846
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES...847
2.5.1 LOADING AND UNLOADING THE MACHINE...847
2.5.2 TRANSPORTING THE MACHINE...847
2.6 BATTERY...848
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY...848
2.6.2 STARTING WITH BOOSTER CABLES...848
2.7 PRECAUTIONS FOR THE REMOVAL OF THE MACHINE...849
2.8 PRECAUTIONS FOR MAINTENANCE...850
2.8.1 WARNING PLATES...850
2.8.2 TOOLS...850
2.8.3 MAINTENANCE STAFF...850
2.8.4 EQUIPMENT...851
2.8.5 WORKING UNDER THE MACHINE...851
2.8.6 CLEANING THE MACHINE...851
2.8.7 USE OF THE ENGINE DURING MAINTENANCE...852
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY...852
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...852
2.8.10 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL...853
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR...853
2.8.12 USING LAMPS...853
2.8.13 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR...854
2.8.14 PRECAUTIONS CONCERNING THE STARTER...854
2.8.15 HANDLING HIGH-PRESSURE HOSES...854
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL...855
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE...855
2.8.18 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE TRACK TENSION...856
2.8.19 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT...856
2.8.20 HYDRAULIC ACCUMULATOR...856
2.8.21 COOLING FAN AND BELT...857
2.8.22 WASTE MATERIALS...857
2.8.23 COMPRESSED AIR...857
2.8.24 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS...858
2.8.25 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE HEES...858
3.1 MACHINE ILLUSTRATIONS...860
3.1.1 OVERALL VIEW OF THE MACHINE...860
3.1.2 CONTROLS AND GAUGES...861
3.2 INSTRUMENTS AND CONTROLS...862
3.2.1 WARNING LIGHTS AND GAUGES...862
3.2.1.1 EMERGENCY WARNING LIGHTS...863
3.2.1.2 GAUGES...864
3.2.1.3 WARNING LIGHTS...865
3.2.2 SWITCHES AND PUSH BUTTONS...867
3.2.3 CONTROL LEVERS AND PEDALS...870
3.2.4 COVERSWITH LOCK...877
3.2.5 ENGINE HOOD...878
3.2.6 RADIATOR COVER...879
3.2.7 BATTERY COVER...880
3.2.8 TILTING THE CAB FLOOR...881
3.2.9 FUSES...884
3.2.10 MAIN FUSE...885
3.2.11 TECHNICAL DOCUMENTATION COMPARTMENT...885
3.2.12 TOOL BOX...885
3.3 USE OF THE MACHINE AND RELATED CONTROLS...886
3.3.1 BEFORE STARTING THE ENGINE...886
3.3.1.1 VISUAL CHECKS...886
3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...887
3.3.1.3 ADJUSTMENTS...894
3.3.1.4 OPERATIONS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...896
3.3.2 STARTING THE ENGINE...898
3.3.2.1 STARTING WITH WARM ENGINE OR IN WARM CLIMATES...898
3.3.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...900
3.3.3 AFTER STARTING THE ENGINE...902
3.3.3.1 RUNNING IN A NEW MACHINE...902
3.3.3.2 WARMING-UP OPERATIONS...903
3.3.4 STOPPING THE ENGINE...905
3.3.5 HOW TO MOVE THE MACHINE...906
3.3.5.1 PRELIMINARY OPERATIONS TO BE CARRIED OUT BEFORE MOVING THE MACHINE...906
3.3.5.2 MOVING THE MACHINE FORWARD...906
3.3.5.3 MOVING THE MACHINE IN REVERSE...908
3.3.5.4 STOPPING THE MACHINE...909
3.3.6 STEERING THE MACHINE...910
3.3.6.1 STEERING (CHANGING DIRECTION)...910
3.3.7 SWINGING THE TURRET...912
3.3.8 WORK EQUIPMENT CONTROLS AND FUNCTIONS...913
3.3.9 UNAUTHORIZED OPERATIONS...916
3.3.10 PRECAUTIONS FOR USE...918
3.3.11 PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES...920
3.3.12 GETTING THE MACHINE OUT OF MUD...922
3.3.13 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR...923
3.3.14 CHANGING THE BUCKET...925
3.3.15 PARKING THE MACHINE...926
3.3.16 CHECKING THE MACHINE EVERY DAY AFTER WORK...928
3.3.16.1 BEFORE STOPPING THE ENGINE...928
3.3.16.2 AFTER STOPPING THE ENGINE...928
3.3.17 LOCKING THE MACHINE...928
3.3.18 RUBBER TRACKS (Machines equipped with rubber tracks only)...929
3.3.18.1 OPTIMAL USE OF THE RUBBER TRACKS...929
3.3.18.2 WARRANTY ON RUBBER TRACKS...929
3.3.18.3 USE OF THE RUBBER TRACKS...930
3.3.18.4 HOW TO PRESERVE THE RUBBER TRACKS OVER TIME...930
3.4 TRANSPORTING THE MACHINE...934
3.4.1 TRANSPORT PROCEDURE...934
3.4.2 LOADING AND UNLOADING THE MACHINE...934
3.4.3 LIFTING THE MACHINE...940
3.5 USING THE MACHINE IN THE COLD SEASON...942
3.5.1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON...942
3.5.1.1 FUEL AND LUBRICANTS...942
3.5.1.2 COOLANT...942
3.5.1.3 BATTERY...943
3.5.2 PRECAUTIONS TO BE TAKEN EVERY DAY AT THE END OF WORK...944
3.5.3 HOW TO PROCEED AT THE END OF THE COLD SEASON...944
3.6 LONG PERIODS OF INACTIVITY...945
3.6.1 BEFORE A PERIOD OF INACTIVITY...945
3.6.2 DURING A PERIOD OF INACTIVITY...945
3.6.3 AFTER A PERIOD OF INACTIVITY...945
3.7 TROUBLESHOOTING...946
3.7.1 IF FUEL RUNS OUT COMPLETELY...946
3.7.2 OCCURRENCES THAT ARE NOT FAILURES...946
3.7.3 REMOVING THE MACHINE...946
3.7.4 PRECAUTIONS TO BE TAKEN WHEN WORKING IN PARTICULAR CONDITIONS...947
3.7.5 IF THE BATTERY IS DOWN...947
3.7.5.1 REMOVING AND INSTALLING THE BATTERY...948
3.7.5.2 CHARGING THE BATTERY...948
3.7.5.3 STARTING WITH BOOSTER CABLES...949
3.7.6 OTHER TROUBLES...951
3.7.6.1 ELECTRICAL CIRCUIT...951
3.7.6.2 FRAME...952
3.7.6.3 ENGINE...952
4.1 GUIDE TO MAINTENANCE...956
4.2 MAINTENANCE NOTES...958
4.2.1 OIL, FUEL AND COOLANT...958
4.2.1.1 OIL...958
4.2.1.2 FUEL...959
4.2.1.3 COOLANT...959
4.2.1.4 KOWA (KOMATSU OIL WEAR ANALYSIS)...960
4.2.1.5 STORING OIL AND FUEL...961
4.2.1.6 FILTERS...961
4.2.2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM...962
4.2.3 NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM...962
4.2.4 MAINTENANCE NOTES REGARDING LUBRICATION...962
4.3 PARTS SUBJECT TO WEAR...963
4.3.1 LIST OF THE PARTS SUBJECT TO WEAR...963
4.4 FUEL, COOLANT AND LUBRICANTS...964
4.4.1 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES...966
4.5 TIGHTENING TORQUES...967
4.5.1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS...967
4.5.2 STANDARD TIGHTENING TORQUES FOR HOSES WITH ORFS...968
4.6 LUBRICATION...969
4.6.1 LUBRICATION DIAGRAM...969
4.7 PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS...970
4.7.1 SAFETY-RELATED PARTS...971
4.8 MAINTENANCE PLAN...972
4.8.1 MAINTENANCE PLAN...972
4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER...973
4.8.2.a CHANGING THE HYDRAULIC OIL FILTER...973
4.8.2.b CHANGING THE HYDRAULIC OIL...973
4.9 MAINTENANCE PROCEDURES...974
4.9.1 WHEN REQUIRED...974
4.9.1.a CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE...974
4.9.1.b CHECKING THE BATTERY CHARGE LEVEL...976
4.9.1.c CLEANING THE WATER SEPARATOR FILTER...977
4.9.1.d DRAINING THE FUEL TANK...978
4.9.1.e CHECKING AND ADJUSTING THE STEEL TRACK TENSION...978
4.9.1.f CHECKING THE RUBBER TRACKS...980
4.9.1.g CHECKING AND ADJUSTING THE RUBBER TRACK TENSION...982
4.9.1.h CHANGING THE RUBBER TRACKS...984
4.9.1.i BLEEDING THE HYDRAULIC SYSTEM...987
4.9.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...988
4.9.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...988
4.9.4 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...988
4.9.5 MAINTENANCE EVERY 500 HOURS OF OPERATION...989
4.9.5.a LUBRICATION...989
4.9.5.b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE...991
4.9.5.c CHANGING THE FUEL FILTER CARTRIDGE...992
4.9.5.d CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS...993
4.9.5.e CHECKING AND CLEANING THE FINS OF THE RADIATOR AND OF THE EXCHANGER...993
4.9.5.f CHECKING AND ADJUSTING THE FAN BELT TENSION...994
4.9.5.g DRAINING THE HYDRAULIC OIL TANK (Only for machines in which synthetic biodegradable oil type HEES is used)...995
4.9.6 MAINTENANCE EVERY 1000 HOURS OF OPERATION...996
4.9.6.a CHANGING THE HYDRAULIC OIL FILTER...996
4.9.6.b CHANGING THE OIL IN THE FINAL REDUCTION GEARS...998
4.9.6.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE...998
4.9.7 MAINTENANCE EVERY 2000 HOURS OF OPERATION...999
4.9.7.a CHANGING THE OIL IN THE HYDRAULIC TANK AND CLEANING THE FILTER...999
4.9.7.b CHANGING THE COOLANT...1001
4.9.7.c CHECKING THE ALTERNATOR AND THE STARTER...1002
5.1 TECHNICAL DATA...1004
5.2 LIFTING CAPACITIES...1006
5.2.1 LIFTING CAPACITIES...1006
6.1 AUTHORIZED OPTIONAL EQUIPMENT...1010
6.1.1 PRECAUTIONS REGARDING SAFETY...1010
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT...1011
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT...1012
6.1.3.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT...1012
6.2 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS...1013
6.2.1 POSITION OF THE DEVICES...1013
6.2.2 HYDRAULIC CIRCUIT...1015
6.2.2.1 INSTALLING AND CONNECTING THE EQUIPMENT...1015
6.2.2.2 MAINTENANCE...1015
6.2.2.3 BLEEDING...1016
6.3 OPERATING THE EQUIPMENT...1017
6.3.1 LONG PERIODS OF INACTIVITY...1018
6.4 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT...1019
6.4.1 HYDRAULIC BREAKER...1019
WEAM007800 - Hydraulic Excavator GALEO PC16R-2 Operation & Maintenance Manual...1027
1.1 FOREWORD...1029
1.2 INFORMATION ON SAFETY...1030
1.3 INTRODUCTION...1032
1.3.1 INTENDED USE OF THE MACHINE...1032
1.3.2 IMPROPER OR UNAUTHORIZED USES...1032
1.3.3 MAIN CHARACTERISTICS...1032
1.3.4 RUNNING-IN...1033
1.3.5 POSITIONS AND DIRECTIONS OF THE MACHINE...1033
1.4 PRODUCT IDENTIFICATION...1034
1.4.1 MACHINE SERIAL NUMBER...1034
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)...1034
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE...1035
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER...1035
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER...1036
1.4.6 SERIAL NUMBERS AND DEALER’S ADDRESS...1037
TABLE OF CONTENTS...1038
2.1 SAFETY, NOISE AND VIBRATION PLATES...1046
2.1.1 POSITION OF THE SAFETY PLATES...1046
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...1047
2.1.3 POSITION OF THE NOISE PLATES...1052
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...1052
2.2 GENERAL PRECAUTIONS...1053
2.2.1 GENERAL SAFETY RULES...1053
2.2.2 SAFETY DEVICES AND GUARDS...1053
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...1053
2.2.4 UNAUTHORIZED MODIFICATIONS...1054
2.2.5 LEAVING THE OPERATOR SEAT...1054
2.2.6 GETTING ON AND OFF THE MACHINE...1055
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL...1056
2.2.8 PREVENTING BURNS...1056
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...1057
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...1057
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT...1058
2.2.12 PRECAUTIONS CONCERNING THE ROPS STRUCTURE...1058
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT...1058
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...1059
2.3.1 SAFETY AT THE WORK SITE...1059
2.3.2 FIRE PREVENTION...1059
2.3.3 PRECAUTIONS CONCERNING THE OPERATOR SEAT...1059
2.3.4 ROOM VENTILATION...1060
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS...1060
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING...1061
2.4.1 STARTING THE ENGINE...1061
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE...1061
2.4.3 HAND SIGNALS...1062
2.4.4 CHECKS FOR TRAVELLING IN REVERSE...1067
2.4.5 MOVING THE MACHINE...1067
2.4.6 MOVING ON SLOPES...1068
2.4.7 WORKING ON SLOPES...1069
2.4.8 UNAUTHORIZED OPERATIONS...1069
2.4.9 PREVENTING ELECTROCUTION...1071
2.4.10 VISIBILITY...1071
2.4.11 WORKING ON ICY OR SNOW-COVERED SURFACES...1071
2.4.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...1072
2.4.13 WORKING ON LOOSE GROUND...1072
2.4.14 PARKING THE MACHINE...1072
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES...1073
2.5.1 LOADING AND UNLOADING THE MACHINE...1073
2.5.2 TRANSPORTING THE MACHINE...1073
2.6 BATTERY...1074
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY...1074
2.6.2 STARTING WITH BOOSTER CABLES...1074
2.7 PRECAUTIONS FOR THE REMOVAL OF THE MACHINE...1075
2.8 PRECAUTIONS FOR MAINTENANCE...1076
2.8.1 WARNING PLATES...1076
2.8.2 TOOLS...1076
2.8.3 MAINTENANCE STAFF...1076
2.8.4 EQUIPMENT...1077
2.8.5 WORKING UNDER THE MACHINE...1077
2.8.6 CLEANING THE MACHINE...1077
2.8.7 USE OF THE ENGINE DURING MAINTENANCE...1078
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY...1078
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...1078
2.8.10 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL...1079
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR...1079
2.8.12 USING LAMPS...1079
2.8.13 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR...1080
2.8.14 PRECAUTIONS CONCERNING THE STARTER...1080
2.8.15 HANDLING HIGH-PRESSURE HOSES...1080
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL...1081
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE...1081
2.8.18 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE TRACK TENSION...1082
2.8.19 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT...1082
2.8.20 HYDRAULIC ACCUMULATOR...1082
2.8.21 COOLING FAN AND BELT...1083
2.8.22 WASTE MATERIALS...1083
2.8.23 COMPRESSED AIR...1083
2.8.24 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS...1084
2.8.25 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE HEES...1084
3.1 MACHINE ILLUSTRATIONS...1086
3.1.1 OVERALL VIEW OF THE MACHINE...1086
3.1.2 CONTROLS AND GAUGES...1087
3.2 INSTRUMENTS AND CONTROLS...1088
3.2.1 WARNING LIGHTS AND GAUGES...1088
3.2.1.1 EMERGENCY WARNING LIGHTS...1089
3.2.1.2 GAUGES...1090
3.2.1.3 WARNING LIGHTS...1091
3.2.2 SWITCHES AND PUSH BUTTONS...1093
3.2.3 CONTROL LEVERS AND PEDALS...1096
3.2.4 COVERSWITH LOCK...1103
3.2.5 ENGINE HOOD...1104
3.2.6 RADIATOR COVER...1105
3.2.7 BATTERY COVER...1106
3.2.8 TILTING THE CAB FLOOR...1107
3.2.9 FUSES...1110
3.2.10 MAIN FUSE...1111
3.2.11 TECHNICAL DOCUMENTATION COMPARTMENT...1111
3.2.12 TOOL BOX...1111
3.3 USE OF THE MACHINE AND RELATED CONTROLS...1112
3.3.1 BEFORE STARTING THE ENGINE...1112
3.3.1.1 VISUAL CHECKS...1112
3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...1113
3.3.1.3 ADJUSTMENTS...1120
3.3.1.4 OPERATIONS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...1122
3.3.2 STARTING THE ENGINE...1124
3.3.2.1 STARTING WITH WARM ENGINE OR IN WARM CLIMATES...1124
3.3.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...1126
3.3.3 AFTER STARTING THE ENGINE...1128
3.3.3.1 RUNNING IN A NEW MACHINE...1128
3.3.3.2 WARMING-UP OPERATIONS...1129
3.3.4 STOPPING THE ENGINE...1131
3.3.5 HOW TO MOVE THE MACHINE...1132
3.3.5.1 PRELIMINARY OPERATIONS TO BE CARRIED OUT BEFORE MOVING THE MACHINE...1132
3.3.5.2 MOVING THE MACHINE FORWARD...1132
3.3.5.3 MOVING THE MACHINE IN REVERSE...1134
3.3.5.4 STOPPING THE MACHINE...1135
3.3.6 STEERING THE MACHINE...1136
3.3.6.1 STEERING (CHANGING DIRECTION)...1136
3.3.7 SWINGING THE TURRET...1138
3.3.8 WORK EQUIPMENT CONTROLS AND FUNCTIONS...1139
3.3.9 UNAUTHORIZED OPERATIONS...1142
3.3.10 PRECAUTIONS FOR USE...1144
3.3.11 PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES...1146
3.3.12 GETTING THE MACHINE OUT OF MUD...1148
3.3.13 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR...1149
3.3.14 CHANGING THE BUCKET...1151
3.3.15 PARKING THE MACHINE...1152
3.3.16 CHECKING THE MACHINE EVERY DAY AFTER WORK...1154
3.3.16.1 BEFORE STOPPING THE ENGINE...1154
3.3.16.2 AFTER STOPPING THE ENGINE...1154
3.3.17 LOCKING THE MACHINE...1154
3.3.18 RUBBER TRACKS (Machines equipped with rubber tracks only)...1155
3.3.18.1 OPTIMAL USE OF THE RUBBER TRACKS...1155
3.3.18.2 WARRANTY ON RUBBER TRACKS...1155
3.3.18.3 USE OF THE RUBBER TRACKS...1156
3.3.18.4 HOW TO PRESERVE THE RUBBER TRACKS OVER TIME...1156
3.4 TRANSPORTING THE MACHINE...1160
3.4.1 TRANSPORT PROCEDURE...1160
3.4.2 LOADING AND UNLOADING THE MACHINE...1160
3.4.3 LIFTING THE MACHINE...1166
3.5 USING THE MACHINE IN THE COLD SEASON...1168
3.5.1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON...1168
3.5.1.1 FUEL AND LUBRICANTS...1168
3.5.1.2 COOLANT...1168
3.5.1.3 BATTERY...1169
3.5.2 PRECAUTIONS TO BE TAKEN EVERY DAY AT THE END OF WORK...1170
3.5.3 HOW TO PROCEED AT THE END OF THE COLD SEASON...1170
3.6 LONG PERIODS OF INACTIVITY...1171
3.6.1 BEFORE A PERIOD OF INACTIVITY...1171
3.6.2 DURING A PERIOD OF INACTIVITY...1171
3.6.3 AFTER A PERIOD OF INACTIVITY...1171
3.7 TROUBLESHOOTING...1172
3.7.1 IF FUEL RUNS OUT COMPLETELY...1172
3.7.2 OCCURRENCES THAT ARE NOT FAILURES...1172
3.7.3 REMOVING THE MACHINE...1172
3.7.4 PRECAUTIONS TO BE TAKEN WHEN WORKING IN PARTICULAR CONDITIONS...1173
3.7.5 IF THE BATTERY IS DOWN...1173
3.7.5.1 REMOVING AND INSTALLING THE BATTERY...1174
3.7.5.2 CHARGING THE BATTERY...1174
3.7.5.3 STARTING WITH BOOSTER CABLES...1175
3.7.6 OTHER TROUBLES...1177
3.7.6.1 ELECTRICAL CIRCUIT...1177
3.7.6.2 FRAME...1178
3.7.6.3 ENGINE...1178
4.1 GUIDE TO MAINTENANCE...1182
4.2 MAINTENANCE NOTES...1184
4.2.1 OIL, FUEL AND COOLANT...1184
4.2.1.1 OIL...1184
4.2.1.2 FUEL...1185
4.2.1.3 COOLANT...1185
4.2.1.4 KOWA (KOMATSU OIL WEAR ANALYSIS)...1186
4.2.1.5 STORING OIL AND FUEL...1187
4.2.1.6 FILTERS...1187
4.2.2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM...1188
4.2.3 NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM...1188
4.2.4 MAINTENANCE NOTES REGARDING LUBRICATION...1188
4.3 PARTS SUBJECT TO WEAR...1189
4.3.1 LIST OF THE PARTS SUBJECT TO WEAR...1189
4.4 FUEL, COOLANT AND LUBRICANTS...1190
4.4.1 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES...1192
4.5 TIGHTENING TORQUES...1193
4.5.1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS...1193
4.5.2 STANDARD TIGHTENING TORQUES FOR HOSES WITH ORFS...1194
4.6 LUBRICATION...1195
4.6.1 LUBRICATION DIAGRAM...1195
4.7 PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS...1196
4.7.1 SAFETY-RELATED PARTS...1197
4.8 MAINTENANCE PLAN...1198
4.8.1 MAINTENANCE PLAN...1198
4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER...1199
4.8.2.a CHANGING THE HYDRAULIC OIL FILTER...1199
4.8.2.b CHANGING THE HYDRAULIC OIL...1199
4.9 MAINTENANCE PROCEDURES...1200
4.9.1 WHEN REQUIRED...1200
4.9.1.a CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE...1200
4.9.1.b CHECKING THE BATTERY CHARGE LEVEL...1202
4.9.1.c CLEANING THE WATER SEPARATOR FILTER...1203
4.9.1.d DRAINING THE FUEL TANK...1204
4.9.1.e CHECKING AND ADJUSTING THE STEEL TRACK TENSION...1204
4.9.1.f CHECKING THE RUBBER TRACKS...1206
4.9.1.g CHECKING AND ADJUSTING THE RUBBER TRACK TENSION...1208
4.9.1.h CHANGING THE RUBBER TRACKS...1210
4.9.1.i BLEEDING THE HYDRAULIC SYSTEM...1213
4.9.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...1214
4.9.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...1214
4.9.4 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...1214
4.9.5 MAINTENANCE EVERY 500 HOURS OF OPERATION...1215
4.9.5.a LUBRICATION...1215
4.9.5.b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE...1217
4.9.5.c CHANGING THE FUEL FILTER CARTRIDGE...1218
4.9.5.d CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS...1219
4.9.5.e CHECKING AND CLEANING THE FINS OF THE RADIATOR AND OF THE EXCHANGER...1219
4.9.5.f CHECKING AND ADJUSTING THE FAN BELT TENSION...1220
4.9.5.g DRAINING THE HYDRAULIC OIL TANK (Only for machines in which synthetic biodegradable oil type HEES is used)...1221
4.9.6 MAINTENANCE EVERY 1000 HOURS OF OPERATION...1222
4.9.6.a CHANGING THE HYDRAULIC OIL FILTER...1222
4.9.6.b CHANGING THE OIL IN THE FINAL REDUCTION GEARS...1224
4.9.6.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE...1224
4.9.7 MAINTENANCE EVERY 2000 HOURS OF OPERATION...1225
4.9.7.a CHANGING THE OIL IN THE HYDRAULIC TANK AND CLEANING THE FILTER...1225
4.9.7.b CHANGING THE COOLANT...1227
4.9.7.c CHECKING THE ALTERNATOR AND THE STARTER...1228
5.1 TECHNICAL DATA...1230
5.2 LIFTING CAPACITIES...1232
5.2.1 LIFTING CAPACITIES...1232
6.1 AUTHORIZED OPTIONAL EQUIPMENT...1236
6.1.1 PRECAUTIONS REGARDING SAFETY...1236
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT...1237
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT...1238
6.1.3.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT...1238
6.2 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS...1239
6.2.1 POSITION OF THE DEVICES...1239
6.2.2 HYDRAULIC CIRCUIT...1241
6.2.2.1 INSTALLING AND CONNECTING THE EQUIPMENT...1241
6.2.2.2 MAINTENANCE...1241
6.2.2.3 BLEEDING...1242
6.3 OPERATING THE EQUIPMENT...1243
6.3.1 LONG PERIODS OF INACTIVITY...1244
6.4 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT...1245
6.4.1 HYDRAULIC BREAKER...1245
Komatsu Excavator PC05, PC07, PC10, PC15, PC20 Repair Service Manuals
