Komatsu Hydraulic Excavator PC12R, PC15R Repair Service Manuals
Catalog:
Model:
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC12R-8, PC15R-8, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC12R-8, PC15R-8 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.
WEBM000100 - Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual.pdf
WEBM000101 - Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual.pdf
WEBM002800 - Hydraulic Excavator PC15R-8 Shop Manual.pdf
SEBM013103 - Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual.pdf
SEAM015102T - Hydraulic Excavator PC12R-8, PC15R-8 Operation & Maintenance Manual.pdf
WEAM002702 - Hydraulic Excavator PC12R-8, PC12R-8 HS, PC15R-8, PC15R-8 HS Operation & Maintenance Manual.pdf
WEAM003000 - Hydraulic Excavator PC15R-8 Operation & Maintenance Manual.pdf
WEAM003001 - Hydraulic Excavator PC15R-8 Deluxe Operation & Maintenance Manual.pdf
Total Pages: 2,030 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
SEAM015102T - Hydraulic Excavator PC12R-8, PC15R-8 Operation & Maintenance Manual....2
COVER....2
1. FOREWORD....3
2. SAFETY INFORMATION....6
3. INTRODUCTION....7
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....8
5. CONTENTS....9
SAFETY....13
6. GENERAL PRECAUTIONS ....14
7. PRECAUTIONS DURING OPERATION....19
7.1 BEFORE STARTING ENGINE....19
7.2 AFTER STARTING ENGINE....21
7.3 TRANSPORTATION....28
7.4 BATTERY....29
7.5 TOWING....31
8. PRECAUTIONS FOR MAINTENANCE....32
8.1 BEFORE CARRYING OUT MAINTENANCE....32
8.2 DURING MAINTENANCE....36
9. POSITION FOR ATTACHING SAFETY LABELS....41
OPERATION....44
10. GENERAL VIEW ....45
10.1 GENERAL VIEW OF MACHINE....45
10.2 GENERAL VIEW OF CONTROLS AND GAUGES....46
11. EXPLANATION OF COMPONENTS....47
11.1 MACHINE MONITOR....47
11.2 SWITCHES ....50
11.3 CONTROL LEVERS AND PEDALS....52
11.4 ENGINE HOOD....56
11.5 OPERATOR'S SEAT....57
11.6 MANUAL STORAGE SPACE・TOOL BOX....57
11.7 BATTERY HOOK....57
11.8 FRONT WINDOW (FOR MACHINE EQUIPPED WITH CAB (OPTION))....58
11.9 DOOR LOCK (FOR MACHINE EQUIPPED WITH CAB (OPTION))....60
11.10 HAMMER FOR EMERGENCY ESCAPE (FOR MACHINE EQUIPPED WITH CAB (OPTION))....61
11.11 CAP, COVER WITH LOCK....61
11.12 FUSE....63
11.13 FUSIBLE LINK....63
12. OPERATION....64
12.1 CHECK BEFORE STARTING ENGINE....64
12.2 STARTING ENGINE....71
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE....74
12.4 MOVING MACHINE OFF....76
12.5 STEERING MACHINE....79
12.6 STOPPING MACHINE....81
12.7 SWINGING....82
12.8 OPERATION OF WORK EQUIPMENT....83
12.9 PROHIBITIONS FOR OPERATION....84
12.10 PRECAUTIONS FOR OPERATION....87
12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS....88
12.12 HOW TO ESCAPE FROM MUD....90
12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR....91
12.14 REPLACEMENT OF BUCKET....93
12.15 PARKING MACHINE....94
12.16 CHECK AFTER FINISHING WORK....95
12.17 STOPPING ENGINE....95
12.18 CHECK AFTER STOPPING ENGINE....96
12.19 LOCKING....96
12.20 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)....97
13. TRANSPORTATION....103
13.1 LOADING, UNLOADING WORK....103
13.2 PRECAUTIONS FOR LOADING....105
13.3 PRECAUTIONS FOR TRANSPORTATION....105
13.4 METHOD OF LIFTING MACHINE....106
14. COLD WEATHER OPERATION....107
14.1 PRECAUTIONS FOR LOW TEMPERATURE....107
14.2 PRECAUTIONS AFTER COMPLETION OF WORK....109
14.3 AFTER COLD WEATHER....109
15. LONG-TERM STORAGE....110
15.1 BEFORE STORAGE....110
15.2 DURING STORAGE....111
15.3 AFTER STORAGE....111
16. TROUBLESHOOTING....112
16.1 PHENOMENA THAT ARE NOT FAILURES....112
16.2 METHOD OF TOWING MACHINE....112
16.3 IF BATTERY IS DISCHARGED....113
16.4 OTHER TROUBLE....118
MAINTENANCE....122
17. GUIDES TO MAINTENANCE....123
18. OUTLINES OF SERVICE....125
18.1 OUTLINE OF OIL,FUEL,COOLANT....125
18.2 OUTLINE OF ELECTRIC SYSTEM....128
18.3 OUTLINE OF HYDRAULIC SYSTEM....128
19. WEAR PARTS LIST....129
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....130
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....134
21.1 INTRODUCTION OF NECESSARY TOOLS....134
21.2 TORQUE LIST....135
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....136
23. MAINTENANCE SCHEDULE CHART....138
23.1 MAINTENANCE SCHEDULE CHART....138
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER....140
24. SERVICE PROCEDURE....141
24.1 INITIAL 250 HOURS SERVICE....141
24.2 WHEN REQUIRED....142
24.3 CHECK BEFORE STARTING....160
24.4 EVERY 100 HOURS SERVICE....164
24.5 EVERY 250 HOURS SERVICE....165
24.6 EVERY 500 HOURS SERVICE....170
24.7 EVERY 1000 HOURS SERVICE....175
24.8 EVERY 2000 HOURS SERVICE....176
SPECIFICATIONS....179
25. SPECIFICATIONS....180
OPTIONS, ATTACHMENTS....186
26. GENERAL PRECAUTIONS....187
26.1 PRECAUTIONS RELATED TO SAFETY....187
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS....188
27. USING SEAT BELT....189
27.1 SEAT BELT....189
28. HANDLING BUCKET WITH HOOK....191
28.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK....191
28.2 PROHIBITED OPERATIONS....191
28.3 PRECAUTIONS DURING OPERATIONS....191
29. HANDLING 2-WAY PIPING....192
29.1 SWITCHING BETWEEN 1-WAY AND 2-WAY....192
29.2 OPERATING PEDAL....192
30. INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS....193
30.1 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS....193
30.2 SELECTION OF TRACK SHOES (STEEL SHOE)....194
30.3 COMBINATIONS TABLE OF ATTACHMENTS....195
30.4 PRECAUTIONS FOR OPERATING WITH HYDRAULIC BREAKER....196
30.5 OPERATION OF QUICK BREAKER ARM....199
SEBM013103 - Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual....214
COVER....214
CONTENTS....215
SAFETY....218
00 FOREWORD....220
01 GENERAL....238
General assembly drawing....239
Specifications....243
List of lubricant and water....247
10 STRUCTURE AND FUNCTION....248
Power Train....249
Swing circle....250
Track frame and recoil spring....251
Hydraulic piping....252
Hydraulic tank....253
Hydraulic pump....254
Control valve (PC12R-8)....258
CLSS (PC12R-8)....266
Control valve (PC15R-8)....289
CLSS (PC15R-8)....297
Center swivel joint....318
Swing motor....320
Travel motor....322
Valve control....325
PPC valve....326
Work equipment....330
Machine monitor system....331
20 TESTING AND ADJUSTING....334
STANDARD VALUE TABLE....335
Standard value table for engine related parts....335
Standard value table for chassis related parts....337
Standard value table for electrical parts....351
TESTING AND ADJUSTING....353
Tools for testing, adjusting, and troubleshooting....354
Measuring engine speed....355
Measuring exhaust color....356
Adjusting valve clearance....357
Measuring compression pressure....358
Testing and adjusting fuel injection timing....359
Measuring engine oil pressure....360
Testing and adjusting fan belt tension....361
Testing and adjusting fuel control lever....362
Measuring sprocket wear....363
Testing and adjusting track shoe tension....364
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ....365
Testing and adjusting LS differential pressure....371
Adjusting PC valve spring....373
Testing and adjusting control circut pressure....374
Measuring output pressure of PPC lock valve and travel boost valve....376
Testing PPC valve output pressure and swing holding brake inlet port pressure....377
Adjusting work equipment, swing PPC valve ....379
Testing and adjusting travel deviation....380
Measuring oil leakage inside work equipment cylinder....381
Releasing remaining pressure from hydraulic circuit....382
Releasing remaining pressure from hydraulic tank ....382
Pressurizing hydraulic tank....382
Bleeding air....383
TROUBLESHOOTING....385
Type of connector and position of installation....386
Connection table for connector pin numbers ....389
Troubleshooting of engine electrical system (E mode)....399
E-Mode related electrical circuit diagram....400
E-1 Engine does not start....401
a) When starting motor does not turn (starting system)....401
b) When starting motor turns (engine stop solenoid system)....403
E-2 Engine does not stop....405
Troubleshooting of hydraulic, mechanical system (H mode)....406
Table of failure modes and causes....407
H- 1 Speeds of all work equipment, swing, travel are slow or lack power....411
H- 2 There is excessive drop in engine speed, or engine stalls....413
H- 3 No work equipment, travel, swing move....414
H- 4 Abnormal noise generated (from around pump)....415
H- 5 Fine control ability is poor or response is poor (PC15R)....415
H- 6 Boom is slow or lacks power....416
H- 7 Arm is slow or lacks power....416
H- 8 Bucket is slow or lacks power....417
H- 9 Boom swing is slow or lacks power....417
H-10 Blade is slow or lacks power....418
H-11 Boom, arm, bucket do not move (boom swing, blade, travel and swing are normal)....418
H-12 Excessive hydraulic drift (boom, arm, bucket, boom swing, blade)....419
a) Boom, bucket, boom swing, blade....419
b) Arm....419
H-13 Excessive time lag (engine at low idling)....419
a) Boom, arm....419
b) Bucket....419
H-14 In compound operations, work equipment with larger load is slow....420
H-15 Travel deviation....421
a) Deviation in normal travel....421
b) Deviation when starting....421
H-16 Travel speed is slow or lacks power....422
H-17 Steering does not turn easily....422
H-18 Travel speed does not switch....423
H-19 Travel does not move (one side only)....423
H-20 Swing speed is slow or lacks power....424
a) Speed is slow or lacks power in both directions....424
b) Speed is slow or lacks power in one direction only (left or right)....424
H-21 Does not swing....425
a) Does not swing in either direction....425
b) Does not swing in one direction (left or right)....425
H-22 Swing acceleration is poor....426
a) Acceleration is poor in both directions....426
b) Acceleration is poor in one direction only (left or right)....426
H-23 Excessive overrun when stopping swing....427
a) Overrun when stopping is excessive in both directions....427
b) Overrun when stopping is excessive in one direction only (left or right)....427
H-24 Excessive shock when stopping swing (in one direction only)....427
H-25 Excessive abnormal noise when stopping swing....428
H-26 Excessive hydraulic drift of swing....428
Troubleshooting of machine monitor system (M mode)....429
Electrical circuit diagram for M Mode related parts....430
M-1 Abnormality in engine oil pressure caution lamp system....431
a) Lamp does not light up when starting switch is turned ON....431
b) Lamp lights up when engine is running (engine oil pressure is normal)....431
M-2 Abnormality in charge caution lamp system....433
a) Lamp does not light up when starting switch is turned ON....433
b) Lamp lights up when engine is running (battery charge is normal)....433
M-3 Abnormality in engine water temperature caution lamp system....435
a) Lamp does not stay lighted up for 3 seconds when starting switch is turned ON....435
b) Lamp does not go out after starting switch has been at ON for 3 seconds....435
c) Lamp lights up when engine is running (engine water temperature is normal)....436
M-4 Abnormality in preheating pilot lamp....437
a) Lamp does not light up when starting switch is turned to HEAT....437
b) Lamp does not go out when starting switch is at HEAT and preheating time (approx. 18 sec.) is completed....437
c) Lamp lights up when starting switch is at position other than HEAT....438
M-5 Abnormality in fuel gauge system....439
a) Gauge does not go up from E when fuel is added to fuel tank....439
b) Gauge does not go down from F even when there is no fuel in fuel tank....439
c) Fuel level does not match gauge display....440
M-6 Abnormality in service meter system....441
a) Service meter does not advance when starting switch is at ON....441
b) Service meter advances when starting switch is at OFF....441
c) Pilot lamp does not flash when service meter is advancing....441
M-7 Abnormality in night lighting system....443
a) Night lighting does not light up when lamp switch is turned ON....443
b) Night lighting lights up when lamp switch is turned OFF ....443
30 DISASSEMBLY AND ASSEMBLY....445
Method of using manual....447
Precautions when carrying out operation....448
Special tool list....450
Starting motor....451
Removal and installation....451
Alternator ....452
Removal and installation....452
Fuel injection pump ....453
Removal and installation....453
Nozzle holder ....454
Removal and installation....454
Water pump ....455
Removal and installation....455
Thermostat ....456
Removal and installation....456
Engine front seal....457
Removal and installation....457
Engine rear seal....458
Removal....458
Installation....459
Cylinder head....460
Removal....460
Installation....461
Radiator....462
Removal....462
Installation....463
Engine, hydraulic pump....464
Removal....445
Installation....466
Fuel tank....467
Removal and installation....467
Damper....468
Removal and installation....468
Center swivel joint....469
Removal and installation....469
Disassembly and assembly....470
Travel motor....471
Removal and installation....471
Sprocket....472
Removal and installation....472
Swing motor....473
Removal and installation....473
Revolving frame....474
Removal....474
Installation....475
Swing circle....476
Removal and installation....476
Idler....477
Removal and installation....477
Disassembly....478
Assembly....479
Idler cushion (rubber shoe)....480
Removal and installation....480
Disassembly and assembly....481
Idler cushion (steel shoe)....482
Disassembly....445
Assembly....483
Track roller....484
Removal and installation....484
Disassembly and assembly....485
Rubber shoe....486
Removal and installation....486
Steel shoe....487
Removal and installation....487
Hydraulic tank....488
Removal....488
Installation....489
Hydraulic oil cooler....490
Removal and installation....490
Hydraulic pump....491
Removal and installation....491
Control valve....492
Removal....492
Installation....493
Disassembly....494
Assembly....499
PPC valve....506
Removal and installation....506
Disassembly....507
Assembly....508
Boom cylinder....509
Removal....509
Installation....510
Arm cylinder....511
Removal....511
Installation....512
Bucket cylinder....513
Removal....513
Installation....514
Swing cylinder....515
Removal....515
Installation....516
Blade cylinder....517
Removal and installation....517
Hydraulic cylinder....518
Disassembly....518
Assembly....521
Work equipment....525
Removal....525
Installation....526
Bucket....527
Removal and installation....527
Arm....528
Removal....528
Installation....529
Bucket, arm....530
Removal....530
Installation....531
Boom....532
Removal ....532
Installation....533
Swing bracket....534
Removal....534
Installation....535
Blade....536
Removal and installation....536
Canopy....537
Removal and installation....537
40 MAINTENANCE STANDARD....538
Swing circle....539
Track frame, recoil spring....540
Idler....541
Track roller....542
Track shoe....543
Hydraulic pump (PC15R-8)....545
Control valve (PC12R-8)....546
Control valve (PC15R-8)....552
Center swivel joint....558
Swing motor....559
PPC valve....560
Hydraulic cylinder....561
Work equipment....563
90 OTHERS....565
Hydraulic circuit diagram PC12R-8....566
Hydraulic circuit diagram PC15R-8....567
Electric circuit diagram PC12R,15R-8....568
WEAM002702 - Hydraulic Excavator PC12R-8, PC12R-8 HS, PC15R-8, PC15R-8 HS Operation & Maintenance Manual....569
1.1 FOREWORD....571
1.2 INFORMATION ON SAFETY....572
1.3 INTRODUCTION....574
1.3.1 INTENDED USES....574
1.3.2 IMPROPER OR UNAUTHORIZED USES....574
1.3.3 MAIN CHARACTERISTICS....575
1.3.4 RUNNING-IN....575
1.4 PRODUCT IDENTIFICATION....576
1.4.1 MACHINE SERIAL NUMBER....576
1.4.2 MACHINE IDENTIFICATION PLATE....576
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE....577
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER....577
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER....578
1.4.6 CAB SERIAL NUMBER....578
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS....579
TABLE OF CONTENTS....581
1.1 FOREWORD 1....581
1.2 INFORMATION ON SAFETY 2....581
1.3 INTRODUCTION 4....581
1.3.1 INTENDED USES 4....581
1.3.2 IMPROPER OR UNAUTHORIZED USES 4....581
1.3.3 MAIN CHARACTERISTICS 5....581
1.3.4 RUNNING-IN 5....581
1.4 PRODUCT IDENTIFICATION 6....581
1.4.1 MACHINE SERIAL NUMBER 6....581
1.4.2 MACHINE IDENTIFICATION PLATE 6....581
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE 7....581
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER 7....581
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER 8....581
1.4.6 CAB SERIAL NUMBER 8....581
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS 9....581
2.1 SAFETY, NOISE AND VIBRATION PLATES 20....581
2.1.1 POSITION OF THE SAFETY PLATES 20....581
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS 22....581
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB 26....581
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY 27....581
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED 28....581
2.2 GENERAL PRECAUTIONS 29....581
2.2.1 GENERAL SAFETY RULES 29....581
2.2.2 SAFETY DEVICES AND GUARDS 29....581
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS 29....581
2.2.4 UNAUTHORIZED MODIFICATIONS 30....581
2.2.5 LEAVING THE OPERATOR’S SEAT 30....581
2.2.6 GETTING ON AND OFF THE MACHINE 31....581
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL 31....581
2.2.8 PREVENTING BURNS 32....581
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER 32....581
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT 32....581
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT 33....581
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE 33....581
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT 33....581
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE 34....581
2.3.1 SAFETY ON THE WORK SITE 34....581
2.3.2 FIRE PREVENTION 34....581
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB 34....581
2.3.4 ROOM VENTILATION 35....581
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS 35....581
2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHIELD WIPER BLADES 35....581
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING 36....582
2.4.1 STARTING THE ENGINE 36....582
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE 36....582
2.4.3 CHECKS FOR TRAVELLING IN REVERSE 36....582
2.4.4 MOVING THE MACHINE 37....582
2.4.5 MOVING ON SLOPES 38....582
2.4.6 WORKING ON SLOPES 39....582
2.4.7 UNAUTHORIZED OPERATIONS 39....582
2.4.8 PREVENTING ELECTROCUTION 40....582
2.4.9 VISIBILITY 41....582
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES 41....582
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT 41....582
2.4.12 WORKING ON LOOSE GROUND 41....582
2.4.13 PARKING THE MACHINE 42....582
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES 43....582
2.5.1 LOADING AND UNLOADING 43....582
2.5.2 TRANSPORT 43....582
2.6 BATTERY 44....582
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY 44....582
2.6.2 STARTING WITH BOOSTER CABLES 44....582
2.7 PRECAUTIONS FOR THE REMOVAL 45....582
2.8 PRECAUTIONS FOR MAINTENANCE 46....582
2.8.1 WARNING PLATES 46....582
2.8.2 TOOLS 46....582
2.8.3 PERSONNEL 46....582
2.8.4 EQUIPMENT 47....582
2.8.5 WORKING UNDER THE MACHINE 47....582
2.8.6 CLEANING THE MACHINE 47....582
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS 48....582
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY 48....582
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION 48....582
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP 49....582
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR 49....582
2.8.12 USING LAMPS 49....582
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR 50....582
2.8.14 PRECAUTIONS CONCERNING THE STARTER 50....582
2.8.15 HANDLING HIGH-PRESSURE PIPES 51....582
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL 51....582
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE 51....582
2.8.18 COOLING FAN AND BELT 52....582
2.8.19 WASTE MATERIALS 52....582
2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES 52....582
3.1 SAFETY LOCKS 54....583
3.1.1 MACHINE LOCKS 54....583
3.2 GENERAL VIEWS 55....583
3.2.1 FRONT GENERAL VIEW 55....583
3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY 56....583
3.2.3 GENERAL VIEW OF THE DRIVER’S SEAT 57....583
3.3 INSTRUMENTS AND CONTROLS 58....583
3.3.1 INSTRUMENTS 58....583
3.3.2 WARNING LIGHTS 59....583
3.3.3 SWITCHES AND PUSH BUTTONS 61....583
3.3.4 ELECTRICAL ACCESSORIES 64....583
3.3.5 MACHINE CONTROLS 66....583
3.4 FUSES AND RELAYS 75....583
3.4.1 FUSES 75....583
3.4.2 RELAYS 76....583
3.5 GUARDS AND DRIVER’S SEAT 77....583
3.5.1 ENGINE HOOD 77....583
3.5.2 CANOPY 78....583
3.5.3 CAB 78....583
3.5.3.1 SLIDING DOOR 79....583
3.5.3.2 FRONT OPENING WINDSHIELD 80....583
3.5.3.3 FRONT WINDSHIELD (LOWER PART) 81....583
3.5.3.4 SIDE OPENING WINDOW 82....583
3.5.4 VENTILATION AND HEATING 83....583
3.5.5 SEAT 83....583
3.5.6 SAFETY BELT 84....583
3.5.7 EMERGENCY EXIT 84....583
3.5.8 TECHNICAL DOCUMENTATION CASE 85....583
3.5.9 FIRE EXTINGUISHER 85....583
3.5.10 FIRST AID KIT 85....583
3.6 USE OF THE MACHINE 87....583
3.6.1 CHECKS BEFORE STARTING THE ENGINE 87....583
3.6.1.1 VISUAL CHECKS 87....583
3.6.1.2 DAILY CHECKS 87....583
3.6.1.3 OPERATIONAL CHECKS 88....583
3.6.2 STARTING THE ENGINE 89....583
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES 89....583
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES 90....583
3.6.3 WARMING THE ENGINE 91....583
3.6.4 HEATING THE HYDRAULIC OIL 91....583
3.6.5 HOW TO MOVE THE MACHINE 91....583
3.6.5.1 STEERING (CHANGING DIRECTION) 93....583
3.6.5.2 MOVING ON SLOPES 94....583
3.6.5.3 MAXIMUM IMMERSION DEPTH 95....583
3.7 PARKING THE MACHINE 96....584
3.7.1 PARKING ON LEVEL GROUND 96....584
3.7.2 PARKING ON SLOPES 97....584
3.8 STOPPING THE ENGINE 98....584
3.9 TRANSPORTING THE MACHINE ON MOTOR VEHICLES 99....584
3.9.1 LOADING AND UNLOADING THE MACHINE 99....584
3.9.2 TRANSPORT 100....584
3.10 LIFTING THE MACHINE 101....584
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON 102....584
3.11.1 FUEL AND LUBRICANTS 102....584
3.11.2 COOLANT 102....584
3.11.3 BATTERY 102....584
3.11.4 OTHER PRECAUTIONS 103....584
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK 103....584
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON 104....584
3.13 USING THE WORK EQUIPMENT 105....584
3.13.1 ORGANIZING THE WORK AREA 105....584
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS 106....584
3.13.3 DIGGING METHOD 107....584
3.13.4 CHANGING THE BUCKET 108....584
3.14 USING THE MACHINE WITH VARIABLE TRACK GAUGE 109....584
3.14.1 HOW TO USE THE VARIABLE TRACK GAUGE 109....584
3.14.2 ADJUSTING THE BLADE 110....584
3.15 LONG PERIODS OF INACTIVITY 111....584
3.15.1 BEFORE THE PERIOD OF INACTIVITY 111....584
3.15.2 DURING THE PERIOD OF INACTIVITY 112....584
3.15.3 AFTER THE PERIOD OF INACTIVITY 112....584
3.16 TROUBLESHOOTING 113....584
3.16.1 OCCURRENCES THAT ARE NOT FAILURES 113....584
3.16.2 HOW TO REMOVE THE MACHINE 113....584
3.16.3 AFTER THE FUEL HAS RUN OUT 114....584
3.16.4 IF THE BATTERY IS DOWN 114....584
3.16.4.1 STARTING WITH BOOSTER CABLES 115....584
3.16.5 OTHER TROUBLES 116....584
3.16.5.1 ELECTRICAL CIRCUIT 116....584
3.16.5.2 HYDRAULIC SYSTEM 116....584
3.16.5.3 ENGINE 117....584
4.1 GUIDE TO MAINTENANCE 120....585
4.2 MAINTENANCE NOTES 122....585
4.2.1 NOTES REGARDING THE ENGINE 122....585
4.2.1.1 ENGINE OIL 122....585
4.2.1.2 COOLANT 122....585
4.2.1.3 FUEL 123....585
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM 123....585
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM 124....585
4.2.4 NOTES REGARDING LUBRICATION 124....585
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING 125....585
4.3 FUEL, COOLANT AND LUBRICANTS 126....585
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS 128....585
4.4 DRIVING TORQUES FOR SCREWS AND NUTS 129....585
4.4.1 STANDARD DRIVING TORQUES 129....585
4.4.2 SPECIFIC DRIVING TORQUES 129....585
4.5 LUBRICATION 130....585
4.5.1 LUBRICATION DIAGRAM PC12R 130....585
4.5.2 LUBRICATION DIAGRAM PC12R HS (VARIABLE TRACK GAUGE) 131....585
4.5.3 LUBRICATION DIAGRAM PC15R 132....585
4.5.4 LUBRICATION DIAGRAM PC15R HS (VARIABLE TRACK GAUGE) 133....585
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY 134....585
4.6.1 CRITICAL PARTS FOR SAFETY 135....585
4.7 MAINTENANCE PLAN 138....585
4.7.1 WHEN REQUIRED 141....585
4.7.1.a WASHING THE COOLING CIRCUIT 141....585
4.7.1.b DRAINING THE FUEL TANK 142....585
4.7.1.c CHECKING THE ELECTRICAL SYSTEM 142....585
4.7.1.d CHECKING THE STEEL TRACK TENSION 143....585
4.7.1.e CHECKING THE RUBBER TRACKS 145....585
4.7.1.f CHECKING THE RUBBER TRACK TENSION 147....585
4.7.1.g CHANGING THE RUBBER TRACK 149....585
4.7.1.h LUBRICATING THE ARTICULATIONS 151....585
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER) 152....585
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER 152....585
4.7.2.b CHANGING THE HYDRAULIC OIL 152....585
4.7.3 CHECKS BEFORE STARTING 153....585
4.7.3.a VARIOUS CHECKS 153....585
4.7.3.b CHECKING THE COOLANT LEVEL 153....585
4.7.3.c CHECKING THE FUEL LEVEL 154....585
4.7.3.d CHECKING THE ENGINE OIL LEVEL 154....585
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT 155....585
4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic.....585
4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION 157....586
4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING 157....586
4.7.5.b LUBRICATING THE VARIABLE TRACK GAUGE SLIDING GUIDES (PC12R HS – PC15R HS) 159....586
4.7.5.c CLEANING THE AIR CLEANER CARTRIDGE 160....586
4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION 161....586
4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION 161....586
4.7.7.a ADJUSTING THE FAN BELT TENSION 161....586
4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL 162....586
4.7.7.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS 163....586
4.7.7.d CHANGING THE HYDRAULIC SYSTEM OIL FILTER 164....586
4.7.7.e CHANGING THE ENGINE OIL 165....586
4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the syntheti.....586
4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION 166....586
4.7.9.a CHANGING THE ENGINE OIL FILTER 166....586
4.7.9.b CHANGING THE FUEL FILTER 167....586
4.7.9.c CHANGING THE FUEL PUMP PRECLEANER 168....586
4.7.9.d CHANGING THE AIR CLEANER CARTRIDGE 169....586
4.7.9.e CLEANING THE OUTSIDE OF THE RADIATORS 169....586
4.7.9.f DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable o.....586
4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION 171....586
4.7.10.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS 171....586
4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION 172....586
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER 172....586
4.7.11.b CHANGING THE COOLANT 174....586
4.7.11.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE 174....586
4.7.11.d CHECKING THE ALTERNATOR AND THE STARTER 174....586
5.1 TECHNICAL DATA 176....586
5.1.1 STANDARD OVERALL DIMENSIONS PC12R 176....586
5.1.2 TECHNICAL CHARACTERISTICS PC12R 177....586
5.1.3 STANDARD OVERALL DIMENSIONS PC12R HS (VARIABLE TRACK GAUGE) 178....586
5.1.4 TECHNICAL CHARACTERISTICS PC12R HS (VARIABLE TRACK GAUGE) 179....586
5.1.5 STANDARD OVERALL DIMENSIONS PC15R 180....586
5.1.6 TECHNICAL CHARACTERISTICS PC15R 181....586
5.1.7 STANDARD OVERALL DIMENSIONS PC15R HS (VARIABLE TRACK GAUGE) 182....586
5.1.8 TECHNICAL CHARACTERISTICS PC15R HS (VARIABLE TRACK GAUGE) 183....586
5.1.9 LIFTING CAPACITY WITH RAISED BLADE PC12R 184....586
5.1.10 LIFTING CAPACITY WITH LOWERED BLADE PC12R 185....586
5.1.11 LIFTING CAPACITY WITH RAISED BLADE PC12R HS (VARIABLE TRACK GAUGE NARROWED) 186....587
5.1.12 LIFTING CAPACITY WITH RAISED BLADE PC12R HS (VARIABLE TRACK GAUGE WIDENED) 187....587
5.1.13 LIFTING CAPACITY WITH LOWERED BLADE PC12R HS (VARIABLE TRACK GAUGE NARROWED) 188....587
5.1.14 LIFTING CAPACITY WITH LOWERED BLADE PC12R HS (VARIABLE TRACK GAUGE WIDENED) 189....587
5.1.15 LIFTING CAPACITY WITH RAISED BLADE PC15R 190....587
5.1.16 LIFTING CAPACITY LOWERED BLADE PC15R 191....587
5.1.17 LIFTING CAPACITY WITH RAISED BLADE PC15R HS (VARIABLE TRACK GAUGE NARROWED) 192....587
5.1.18 LIFTING CAPACITY WITH RAISED BLADE PC15R HS (VARIABLE TRACK GAUGE WIDENED) 193....587
5.1.19 LIFTING CAPACITY WITH LOWERED BLADE PC15R HS (VARIABLE TRACK GAUGE NARROWED) 194....587
5.1.20 LIFTING CAPACITY WITH LOWERED BLADE PC15R HS (VARIABLE TRACK GAUGE WIDENED) 195....587
6.1 AUTHORIZED OPTIONAL EQUIPMENT 198....587
6.1.1 PRECAUTIONS REGARDING SAFETY 198....587
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT 199....587
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT 200....587
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER) 201....587
6.2.1 DESCRIPTION AND CONTROL 201....587
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED 201....587
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER 205....587
6.2.3.1 INSTALLING THE HAMMER 205....587
6.2.3.2 REMOVING THE HAMMER 206....587
6.2.4 MAINTENANCE 206....587
2.1 SAFETY, NOISE AND VIBRATION PLATES....590
2.1.1 POSITION OF THE SAFETY PLATES....590
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS....592
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB....596
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY....597
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....598
2.2 GENERAL PRECAUTIONS....599
2.2.1 GENERAL SAFETY RULES....599
2.2.2 SAFETY DEVICES AND GUARDS....599
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS....599
2.2.4 UNAUTHORIZED MODIFICATIONS....600
2.2.5 LEAVING THE OPERATOR’S SEAT....600
2.2.6 GETTING ON AND OFF THE MACHINE....601
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL....601
2.2.8 PREVENTING BURNS....602
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER....602
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....602
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT....603
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE....603
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT....603
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....604
2.3.1 SAFETY ON THE WORK SITE....604
2.3.2 FIRE PREVENTION....604
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB....604
2.3.4 ROOM VENTILATION....605
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS....605
2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHIELD WIPER BLADES....605
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING....606
2.4.1 STARTING THE ENGINE....606
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE....606
2.4.3 CHECKS FOR TRAVELLING IN REVERSE....606
2.4.4 MOVING THE MACHINE....607
2.4.5 MOVING ON SLOPES....608
2.4.6 WORKING ON SLOPES....609
2.4.7 UNAUTHORIZED OPERATIONS....609
2.4.8 PREVENTING ELECTROCUTION....610
2.4.9 VISIBILITY....611
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES....611
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....611
2.4.12 WORKING ON LOOSE GROUND....611
2.4.13 PARKING THE MACHINE....612
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES....613
2.5.1 LOADING AND UNLOADING....613
2.5.2 TRANSPORT....613
2.6 BATTERY....614
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY....614
2.6.2 STARTING WITH BOOSTER CABLES....614
2.7 PRECAUTIONS FOR THE REMOVAL....615
2.8 PRECAUTIONS FOR MAINTENANCE....616
2.8.1 WARNING PLATES....616
2.8.2 TOOLS....616
2.8.3 PERSONNEL....616
2.8.4 EQUIPMENT....617
2.8.5 WORKING UNDER THE MACHINE....617
2.8.6 CLEANING THE MACHINE....617
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS....618
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY....618
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION....618
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP....619
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR....619
2.8.12 USING LAMPS....619
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR....620
2.8.14 PRECAUTIONS CONCERNING THE STARTER....620
2.8.15 HANDLING HIGH-PRESSURE PIPES....621
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL....621
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE....621
2.8.18 COOLING FAN AND BELT....622
2.8.19 WASTE MATERIALS....622
2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES....622
3.1 SAFETY LOCKS....624
3.1.1 MACHINE LOCKS....624
3.2 GENERAL VIEWS....625
3.2.1 FRONT GENERAL VIEW....625
3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY....626
3.2.3 GENERAL VIEW OF THE DRIVER’S SEAT....627
3.3 INSTRUMENTS AND CONTROLS....628
3.3.1 INSTRUMENTS....628
3.3.2 WARNING LIGHTS....629
3.3.3 SWITCHES AND PUSH BUTTONS....631
3.3.4 ELECTRICAL ACCESSORIES....634
3.3.5 MACHINE CONTROLS....636
A - (STANDARD PEDAL)....643
B - (OPTIONAL PEDAL)....643
3.4 FUSES AND RELAYS....645
3.4.1 FUSES....645
3.4.2 RELAYS....646
3.5 GUARDS AND DRIVER’S SEAT....647
3.5.1 ENGINE HOOD....647
3.5.2 CANOPY....648
3.5.3 CAB....648
3.5.3.1 SLIDING DOOR....649
3.5.3.2 FRONT OPENING WINDSHIELD....650
3.5.3.3 FRONT WINDSHIELD (LOWER PART)....651
3.5.3.4 SIDE OPENING WINDOW....652
3.5.4 VENTILATION AND HEATING....653
3.5.5 SEAT....653
3.5.6 SAFETY BELT....654
3.5.7 EMERGENCY EXIT....654
3.5.8 TECHNICAL DOCUMENTATION CASE....655
3.5.9 FIRE EXTINGUISHER....655
3.5.10 FIRST AID KIT....655
3.6 USE OF THE MACHINE....657
3.6.1 CHECKS BEFORE STARTING THE ENGINE....657
3.6.1.1 VISUAL CHECKS....657
3.6.1.2 DAILY CHECKS....657
3.6.1.3 OPERATIONAL CHECKS....658
3.6.2 STARTING THE ENGINE....659
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES....659
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES....660
3.6.3 WARMING THE ENGINE....661
3.6.4 HEATING THE HYDRAULIC OIL....661
3.6.5 HOW TO MOVE THE MACHINE....661
3.6.5.1 STEERING (CHANGING DIRECTION)....663
CHANGING DIRECTION WHEN THE MACHINE IS NOT MOVING....663
CHANGING DIRECTION WHEN THE MACHINE IS MOVING (the left and right travel levers are in the same p.....663
HOW TO CARRY OUT A COUNTER-ROTATION (with the machine not moving)....663
3.6.5.2 MOVING ON SLOPES....664
3.6.5.3 MAXIMUM IMMERSION DEPTH....665
3.7 PARKING THE MACHINE....666
3.7.1 PARKING ON LEVEL GROUND....666
3.7.2 PARKING ON SLOPES....667
3.8 STOPPING THE ENGINE....668
3.9 TRANSPORTING THE MACHINE ON MOTOR VEHICLES....669
3.9.1 LOADING AND UNLOADING THE MACHINE....669
3.9.2 TRANSPORT....670
3.10 LIFTING THE MACHINE....671
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....672
3.11.1 FUEL AND LUBRICANTS....672
3.11.2 COOLANT....672
3.11.3 BATTERY....672
3.11.4 OTHER PRECAUTIONS....673
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK....673
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....674
3.13 USING THE WORK EQUIPMENT....675
3.13.1 ORGANIZING THE WORK AREA....675
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS....676
3.13.3 DIGGING METHOD....677
3.13.4 CHANGING THE BUCKET....678
3.14 USING THE MACHINE WITH VARIABLE TRACK GAUGE....679
3.14.1 HOW TO USE THE VARIABLE TRACK GAUGE....679
3.14.2 ADJUSTING THE BLADE....680
3.15 LONG PERIODS OF INACTIVITY....681
3.15.1 BEFORE THE PERIOD OF INACTIVITY....681
3.15.2 DURING THE PERIOD OF INACTIVITY....682
3.15.3 AFTER THE PERIOD OF INACTIVITY....682
3.16 TROUBLESHOOTING....683
3.16.1 OCCURRENCES THAT ARE NOT FAILURES....683
3.16.2 HOW TO REMOVE THE MACHINE....683
3.16.3 AFTER THE FUEL HAS RUN OUT....684
3.16.4 IF THE BATTERY IS DOWN....684
3.16.4.1 STARTING WITH BOOSTER CABLES....685
3.16.5 OTHER TROUBLES....686
3.16.5.1 ELECTRICAL CIRCUIT....686
3.16.5.2 HYDRAULIC SYSTEM....686
3.16.5.3 ENGINE....687
4.1 GUIDE TO MAINTENANCE....690
4.2 MAINTENANCE NOTES....692
4.2.1 NOTES REGARDING THE ENGINE....692
4.2.1.1 ENGINE OIL....692
4.2.1.2 COOLANT....692
4.2.1.3 FUEL....693
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM....693
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM....694
4.2.4 NOTES REGARDING LUBRICATION....694
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING....695
4.3 FUEL, COOLANT AND LUBRICANTS....696
LUBRICATION WITH GREASE....696
4.4 DRIVING TORQUES FOR SCREWS AND NUTS....699
4.4.1 STANDARD DRIVING TORQUES....699
4.4.2 SPECIFIC DRIVING TORQUES....699
4.5 LUBRICATION....700
4.5.1 LUBRICATION DIAGRAM PC12R....700
4.5.2 LUBRICATION DIAGRAM PC12R HS (VARIABLE TRACK GAUGE)....701
4.5.3 LUBRICATION DIAGRAM PC15R....702
4.5.4 LUBRICATION DIAGRAM PC15R HS (VARIABLE TRACK GAUGE)....703
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY....704
4.7 MAINTENANCE PLAN....708
4.7.1 WHEN REQUIRED....711
4.7.1.a WASHING THE COOLING CIRCUIT....711
4.7.1.b DRAINING THE FUEL TANK....712
4.7.1.c CHECKING THE ELECTRICAL SYSTEM....712
4.7.1.d CHECKING THE STEEL TRACK TENSION....713
4.7.1.e CHECKING THE RUBBER TRACKS....715
4.7.1.f CHECKING THE RUBBER TRACK TENSION....717
4.7.1.g CHANGING THE RUBBER TRACK....719
4.7.1.h LUBRICATING THE ARTICULATIONS....721
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER)....722
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER....722
4.7.2.b CHANGING THE HYDRAULIC OIL....722
4.7.3 CHECKS BEFORE STARTING....723
4.7.3.a VARIOUS CHECKS....723
4.7.3.b CHECKING THE COOLANT LEVEL....723
4.7.3.c CHECKING THE FUEL LEVEL....724
4.7.3.d CHECKING THE ENGINE OIL LEVEL....724
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT....725
4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic.....726
4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION....727
4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING....727
4.7.5.b LUBRICATING THE VARIABLE TRACK GAUGE SLIDING GUIDES (PC12R HS – PC15R HS)....729
4.7.5.c CLEANING THE AIR CLEANER CARTRIDGE....730
4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION....731
4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION....731
4.7.7.a ADJUSTING THE FAN BELT TENSION....731
4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL....732
4.7.7.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS....733
4.7.7.d CHANGING THE HYDRAULIC SYSTEM OIL FILTER....734
4.7.7.e CHANGING THE ENGINE OIL....735
4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the syntheti.....736
4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION....736
4.7.9.a CHANGING THE ENGINE OIL FILTER....736
4.7.9.b CHANGING THE FUEL FILTER....737
4.7.9.c CHANGING THE FUEL PUMP PRECLEANER....738
4.7.9.d CHANGING THE AIR CLEANER CARTRIDGE....739
4.7.9.e CLEANING THE OUTSIDE OF THE RADIATORS....739
4.7.9.f DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable o.....740
4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION....741
4.7.10.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS....741
4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION....742
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER....742
4.7.11.b CHANGING THE COOLANT....744
4.7.11.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE....744
4.7.11.d CHECKING THE ALTERNATOR AND THE STARTER....744
5.1 TECHNICAL DATA....746
5.1.1 STANDARD OVERALL DIMENSIONS PC12R....746
WITH CAB....746
WITH CANOPY....746
5.1.2 TECHNICAL CHARACTERISTICS PC12R....747
5.1.3 STANDARD OVERALL DIMENSIONS PC12R HS (VARIABLE TRACK GAUGE)....748
WITH CAB....748
WITH CANOPY....748
5.1.4 TECHNICAL CHARACTERISTICS PC12R HS (VARIABLE TRACK GAUGE)....749
5.1.5 STANDARD OVERALL DIMENSIONS PC15R....750
WITH CAB....750
WITH CANOPY....750
5.1.6 TECHNICAL CHARACTERISTICS PC15R....751
5.1.7 STANDARD OVERALL DIMENSIONS PC15R HS (VARIABLE TRACK GAUGE)....752
WITH CAB....752
WITH CANOPY....752
5.1.8 TECHNICAL CHARACTERISTICS PC15R HS (VARIABLE TRACK GAUGE)....753
5.1.9 LIFTING CAPACITY WITH RAISED BLADE PC12R....754
5.1.10 LIFTING CAPACITY WITH LOWERED BLADE PC12R....755
5.1.11 LIFTING CAPACITY WITH RAISED BLADE PC12R HS (VARIABLE TRACK GAUGE NARROWED)....756
5.1.12 LIFTING CAPACITY WITH RAISED BLADE PC12R HS (VARIABLE TRACK GAUGE WIDENED)....757
5.1.13 LIFTING CAPACITY WITH LOWERED BLADE PC12R HS (VARIABLE TRACK GAUGE NARROWED)....758
5.1.14 LIFTING CAPACITY WITH LOWERED BLADE PC12R HS (VARIABLE TRACK GAUGE WIDENED)....759
5.1.15 LIFTING CAPACITY WITH RAISED BLADE PC15R....760
5.1.16 LIFTING CAPACITY LOWERED BLADE PC15R....761
5.1.17 LIFTING CAPACITY WITH RAISED BLADE PC15R HS (VARIABLE TRACK GAUGE NARROWED)....762
5.1.18 LIFTING CAPACITY WITH RAISED BLADE PC15R HS (VARIABLE TRACK GAUGE WIDENED)....763
5.1.19 LIFTING CAPACITY WITH LOWERED BLADE PC15R HS (VARIABLE TRACK GAUGE NARROWED)....764
5.1.20 LIFTING CAPACITY WITH LOWERED BLADE PC15R HS (VARIABLE TRACK GAUGE WIDENED)....765
6.1 AUTHORIZED OPTIONAL EQUIPMENT....768
6.1.1 PRECAUTIONS REGARDING SAFETY....768
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT....769
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT....770
(PC12R-PC12R HS)....770
(PC15R-PC15R HS)....770
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)....771
6.2.1 DESCRIPTION AND CONTROL....771
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED....771
FOR A CORRECT USE, IT IS NECESSARY TO:....771
ALWAYS AVOID THE FOLLOWING INCORRECT USES:....773
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER....775
6.2.3.1 INSTALLING THE HAMMER....775
6.2.3.2 REMOVING THE HAMMER....776
6.2.4 MAINTENANCE....776
WEAM003000 - Hydraulic Excavator PC15R-8 Operation & Maintenance Manual....777
COVER....777
CONTENTS....787
1.1 FOREW0RD....778
1.2 INFORMATION ON SAFETY....779
1.3 INTRODUCTION....781
1.3.1 INTENDED USES....781
1.3.2 IMPROPER OR UNAUTHORIZED USES....781
1.3.3 MAIN CHARACTERISTICS....782
1.3.4 RUNNING-IN....782
1.4 PRODUCT IDENTIFICATION....783
1.4.1 MACHINE SERIAL NUMBER....783
1.4.2 MACHINE IDENTIFICATION PLATE....783
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL....784
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER....784
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER....784
1.4.6 CAB SERIAL NUMBER....785
1.4.7 SERIAL NUMBERS AND DEALER'S ADDRESS....786
SAFETY AND ACCIDENT PREVENTION....794
2.1 SAFETY PLATES....795
2.1.1 POSITION OF THE SAFETY PLATES....795
2.1.2 POSITION OF THE PICTOGRAMS....810
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS....812
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....814
2.2 GENERAL PRECAUTIONS....815
2.2.1 GENERAL SAFETY RULES....815
2.2.2 SAFETY DEVICES AND GUARDS....815
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS....815
2.2.4 UNAUTHORIZED MODIFICATIONS....816
2.2.5 LEAVING THE OPERATOR'S SEAT....816
2.2.6 GETTING ON AND OFF THE MACHINE ....817
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL....817
2.2.8 PREVENTING BURNS....818
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWER....818
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....818
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT....819
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE....819
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT....819
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....820
2.3.1 SAFETY ON THE WORK SITE....820
2.3.2 FIRE PREVENTION....820
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB....820
2.3.4 ROOM VENTILATION....821
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS....821
2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHIELD WIPER BLADES....821
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING....822
2.4.1 STARTING THE ENGINE....822
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE....822
2.4.3 CHECKS FOR TRAVELING IN REVERSE....822
2.4.4 MOVING THE MACHINE....823
2.4.5 MOVING THE SLOPES....824
2.4.6 WORKING THE SLOPES....825
2.4.7 UNAUTHORIZED OPERATIONS....825
2.4.8 PREVENTING ELECTROCUTION....826
2.4.9 VISIBILITY....827
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES....827
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....827
2.4.12 WORKING ON LOOSE GROUND....827
2.4.13 PARKING THE MACHINE....828
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES....829
2.5.1 LOADING AND UNLOADING....829
2.5.2 TRANSPORT....829
2.6 BATTERY....830
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY....830
2.6.2 STARTING WITH BOOSTER CABLES....830
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY....831
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE....832
2.8.1 WARNING PLATES....832
2.8.2 TOOLS....832
2.8.3 PERSONNEL....833
2.8.4 EQUIPMENT....833
2.8.5 WORKING UNDER THE MACHINE....833
2.8.6 CLEANING THE MACHINE....833
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS....834
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY....834
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION....834
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP....835
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR....835
2.8.12 USING LAMPS....835
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR....836
2.8.14 PRECAUTIONS CONCERNING THE STARTER....836
2.8.15 HANDLING HIGH-PRESSURE PIPES....837
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH PRESSURE OIL....837
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE....837
2.8.18 COOLING FAN AND BELT....838
2.8.19 WASTE MATERIALS....838
THE MACHINE AND ITS OPERATIONS....840
3.1 SAFETY LOCKS....841
3.1.1 MACHINE LOCKS....841
3.2 GENERAL VIEWS....842
3.2.1 GENERAL VIEW OF THE MACHINE WITH CAB (OPTIONAL)....842
3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY....843
3.2.3 GENERAL VIEW OF THE DRIVER'S SEAT....844
3.3. INSTRUMENTS AND CONTROLS....845
3.3.1 INSTRUMENTS....845
3.3.2 WARNINGS LIGHTS....846
3.3.3 SWITCHES AND PUSH BUTTONS....848
3.3.4 ELECTRICAL ACCESSORIES....851
3.3.5 MACHINE CONTROLS....853
3.4 FUSES AND RELAYS....862
3.4.1 FUSES....862
3.4.2 RELAYS....863
3.5 GUARDS AND DRIVER'S SEAT....864
3.5.1 ENGINE HOOD....864
3.5.2 CANOPY....865
3.5.3 CAB (OPTIONAL)....865
3.5.3.1 SLIDING DOOR....866
3.5.3.2 FRONT OPENING WINDSHEILD....867
3.5.3.3 FRONT WINDSHEILD (LOWER PART)....868
3.5.3.4 SIDE OPENING WINDOW....869
3.5.4 VENTILATION AND HEATING (ONLY ON MACHINES WITH CAB)....870
3.5.5 SEAT....870
3.5.6 SAFETY BELT....871
3.5.7 EMERGENCY EXIT (ONLY ON MACHINES WITH CAB)....871
3.5.8 TECHNICAL DOCUMENTATION CASE....872
3.5.9 FIRE EXTINGUISHER....872
3.5.10 FIRST AID KIT....872
3.6 USE OF THE MACHINE....874
3.6.1 CHECKS BEFORE STARTING THE ENGINE....874
3.6.1.1 VISUAL CHECKS....874
3.6.1.2 DAILY CHECKS....874
3.6.1.3 OPERATIONAL CHECKS....875
3.6.2 STARTING THE ENGINE....876
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES....876
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES....877
3.6.3 WARMING THE ENGINE....878
3.6.4 HEATING THE HYDRAULIC OIL....878
3.6.5 HOW TO MOVE THE MACHINE....878
3.6.5.1 STEERING (CHANGING DIRECTION)....880
3.6.5.2 MOVING ON SLOPES....881
3.6.5.3 MAXIMUM IMMERSION DEPTH....882
3.7 PARKING THE MACHINE....883
3.7.1 PARKING ON LEVEL GROUND....883
3.7.2 PARKING ON SLOPES....884
3.8 STOPPING THE ENGINE....885
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES....886
3.9.1 LOADING AND UNLOADING THE MACHINE....886
3.9.2 TRANSPORT....887
3.10 LIFTING THE MACHINE....888
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....889
3.11.1 FUEL AND LUBRICANTS....889
3.11.2 COOLANT....889
3.11.3 BATTERY....889
3.11.4 OTHER PRECAUTIONS....890
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF THE END OF WORK....890
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....891
3.13 USING THE WORK EQUIPMENT....892
3.13.1 ORGANIZING THE WORK AREA....892
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS....893
3.13.3 DIGGING METHOD....894
3.13.4 CHANING THE BUCKET....895
3.14 USING THE MACHINE WITH VARIABLE TRACK GAUGE....896
3.14.1 HOW TO SEE THE VARIABLE TRACK GAUGE....896
3.14.2 ADJUSTING THE BLADE....897
3.15 LONG PERIODS OF INACTIVITY....898
3.15.1 BEFORE THE PERIOD OF INACTIVITY....898
3.15.2 DURING THE PERIOD OF INACTIVITY....899
3.15.3 AFTER THE PERIOD OF INACTIVITY....899
3.16 TROUBLESHOOTING....900
3.16.1 OCCURRENCES THAT ARE NOT FAILURES....900
3.16.2 HOW TO REMOVE THE MACHINE....900
3.16.3 AFTER THE FUEL HAS RUN OUT....901
3.16.4 IF THE BATTERY IS DOWN....901
3.16.4.1 STARTING WITH BOOSTER CABLES....902
3.16.5 OTHER TROUBLES....903
3.16.5.1 ELECTRICAL CIRCUT....903
3.16.5.2 HYDRAULIC SYSTEM....903
3.16.5.3 ENGINE....904
MAINTENANCE....906
4.1 GUIDE TO MAINTENANCE....907
4.2 MAINTENANCE NOTES....909
4.2.1 NOTES REGARDING THE ENGINE....909
4.2.1.1 ENGINE OIL....909
4.2.1.2 COOLANT....909
4.2.1.3 FUEL....910
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM....910
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM....911
4.2.4 NOTES REGARDING LUBRICATION....911
4.2.5 PARTS SUJECT TO WEAR THAT PERIODICALLY NEED CHANGING....912
4.3 FUEL, COOLANT AND LUBRICANTS....913
4.4 NUT AND BOLT TIGHTEN TOU....917
4.4.1 STANDARD TIGHTENING TORQUES....917
4.4.2 SPECIFIC TIGHTENING TORQUES....917
4.5 LUBRICATION....918
4.5.1 LUBRICATION DIAGRAM....918
4.5.2 LUBRICATION DIAGRAM (VARIABLE TRACK GAUGE)....919
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY....920
4.6.1 CRITICAL PARTS FOR SAFETY....921
4.7 MAINTENANCE PLAN....923
4.7.1 WHEN REQUIRED....926
4.7.1.A WASHING THE COOLING CIRCUIT....926
4.7.1.B DRAINING THE FUEL TANK....927
4.7.1.C CHECKING THE ELECTRICAL SYSTEM....927
4.7.1.D CHECKING THE STEEL TRACK TENSION....928
4.7.1.E CHECKING THE RUBBER TRACKS....930
4.7.1.F CHECKING THE RUBBER TRACK TENSION....932
4.7.1.G CHANGING THE RUBBER TRACK....934
4.7.2 MAINTENANCE INTERVALS IN CASE OF THE DEMOLITION HAMMER (BREAKER)....936
4.7.2 A CHANGING THE HYDRAULIC OIL FILTER....936
4.7.2.B CHANGING THE HYDRAULIC OIL....936
4.7.3 CHECKS BEFORE STARTING....937
4.7.3.A VARIOUS CHECKS....937
4.7.3.B CHECKING THE COOLANT LEVEL....937
4.7.3 C CHECKING THE FUEL LEVEL....938
4.7.3.D CHECKING THE ENGINE OIL LEVEL....938
4.7.3.E CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT....939
4.7.4 MAINTENANCE EVERY 100 HOURS OF OPERATION....940
4.7.4.A LUBRICATING THE JOINTS AND THE BALL - BEARING RING....940
4.7.4.B LUBRICATING THE VARIABLE TRACK GAUGE SLIDING GUIDES (ONLY <<HS>> VERSION)....941
4.7.4.C. CLEANING THE AIR CLEANER CARTRIDGE....942
4.7.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION....943
4.7.6 MAINTENANCE EVERY N250 HOURS OF OPERATION....943
4.7.6.A ADJUSTING THE FAN BELT TENSION....943
4.7.6.B CHECKING THE BATTERY ELECTROLYTE LEVEL....944
4.7.6.C CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS....945
4.7.6.D CHANGING THE HYDRAULIC SYSTEM OIL FILTER....946
4.7.6.E CHANGING THE ENGINE OIL....947
4.7.7 MAINTENANCE EVERY 500 HOURS OF OPERATION....948
4.7.7.A CHANGING THE ENGINE OIL FILTER....948
4.7.7.B CHANGING THE FUEL FILTER....949
4.7.7.C CHANGING THE FUEL PUMP PRECLEANER....950
4.7.7.D CHANGING THE AIR CLEANER CARTRIDGE....951
4.7.7.E CLEANING THE OUTSIDE OF THE RADIATORS....951
4.7.8 MAINTENANCE EVERY 1000 HOURS OF OPERATION....952
4.7.8.A CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS....952
4.7.9 MAINTENANCE EVERY 2000 HOURS OF OPERATION....953
4.7.9.A CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER....953
4.7.9.B CHANGING THE COOLANT....955
4.7.9.C CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE....955
4.7.9.D CHECKING THE ALTERNATOR AND THE STARTER....955
TECHNICAL SPECIFICATIONS....956
5.1 TECHNICAL DATA....957
5.1.1 STANDARD OVERALL DIMENSIONS....957
5.1.2 TECHNICAL CHARACTERISTICS....958
5.1.3 OVERALL DIMENSIONS (ONLY <<HS>> VERSION)....959
5.1.4 TECHNICAL CHARACTERISTICS (ONLY <<HS>> VERSION)....960
5.1.5 LIFTING CAPACITY....961
5.1.6 LIFTING CAPACITY (ONLY <<HS>> VERSION)....962
AUTHORIZED OPTIONAL EQUIPMENT....964
6.1 AUTHORIZED OPTIONAL EQUIPMENT....965
6.1.1 PRECAUTIONS REGARDING SAFETY....965
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT....966
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT....967
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)....968
6.2.1 DESCRIPTION AND CONTROL....968
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED....968
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER....972
6.2.3.1 INSTALLING THE HAMMER....972
6.2.3.2 REMOVING THE HAMMER....973
6.2.4 MAINTENANCE....973
WEAM003001 - Hydraulic Excavator PC15R-8 Deluxe Operation & Maintenance Manual....974
COVER....974
1.1 FOREWARD....975
1.2 INFORMATION ON SAFETY....976
1.3 INTRODUCTION....978
1.3.1 INTENDED USES....978
1.3.2 IMPROPER OR UNAUTHORIZED USES....978
1.3.3 MAIN CHARACTERISTICS....979
1.3.4 RUNNING-IN....979
1.4 PRODUCT IDENTIFICATION....980
1.4.1 MACHINE SERIAL NUMBER....980
1.4.2 MACHINE IDENTIFICATION PLATE....980
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL....981
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER....981
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER....981
1.4.6 CAB SERIAL NUMBER....982
1.4.7 SERIAL NUMBERS AND DEALER'S ADDRESS....983
CONTENTS....984
SAFETY AND ACCIDENT PREVENTION....991
2.1 SAFETY PLATES....992
2.1.1 POSITION OF THE SAFETY PLATES....992
2.1.2 POSITION OF THE PICTOGRAMS....1007
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS....1009
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....1011
2.2 GENERAL PRECAUTIONS....1012
2.2.1 GENERAL SAFETY RULES....1012
2.2.2 SAFETY DEVICES AND GUARDS....1012
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS....1012
2.2.4 UNAUTHORIZED MODIFICATIONS....1013
2.2.5 LEAVING THE OPERATOR'S SEAT....1013
2.2.6 GETTING ON AND OFF THE MACHINE....1014
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL....1014
2.2.8 PREVENTING BURNS....1015
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER....1015
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....1015
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT....1016
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE....1016
2.2.12 PRECAUTIONS CONCERNING THE EQUIPMENT....1016
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....1017
2.3.1 SAFETY ON THE WORK SITE....1017
2.3.2 FIRE PREVENTION....1017
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB....1017
2.3.4 ROOM VENTILATION....1018
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS....1018
2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHIELD WIPER BLADES....1018
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING....1019
2.4.1 STARTING THE ENGINE....1019
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE....1019
2.4.3 CHECKS FOR TRAVELLING IN REVERSE....1019
2.4.4 MOVING THE MACHINE....1020
2.4.5 MOVING ON SLOPES....1021
2.4.6 WORKING ON SLOPES....1022
2.4.7 UNAUTHORIZED OPERATIONS....1022
2.4.8 PREVENTING ELECTROCUTION....1023
2.4.9 VISIBILITY....1024
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES....1024
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....1024
2.4.12 WORKING ON LOOSE GROUND....1024
2.4.13 PARKING THE MACHINE....1025
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES....1026
2.5.1 LOADING AND UNLOADING....1026
2.5.2 TRANSPORT....1026
2.6 BATTERY....1027
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY....1027
2.6.2 STARTING WITH THE BOOSTER CABLES....1027
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY....1028
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE....1029
2.8.1 WARNING PLATES....1029
2.8.2 TOOLS....1029
2.8.3 PERSONNEL....1030
2.8.4 EQUIPMENT....1030
2.8.5 WORKING UNDER THE MACHINE....1030
2.8.6 CLEANING THE MACHINE....1030
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS....1031
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY....1031
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION....1031
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP....1032
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR....1032
2.8.12 USING LAMPS....1032
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR....1033
2.8.14 PRECAUTIONS CONCERNING THE STARTER....1033
2.8.15 HANDLING HIGH-PRESSURE PIPES....1034
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL....1034
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE....1034
2.8.18 COOLING FAN AND BELT....1035
2.8.19 WASTE MATERIALS....1035
2.8.20 PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES....1035
THE MACHINE AND ITS OPERATIONS....1037
3.1 SAFETY LOCKS....1038
3.1.1 MACHINE LOCKS....1038
3.2 GENERAL VIEWS....1039
3.2.1 GENERAL VIEW OF THE MACHINE WITH CAB (OPTIONAL)....1039
3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY....1040
3.2.3 GENERAL VIEW OF THE DRIVER'S SEAT....1041
3.3 INSTRUMENTS AND CONTROLS....1042
3.3.1 INSTRUMENTS....1042
3.3.2 WARNING LIGHTS....1043
3.3.3 SWITCHES AND PUSH BUTTONS....1045
3.3.4 ELECTRICAL ACCESSORIES....1048
3.3.5 MACHINE CONTROLS....1050
3.4 FUSES AND RELAYS....1059
3.4.1 FUSES....1059
3.4.2 RELAYS....1060
3.5 GUARDS AND DRIVER'S SEAT....1061
3.5.1 ENGINE HOOD....1061
3.5.2 CANOPY....1062
3.5.3 CAB (OPTIONAL)....1062
3.5.3.1 SLIDING DOOR....1063
3.5.3.2 FRONT OPENING WINDSHIELD....1064
3.5.3.3 FRONT WINDSHIELD (LOWER PART)....1065
3.5.3.4 SIDE OPENING WINDOW....1066
3.5.4 VENTILATION AND HEATING (ONLY ON MACHINES WITH CAB)....1067
3.5.5 SEAT....1067
3.5.6 SAFETY BELT....1068
3.5.7 EMERGENCY EXIT (ONLY ON MACHINES WITH CAB)....1068
3.5.8 TECHNICAL DOCUMENTATION CASE....1069
3.5.9 FIRE EXTINGUISHER....1069
3.5.10 FIRST AID KIT....1069
3.6 USE OF THE MACHINE....1071
3.6.1 CHECKS BEFORE STARTING MACHINE....1071
3.6.1.1 VISUAL CHECKS....1071
3.6.12 DAILY CHECKS....1071
3.6.1.3 OPERATIONAL CHECKS....1072
3.6.2 STARTING THE ENGINE....1073
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES....1073
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES....1074
3.6.3 WARMING THE ENGINE....1075
3.6.4 HEATING THE HYDRAULIC OIL....1075
3.6.5 HOW TO MOVE THE MACHINE....1075
3.6.5.1 STEERING (CHANGING DIRECTION)....1077
3.6.5.2 MOVING ON SLOPES....1078
3.6.5.3 MAXIMUM IMMERSION DEPTH....1079
3.7 PARKING THE MACHINE....1080
3.7.1 PARKING ON LEVEL GROUND....1080
3.7.2 PARKING ON SLOPES....1081
3.8 STOPPING THE ENGINE....1082
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES....1083
3.9.1 LOADING AND UNLOADING THE MACHINE....1083
3.9.2 TRANSPORT....1084
3.10 LIFTING THE MACHINE....1085
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....1086
3.11.1 FUEL AND LUBRICANTS....1086
3.11.2 COOLANT....1086
3.11.3 BATTERY....1086
3.11.4 OTHER PRECAUTIONS....1087
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK....1087
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....1088
3.13 USING THE WORK EQUIPMENT....1089
3.13.1 ORGANIZING THE WORK AREA....1089
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS....1090
3.13.3 DIGGING METHOD....1091
3.13.4 CHANGING THE BUCKET....1092
3.14 USING THE MACHINE WITH VARIABLE TRACK GUAGE....1093
3.14.1 HOW TO USE THE VARIABLE TRACK GUAGE....1093
3.14.2 ADJUSTING THE BLADE....1094
3.15 LONG PERIODS OF INACTIVITY....1095
3.15.1 BEFORE THE PERIOD OF INACTIVITY....1095
3.15.2 DURING THE PERIOD OF INACTIVITY....1096
3.15.3 AFTER THE PERIOD OF INACTIVITY....1096
3.16 TROUBLESHOOTING....1097
3.16.1 OCCURENCES THAT ARE NOT FAILURES....1097
3.16.2 HOW TO REMOVE THE MACHINE....1097
3.13.3 AFTER THE FUEL HAS RUN OUT....1098
3.16.4 IF THE BATTERY IS DOWN....1098
3.16.4.1 STARTING WITH BOOSTER CABLES....1099
3.16.5 OTHER TROUBLES....1100
3.16.5.1 ELECTRICAL CIRCUIT....1100
3.16.5.2 HYDRAULIC SYSTEM....1100
3.16.5.3 ENGINE....1101
MAINTENANCE....1103
4.1 GUIDE TO MAINTENANCE....1104
4.2 MAINTENANCE NOTES....1106
4.2.1 NOTES REGARDING THE ENGINE....1106
4.2.1.1 ENGINE OIL....1106
4.2.1.2 COOLANT....1106
4.2.1.3 FUEL....1107
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM....1107
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM....1108
4.2.4 NOTES REGARDING LUBRICATION....1108
4.2.5 PARTS SUBJEST TO WEAR THAT PERIODICALLY NEED CHANGING....1109
4.3 FUEL, COOLANT AND LUBRICANTS....1110
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS....1114
4.4 NUT AND BOLT TIGHTENING TORQUES....1115
4.4.1 STANDARD TIGHTENING TORQUES....1115
4.4.2 SPECIFIC TIGHTENING TORQUES....1115
4.5 LUBRICATION....1116
4.5.1 LUBRICATION DIAGRAM....1116
4.5.2 LUBRICATION DIAGRAM (VARIABLE TRACK GUAGE)....1117
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY....1118
4.6.1 CRITICAL PARTS FOR SAFETY....1119
4.7 MAINTENANCE PLAN....1121
4.7.1 WHEN REQUIRED....1124
4.7.1.a WASHING THE COOLING CIRCUIT....1124
4.7.1.b DRAINING THE FUEL TANK....1125
4.7.1.c CHECKING THE ELECTRICAL SYSTEM....1125
4.7.1.d CHECKING THE STEEL TRACK TENSION....1126
4.7.1.e CHECKING THE RUBBER TRACKS....1128
4.7.1.f CHECKING THE RUBBER TRACKS TENSION....1130
4.7.1.g CHANGING THE RUBBER TRACK....1132
4.7.1.h LUBRICATING THE ARTICULATIONS....1134
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER)....1135
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER....1135
4.7.2.b CHANGING THE HYDRAULIC OIL....1135
4.7.3 CHECKS BEFORE STARTING....1136
4.7.3.a VARIOUS CHECKS....1136
4.7.3.b CHECKING THE COOLANT LEVEL....1136
4.7.3.c CHECKING THE FUEL LEVEL....1137
4.7.3.d CHECKING THE ENGINE OIL LEVEL....1137
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT....1138
4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES....1139
4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION....1140
4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING....1140
4.7.5.b LUBRICATING THE VARIABLE TRACK GUAGE SLIDING GUIDES (ONLY IN <HS> VERSION)....1141
4.7.5.c CLEANING THE AIR CLEANER CARTRIDGE....1142
4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION....1143
4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION....1143
4.7.7.a ADJUSTING THE FAN BELT TENSION....1143
4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL....1144
4.7.7.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS....1145
4.7.7.d CHANGING THE HYDRAULIC SYSTEM OIL FILTER....1146
4.7.7.e CHANGING THE ENGINE OIL....1147
4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (ONLY FOR MACHINE IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES....1148
4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION....1148
4.7.9.a CHAINGING THE ENGINE OIL FILTER....1148
4.7.9.b CHANGING THE FUEL FILTER....1149
4.7.9.c CHANGING THE FUEL PUMP PRECLEANER....1150
4.7.9.d CHANGING THE AIR CLEANER CARTRIDGE....1151
4.7.9.e CLEANING THE OUTSIDE OF THE RADIATORS....1151
4.7.9.f DRAINING THE HYDRAULIC OIL TANK (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES IS USED)....1152
4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION....1153
4.7.10.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS....1153
4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION....1154
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER....1154
4.7.11.b CHANGING THE COOLANT....1156
4.7.11.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE....1156
4.7.11.d CHECKING THE ALTERNATOR AND THE STARTER....1156
TECHNICAL SPECIFICATIONS....1157
5.1 TECHNICAL DATA....1158
5.1.1 STANDARD OVERALL DIMENSIONS....1158
5.1.2 TECHNICAL CHARACTERISTICS....1159
5.1.3 OVERALL DIMENSIONS (ONLY <HS> VERSION)....1160
5.1.4 TECHNICAL CHARACTERISTICS (ONLY <HS> VERSION)....1161
5.1.5 LIFTING CAPACITY....1162
5.1.6 LIFTING CAPACITY (ONLY <HS> VERISON)....1163
AUTHORIZED OPTIONAL EQUIPMENT....1165
6.1 AUTHORIZED OPTIONAL EQUIPMENT....1166
6.1.1 PRECAUTIONS REGARDING SAFETY....1166
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT....1167
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT....1168
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)....1169
6.2.1 DESCRIPTION AND CONTROL....1169
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED....1169
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER....1173
6.2.3.1 INSTALLING THE HAMMER....1173
6.2.3.2 REMOVING THE HAMMER....1174
6.2.4 MAINTENANCE....1174
WEBM000100 - Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual....1175
CONTENTS....1177
LIST OF REVISED PAGES....1179
SAFETY....1181
FOREWORD....1183
HOW TO READ THE SHOP MANUAL....1184
HOISTING INSTRUCTIONS....1185
STANDARD TIGHTENING TORQUE....1186
COATING MATERIALS....1187
ELECTRIC WIRE CODE....1188
WEIGHT TABLE....1189
TABLE OF OIL AND COOLANT QUANTITIES....1190
10. STRUCTURE AND FUNCTION....1191
POWER TRAIN....1192
SWING CIRCLE....1194
SWING MOTOR....1195
FINAL DRIVE....1196
TRACK FRAME AND RECOIL SPRING....1197
CARRIER ROLLER....1199
STEEL SHOE....1200
HYDRAULIC SYSTEM....1201
HYDRAULIC CIRCUIT DIAGRAM....1205
HYDRAULIC PUMP....1209
CONTROL VALVE....1214
CLSS....1222
SWIVEL JOINT....1265
TRAVEL MOTOR....1267
CYLINDERS....1270
VALVE CONTROL....1274
ACCUMULATOR....1275
PPC VALVE....1276
SOLENOID VALVE....1281
CUTTING SHOVEL CONTROL VALVE....1283
ELECTRICAL CIRCUIT DIAGRAM....1285
20. TESTING AND ADJUSTMENTS....1287
NORMAL OR STANDARD TECHNICAL DATA....1288
SPECIAL TOOLS....1309
CHECKING THE ENGINE SPEED....1311
ADJUSTMENT OF VALVE CLEARANCE....1312
MEASUREMENT OF THE COMPRESSION PRESSURE....1313
CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT....1314
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING....1315
CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE....1317
ADJUSTMENT OF THE STROKE OF THE BLADE COMMAND LEVER....1318
CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER....1319
CENTERING ADJUSTMENT OF THE BOOM SWING COMMAND PEDAL....1320
ADJUSTMENT OF THE PPC VALVE CLEARANCES....1321
ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT....1322
CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION....1323
CONTROL AND REGULATION OF PRESSURE IN THE HYDRAULIC CIRCUIT....1324
CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE....1330
REGULATION OF THE PC VALVE....1332
CONTROL AND REGULATION OF THE SERVOCONTROL POWER SUPPLY....1333
ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF THE TANK....1335
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS....1336
CONTROL OF HYDRAULIC DRIFTS - ANALYSIS OF THE CAUSES OF A DRIFT....1338
CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS....1344
CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR....1345
METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT....1346
30. REMOVAL AND INSTALLATION....1349
HOW TO READ THE MANUAL....1351
PRECAUTIONS TO BE TAKEN WHILE WORKING....1352
SPECIAL TOOLS....1353
STARTER MOTOR....1355
ALTERNATOR....1356
PUMP GROUP....1357
INJECTION NOZZLES....1358
CYLINDER HEAD....1359
OIL COOLER....1363
RADIATOR....1364
ENGINE HOOD....1365
CAB AND CANOPY....1366
HEATING FAN....1368
REAR COUNTERWEIGHT....1369
TOP COVER AND SIDE PANELS....1370
HYDRAULIC OIL TANK....1372
FUEL TANK....1375
ENGINE PUMP GROUP....1376
PUMP....1379
ENGINE PUMP COUPLING....1380
CONTROL VALVE....1381
RIGHT-HAND PPC VALVE (BOOM-BUCKET)....1383
LEFT-HAND PPC VALVE (ARM-BUCKET)....1384
SERVOCONTROL SOLENOID GROUP....1385
SWIVEL JOINT....1387
SWING MOTOR....1388
REVOLVING FRAME....1389
SWING CIRCLE....1391
TRAVEL MOTOR....1392
RUBBER TRACK SHOES....1393
TRACK SHOES....1394
SPROCKET WHEEL....1395
FINAL DRIVE....1396
IDLER AND RECOIL SPRING ASSEMBLY....1407
TRACK ROLLERS....1410
BOOM CYLINDER....1411
ARM CYLINDER....1412
BUCKET CYLINDER....1413
BOOM SWING CYLINDER....1414
BLADE CYLINDER....1415
WORKING EQUIPMENT CYLINDER....1416
UPPER WORKING EQUIPMENT....1422
BUCKET....1424
ARM....1425
BOOM....1427
BOOM SWING SUPPORT....1429
BLADE....1430
40. STANDARD MAINTENANCE....1431
SWING CIRCLE....1432
TRACK FRAME AND RECOIL SPRING....1433
IDLER....1434
FINAL DRIVE....1435
SPROCKET....1436
TRACK ROLLER....1437
TRACK SHOE....1438
HYDRAULIC PUMP....1440
CONTROL VALVE....1442
SWIVEL JOINT....1454
SWING MOTOR....1455
TRAVEL MOTOR....1456
PPC VALVE....1460
CYLINDERS....1464
WORK EQUIPMENT....1466
WEBM000101 - Hydraulic Excavator PC12R-8, PC15R-8 Shop Manual....1471
COVER....1471
CONTENTS....1473
LIST OF REVISED PAGES....1475
SAFETY....1477
FOREWORD....1479
HOW TO READ THE SHOP MANUAL....1480
HOISTING INSTRUCTIONS....1481
STANDARD TIGHTENING TORQUE....1482
COATING MATERIALS....1483
ELECTRIC WIRE CODE....1484
WEIGHT TABLE....1485
TABLE OF OIL AND COOLANT QUANTITIES....1486
10.STRUCTURE AND FUNCTION....1489
POWER TRAIN....1490
SWING CIRCLE....1492
SWING MOTOR....1493
FINAL DRIVE....1494
TRACK FRAME AND RECOIL SPRING....1495
VARIABLE GAUGE TRACK FRAME AND RECOIL SPRING....1497
CARRIER ROLLER....1498
STEEL SHOE....1499
HYDRAULIC SYSTEM PC12R-8....1501
HYDRAULIC SYSTEM PC15R-8....1503
HYDRAULIC CIRCUIT DIAGRAM PC12R-8....1505
HYDRAULIC CIRCUIT DIAGRAM PC12R-8 MISTRAL....1507
HYDRAULIC CIRCUIT DIAGRAM PC12R-8 HS....1509
HYDRAULIC CIRCUIT DIAGRAM PC12R-8 MISTRAL HS....1511
HYDRAULIC CIRCUIT DIAGRAM PC15R-8....1513
HYDRAULIC CIRCUIT DIAGRAM PC15R-8 HS....1515
HYDRAULIC CIRCUIT DIAGRAM....1516
HYDRAULIC PUMP....1517
CONTROL VALVE PC12R-8 PC12R-8 MISTRAL....1522
CONTROL VALVE PC12R-8 HS PC12R-8 MISTRAL HS....1524
CLSS....1532
CONTROL VALVE PC15R-8....1550
CLSS....1560
SWIVEL JOINT....1577
TRAVEL MOTOR....1580
CYLINDERS....1583
VALVE CONTROL....1587
ACCUMULATOR....1588
PPC VALVE....1589
PPC VALVE....1591
SOLENOID VALVE....1594
VARIABLE GAUGE UNDERCARRIAGE SERVOCONTROL....1597
SAFETY VALVE....1598
CUTTING SHOVEL CONTROL VALVE....1599
ELECTRICAL CIRCUIT DIAGRAM....1601
20.TESTING AND ADJUSTMENTS....1605
NORMAL OR STANDARD TECHNICAL DATA....1606
SPECIAL TOOLS....1627
CHECKING THE ENGINE SPEED....1629
ADJUSTMENT OF VALVE CLEARANCE....1630
MEASUREMENT OF THE COMPRESSION PRESSURE....1631
CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT....1632
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING....1633
CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE....1635
ADJUSTMENT OF THE STROKE OF THE BLADE COMMAND LEVER....1636
CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER....1637
CENTERING ADJUSTMENT OF THE BOOM SWING COMMAND PEDAL....1638
ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT....1639
CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION....1640
CONTROL AND REGULATION OF THE PRESSURE IN THE HYDRAULIC CIRCUITS (PC12R)....1641
CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUITS (PC15R)....1644
CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE....1647
REGULATION OF THE PC VALVE....1649
CONTROL AND REGULATION OF THE SERVO-CONTROL POWER SUPPLY (PC12R)....1650
CONTROL AND REGULATION OF THE SERVO-CONTROL POWER SUPPLY (PC15R)....1651
ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF THE TANK....1652
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS....1653
CONTROL OF HYDRAULIC DRIFTS - ANALYSIS OF THE CAUSES OF A DRIFT....1655
CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS....1661
CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR....1662
METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT....1663
30.REMOVAL AND INSTALLATION....1671
HOW TO READ THE MANUAL....1673
PRECAUTIONS TO BE TAKEN WHILE WORKING....1674
SPECIAL TOOLS....1675
STARTER MOTOR....1677
ALTERNATOR....1678
PUMP GROUP....1679
INJECTION NOZZLES....1680
CYLINDER HEAD....1681
OIL COOLER....1685
RADIATOR....1686
ENGINE HOOD....1687
CAB AND CANOPY....1688
HEATING FAN....1690
REAR COUNTERWEIGHT....1691
TOP COVER AND SIDE PANELS....1692
HYDRAULIC OIL TANK....1694
FUEL TANK....1697
ENGINE-PUMP GROUP....1698
PUMP....1701
ENGINE-PUMP COUPLING....1702
CONTROL VALVE....1703
RIGHT-HAND PPC VALVE (BOOM-BUCKET)....1705
LEFT-HAND PPC VALVE (ARM-BUCKET)....1706
SERVOCONTROL SOLENOID GROUP (PC12 WITHOUT TRAVEL INCREMENT)....1707
SERVOCONTROL SOLENOID GROUP (PC12 WITH TRAVEL INCREMENT - PC15R)....1708
SWIVEL JOINT....1709
SWING MOTOR....1710
REVOLVING FRAME....1711
SWING CIRCLE....1713
TRAVEL MOTOR....1714
RUBBER TRACK SHOES....1715
TRACK-SHOES....1716
SPROCKET WHEEL....1717
COMPLETE FINAL DRIVE....1718
FINAL DRIVE....1719
IDLER AND RECOIL SPRING ASSEMBLY....1729
IDLER....1730
SPRING RECOIL AND THRUST CYLINDER GROUPS....1731
TRACK ROLLERS....1732
BOOM CYLINDER....1733
ARM CYLINDER....1734
BUCKET CYLINDER....1735
BOOM SWING CYLINDER....1736
BLADE CYLINDER....1737
WORKING EQUIPMENT CYLINDER....1738
UPPER WORKING EQUIPMENT....1744
BUCKET....1746
ARM....1747
BOOM....1749
BOOM SWING SUPPORT....1751
BLADE....1752
40.STANDARD MAINTENANCE....1755
SWING CIRCLE....1756
TRACK FRAME AND RECOIL SPRING....1757
VARIABLE GAUGE TRACK FRAME AND RECOIL SPRING....1758
IDLER....1759
FINAL DRIVE....1760
SPROCKET....1761
TRACK ROLLER....1762
TRACK SHOE....1763
HYDRAULIC PUMP....1765
CONTROL VALVE....1767
SWIVEL JOINT....1779
SWING MOTOR....1781
TRAVEL MOTOR....1782
CYLINDERS PC12R-8....1788
CYLINDERS PC15R-8....1789
WORK EQUIPMENT PC12R-8....1790
WORK EQUIPMENT PC15R-8....1792
WEBM002800 - Hydraulic Excavator PC15R-8 Shop Manual....1795
COVER....1795
FOREWARD....1800
HOW TO READ THE SHOP MANUAL....1803
HOISTING INSTRUCTIONS....1804
STANDARD TIGHTENING TORQUE....1805
COATING MATERIALS....1807
WEIGHT TABLE....1809
TABLE OF OIL AND COOLANT QUANTIES....1810
CONTENTS....1796
10 STRUCTURE AND FUNCTION....1813
POWER TRAIN....1814
SWING CIRCLE....1815
SWING MOTOR....1816
FINAL DRIVE....1817
TRACK FRAME AND RECOIL SPRING....1818
CARRIER ROLLER....1820
STEEL SHOE....1821
HYDRAULIC SYSTEM....1822
HYDRAULIC CIRCUIT DIAGRAM....1823
HYDRAULIC PUMP....1825
CONTROL VALVE....1829
CLSS....1837
SWIVEL JOINT....1854
TRAVEL MOTOR....1855
CYLINDERS....1857
VALVE CONTROL....1860
ACCUMULATOR....1861
PPC VALVE....1862
SOLENOID VALVE ....1867
CUTTING SHOVEL CONTROL VALVE....1868
ELECTRICAL CIRCUIT DIAGRAM....1869
20 TESTING AND ADJUSTING....1873
NORMAL OR STANDARD TECHNICAL DATA....1874
SPECIAL TOOLS....1885
CHECKING THE ENGINE SPEED....1886
ADJUSTMENT OF VALVE CLEARANCE....1887
MEASUREMENT OF THE COMPRESSOR PRESSURE....1888
CONTROL AND ADJUSTMENT OF THE TENSION OF THE FAN BELT....1889
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING....1890
CONTROL AND ADJUSTMENT OF THE ACCELERATOR STROKE ....1892
ADJUSTMENTOF THE STROKE OF THE BLADE COMMAND LEVER....1893
CONTROL AND ADJUSTMENT OF THE STROKE OF THE TRAVEL LEVER....1894
CENTERING ADJUSTMENT OF THE BOOM SWING COMMAND PEDAL....1895
ADJUSTMENT OF THE PPC VALVE CLEARANCES....1896
ADJUSTMENT OF THE RUBBER PAD AND SAFETY MICROSWITCH FOR SERVO-CONTROL ENGAGEMENT....1897
CONTROL AND ADJUSTMENTOF THE STROKE OF THE TRACK-SHOE TENSION....1898
CONTROL AND REGULATION OF THE PREEURES IN THE HYDRAULIC CIRCUTIS....1899
CONTROL AND REGULATION OF THE LS DIFFERENTIAL PRESSURE AND ADJUSTMENT OF THE LS VALVE....1902
REGULATION OF THE PC VALVE....1904
CONTROL AND REGULATION O THE SERVO-CONTROL POWER SUPPLY....1905
ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF THE TANK....1906
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS....1907
CONTROL OF HYDRAULIC DRIFTS - ANALYSIS OF THE CAUSES OF A DRIFT....1909
CHECKING FOR ANY LEAKAGES INSIDE THE WORKING EQUIPMENT CYLINDERS....1915
CHECKING FOR ANY LEAKAGES INSIDE THE SWING MOTOR....1916
METHODS FOR TESTING FOR LEAKAGES INSIDE THE SWIVEL JOINT....1917
30 REMOVAL AND INSTALLATION....1922
HOW TO READ THE MANUAL....1924
PRECAUTIONS TO BE TAKEN WHILE WORKING....1925
SPECIAL TOOLS....1926
STARTER MOTOR....1928
REMOVAL....1928
INSTALLATION....1928
ALTERNATOR....1929
REMOVAL....1929
INSTALLATION....1929
PUMP GROUP....1930
REMOVAL....1930
INSTALLATION....1930
INJECTION NOZZLES....1931
REMOVAL....1931
INSTALLATION....1931
CYLINDER HEAD....1932
REMOVAL....1932
INSTALLATION....1935
OIL COOLER....1936
REMOVAL ....1936
INSTALLATION....1936
RADIATOR....1937
REMOVAL....1937
INSTALLATION....1937
ENGINE HOOD....1938
REMOVAL....1938
INSTALLATION....1938
CAB AND CANOPY....1939
REMOVAL....1939
INSTALLATION....1940
HEATING FAN....1941
REMOVAL....1941
INSTALLATION....1941
REAR COUNTERWEIGHT....1942
REMOVAL....1942
INSTALLATION....1942
TOP COVER AND SIDE PANELS....1943
REMOVAL....1943
INSTALLATION....1944
HYDRAULIC OIL TANK....1945
REMOVAL....1945
INSTALLATION....1946
FUEL TANK....1948
REMOVAL....1948
INSTALLATION....1948
ENGINE-PUMP GROUP....1949
REMOVAL....1949
INSTALLATION....1951
PUMP....1952
REMOVAL....1952
INSTALLATION....1952
ENGINE-PUMP COUPLING....1953
REMOVAL....1953
INSTALLATION....1953
CONTROL VALVE....1954
REMOVAL....1954
INSTALLATION....1955
RIGHT-HAND PPC VALVE....1956
REMOVAL....1956
INSTALLATION....1956
LEFT-HAND PPC VALVE....1957
REMOVAL....1957
INSTALLATION....1957
SERVOCONTROL SOLENNIOD GROUP (PC-12R)....1958
REMOVAL....1958
INSTALLATION....1958
SERVOCONTROL SOLENNIOD GROUP (PC12R WITH TRAVEL INCREMENT - PC15R)....1958
REMOVAL....1958
INSTALLATION....1958
SWIVEL JOINT....1959
REMOVAL....1959
INSTALLATION....1959
SWING MOTOR....1960
REMOVAL....1960
INSTALLATION....1960
REVOLVING FRAME....1961
REMOVAL....1961
INSTALLATION....1962
SWING CIRCLE....1963
REMOVAL....1963
INSTALLATION....1963
TRAVEL MOTOR....1964
REMOVAL....1964
INSTALLATION....1964
RUBBER TRACK-SHOES....1965
REMOVAL....1965
INSTALLATION....1965
TRACK-SHOES....1966
REMOVAL....1966
INSTALLATION....1966
SPROCKET WHEEL....1967
REMOVAL....1967
INSTALLATION....1967
COMPLETE FINAL DRIVE....1968
REMOVAL....1968
INSTALLATION....1968
FINAL DRIVE....1969
DISASSEMBLY....1969
ASSEMBLY....1974
IDLER AND RECOIL SPRING ASSEMBLY....1979
REMOVAL....1979
INSTALLATION....1979
IDLER....1980
DISASSEMBLY....1980
ASSEMBLY....1980
SPRING RECOIL AND THRUST CYLINDER GROUPS....1981
DISASSEMBLY....1981
ASSEMBLY....1981
TRACK ROLLERS....1982
REMOVAL ....1982
INSTALLATION....1982
BOOM CYCLINDER....1983
REMOVAL....1983
INSTALLATION....1983
ARM CYLINDER....1984
REMOVAL....1984
INSTALLATION....1984
BUCKET CYLINDER....1985
REMOVAL....1985
INSTALLATION....1985
BOOM SWING CYLINDER....1986
REMOVAL....1986
INSTALLATION....1986
BLADE CYLINDER....1987
REMOVAL....1987
INSTALLATION....1987
WORKING EQUIPMENT CYLINDERS....1988
DISASSEMBLY....1988
ASSEMBLY....1990
UPPER WORKING EQUIPMENT....1994
REMOVAL....1994
INSTALLATION....1995
ARM....1996
REMOVAL....1996
INSTALLATION....1997
BOOM....1998
REMOVAL....1998
INSTALLATION....1999
BOOM SWING SUPPORT....2000
REMOVAL....2000
INSTALLATION....2000
BLADE....2001
REMOVAL....2001
NSTALLATION....2001
40 MAINTENANCE STANDARD....2003
SWING CIRCLE....2004
TRACK FRAME AND RECOIL SPRING....2005
ILDER....2006
FINAL DRIVE....2007
SPROCKET....2008
TRACK ROLLER....2009
TRACK SHOE....2010
HYDRAULIC PUMP....2012
CONTROL VALVE....2013
SWIVEL JOINT....2019
SWING MOTOR....2020
TRAVEL MOTOR....2021
PPC VALVE....2023
CYLINDERS....2026
WORK EQUIPMENT....2028
Komatsu Hydraulic Excavator PC12R, PC15R Repair Service Manuals
