Day: June 8, 2025

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC18MR-2, PC18MR-3, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavators PC18MR-2, PC18MR-3 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.

SEBM038404 – Hydraulic Excavator PC18MR-2 Shop Manual.pdf
SEN04306-04 – Hydraulic Excavator PC18MR-3 Shop Manual.pdf
TEN00052-01 – Hydraulic Excavator GALEO PC18MR-2 Operation & Maintenance Manual.pdf
TEN00292-03 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual.pdf
TEN00514-01 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual.pdf
TEN00549-00 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,743 pages
File Format: PDF
Language: English

TABLE OF CONTENTS

SEBM038404 – Hydraulic Excavator PC18MR-2 Shop Manual…2
COVER…2
CONTENTS…3
01 GENERAL…28
SPECIFICATION DIMENSION DRAWING…29
WORKING RANGE DRAWING…30
SPECIFICATIONS…31
WEIGHT TABLE…34
LUBRICANTS,FUEL AND COOLANT SPECIFICATIONS…36
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD…37
PTO…38
COOLING SYSTEM…39
POWER TRAIN …41
SWING CIRCLE…42
TRACK FRAME…43
IDLER CUSHION…44
IDLER…46
TRACK ROLLER…47
SPROCKET…48
TRACK SHOE…49
HYDRAULIC COMPONENTS LAYOUT DRAWING…51
HYDRAULIC TANK…52
CENTER SWIVEL JOINT…53
TRAVEL MOTOR…54
HYDRAULIC CYLINDER…63
SOLENOID VALVE…66
VARIABLE GAUGE VALVE…69
MULTI-CONTROL VALVE…70
HYDRAULIC PUMP…71
CONTROL VALVE…77
CLSS…89
OPERATION FOR EACH FUNCTION AND VALVE…92
SWING MOTOR…105
PPC VALVE…108
WORK EQUIPMENT …116
DIMENSIONS OF EACH PART OF WORK EQUIPMENT…119
FLOOR…122
ENGINE CONTROL…123
ELECTRIC CONTROL SYSTEM…125
COMPONENT PARTS OF SYSTEM…130
MONITOR SYSTEM…131
MONITOR PANEL…132
SENSORS…134
20 TESTING AND ADJUSTING…136
STANDARD VALUE TABLE FOR ENGING RELATED PARTS…137
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…138
TESTING AND ADJUSTING…147
LIST OF TESTING, ADJUSTING,AND TROUBLESHOOTING TOOLS…148
MEASURING ENGINE SPEED…150
MEASURING OF EXHAUST GAS COLOR…151
ADJUSTING VALVE CLEARANCE…152
TESTING COMPRESSION PRESSURE…154
TESTING ENGINE OIL PRESSURE…155
TESTING AND ADJUSTING FUEL INJECTION TIMING…156
ADJUSTING ENGINE STOP SOLENOID…158
BLEEDING AIR FROM FUEL CIRCUIT…159
TESTING AND ADJUSTING FAN BELT TENSION…160
ADJUSTING FUEL CONTROL LEVER LINKAGE…161
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS…162
TESTING AND ADJUSTING TRACK SHOE TENSION…163
TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT,TRAVEL,SWING,AND BLADE CIRCUITS…165
TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSURE…168
TESTING AND ADJUSTING PUMP LS DIFFERENTIAL PRESSURE…170
MEASURING SOLENOID VALVE OUTPUT PRESSURE…172
MEASURING PPC VALVE OUTPUT PRESSURE…174
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES…176
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE…176
TESTING OIL LEAKAGE FORM CYLINDER…178
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT…180
BLEEDING AIR FROM CYLINDER…180
PRESSURIZING HYDRAULIC TANK…181
HOW TO OPEN AND CLOSE(TILT) FLOOR…182
INSPECTION PROCEDURES FOR DIODE…184
TROUBLESHOOTING…185
POINTS TO REMEMBER WHEN TROUBLESHOOTING…186
SEQUENCE OF EVENTS IN TROUBLESHOOTING…187
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…188
CHECKS BEFORE TROUBLESHOOTING…196
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING…197
CONNECTORS LIST AND CONNECTORS ARRANGEMENT STEREOGRAM …199
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…203
T-ADAPTER-BOXES AND T-ADAPTER TABLE…226
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…229
BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM(E MODE)…230
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…232
E-1 ENGINE DOES NOT START…233
E-2 ENGINE DOES NOT STOP…239
E-3 ENGINE OIL PRESSURE MONITOR DOES NOT INDICATE NORMALLY…241
E-4 CHARGE LEVEL MONITOR DOES NOT INDICATE NORMALLY…244
E-5 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY…247
E-6 SERVICE METER DOES NOT OPERATE NORMALLY…250
E-7 PREHEATING SYSTEM DOES NOT OPERATE NORMALLY…252
E-8 TRAVEL SPEED SHIFTING SYSTEM DOES NOT OPERATE NORMALLY…255
E-9 ENGINE COOLANT TEMPERATURE MONITOR DOES NOT INDICATE NORMALLY…259
E-10 LOCK LEVER DOES NOT OPERATE NORMALLY…263
E-11 BLADE/VARIABLE GAUGE SELECTOR SYSTEM DOES NOT OPERATE NORMALLY…266
E-12 NIGHT LAMP OF MACHINE MONITOR AND WORKING LAMP DO NOT LIGHT UP…269
E-13 TRAVEL ALARM DOES NOT SOUND OR DOES NOT SOUNDING…272
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)…275
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE …276
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT,TRAVEL,SWING,AND BLADE IS LOW…277
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS…278
H-3 WHOLE WORK EQUIPMENT,TRAVEL SYSTEM,SWING SYSTEM,AND BLADE DO NOT MOVE…279
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP…280
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW…280
H-6 SPEED OR POWER OF BOOM IS LOW…281
H-7 SPEED OR POWER OF ARM IS LOW…282
H-8 SPEED OR POWER OF BUCKET IS LOW…283
H-9 SPEED OR POWER OF BOOM SWING IS LOW…284
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY…284
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE…285
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE…286
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT,SPEED OF PART LOADED MORE IS LOW…286
H-14 MACHINE DEVIATES DURING TRAVEL…287
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW…289
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW…289
H-17 TRAVEL SPEED DOES NOT CHANGE…290
H-18 TRAVEL MOTOR DOES NOT WORK(ONE SIDE ONLY)…290
H-19 SPEED OR POWER OF SWING IS LOW…291
H-20 MACHINE DOES NOT SWING…293
H-21 SWING ACCELERATION PERFORMANCE IS LOW…295
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING…296
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING…297
H-24 WHEN UPPER STRUCTURE STOPS SWINGING,IT MAKES LARGE SOUND…297
H-25 HYDRAULIC DRIFT OF SWING IS LARGE…298
H-26 SPEED OR POWER OF BLADE IS LOW…299
H-27 BLADE DOES NOT MOVE…300
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE…300
H-29 VARIABLE GAUGE DOES NOT MOVE…301
H-30 TROUBLESHOOTING FOR HYDRAULIC BREAKER…302
TROUBLESHOOTING OF ENGINE(S MODE)…305
TROUBLESHOOTING CHART…306
30 DISASSEMBLY AND ASSEMBLY…310
HOW TO READ THIS MANUAL…311
PRECAUTIONS WHEN PERFORMING OPERATION…313
SPECIAL TOOL LIST…315
SKETCH OF SPECIAL TOOLS…317
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY…321
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY…322
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY…324
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY…325
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY…329
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…330
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING…331
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY…333
ASSEMBLY OF TRAVEL MOTOR ASSEMBLY…334
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY…343
REMOVAL AND INSTALLATION OF REVOLVING FRAME…348
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY…351
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY…352
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…361
REMOVAL AND INSTALLATION OF HYDRAULIC SYSTEM AND CENTER SWIVEL JOINT ASSEMBLY …365
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY…367
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY…369
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR ASSEMBLY…370
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY…377
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…379
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC BREAKER ASSEMBLY…383
90 OTHERS…390
HYDRAULIC CIRCUIT DIAGRAM …391
ELECTRICAL CIRCUIT DIAGRAM …392
SEN04306-04 – Hydraulic Excavator PC18MR-3 Shop Manual…393
COVER…393
00 Index and foreword…0
100 Index…394
Composition of shop manual…395
Table of contents…397
200 Foreword and general information…402
Safety notice…403
How to read the shop manual…408
Explanation of terms for maintenance standard…410
Handling of electric equipment and hydraulic component…412
Handling of connectors newly used for engines…421
How to read electric wire code…424
Precautions when carrying out operation…427
Method of disassembling and connecting push-pull type coupler…430
Standard tightening torque table…433
Conversion table…437
01 Specification…0
100 Specification and technical data…444
Specification dimension drawing…445
Working range drawing…446
Specifications…447
Weight table…450
Table of fuel, coolant and lubricants…452
10 Structure, function and maintenance standard…0
100 Engine and cooling system…454
PTO…455
Cooling system…457
200 Power train…460
Power train…461
Swing circle…462
300 Undercarriage and frame…464
Track frame…465
Idler cushion…466
Idler…468
Track roller…469
Sprocket…470
Track shoe…471
410 Hydraulic system, Part 1…474
Hydraulic components layout drawing…475
Hydraulic tank…476
Center swivel joint…477
Travel motor…478
Hydraulic cylinder…487
Solenoid valve…491
Variable gauge valve…494
Multi-control valve (If equipped)…495
420 Hydraulic system, Part 2…498
Hydraulic pump…499
Control valve…505
430 Hydraulic system, Part 3…516
CLSS…517
Operation for each function and valve…521
Swing motor…535
PPC valve…538
500 Work equipment…548
Work equipment…550
Dimensions of each part of work equipment…553
600 Cab and its attachments…558
Floor…559
700 Electrical system…562
Engine control system…563
Electric control system…565
Component parts of system…570
KOMTRAX system…571
Monitor system…574
Sensors…577
20 Standard value table…0
100 Standard service value table…580
Standard value table for engine related parts…581
Standard value table for chassis related parts…582
30 Testing and adjusting…0
100 Testing and adjusting…592
List of testing, adjusting, and troubleshooting tools…594
Measuring engine speed…596
Measurement of exhaust gas color…597
Adjusting valve clearance…598
Testing compression pressure…600
Testing engine oil pressure…601
Testing and adjusting fuel injection timing…602
Adjusting engine stop solenoid…604
Bleeding air from fuel circuit…605
Testing and adjusting fan belt tension…606
Adjusting fuel control lever linkage…607
Measurement of clearance in swing circle bearings…608
Testing and adjusting track shoe tension…609
Testing and adjusting oil pressures in work equipment, travel, swing, and blade circuits…611
Testing and adjusting control circuit basic pressure…614
Testing and adjusting pump LS differential pressure…616
Measuring solenoid valve output pressure…618
Measuring PPC valve output pressure…620
Adjusting play of work equipment and swing PPC valves…622
Measuring swing holding brake release pressure…622
Testing oil leakage from cylinder…624
Releasing residual pressure from hydraulic circuit…626
Bleeding air from cylinder…626
Pressurizing hydraulic tank…627
How to open and close (tilt) floor…628
Inspection procedures for diode…630
How to start operation of KOMTRAX terminal…631
Lamp display of KOMTRAX terminal…635
Removal and installation of KOMTRAX terminal…638
Preparation work for troubleshooting of electrical system…639
40 Troubleshooting…0
100 General information on troubleshooting…642
Points to remember when troubleshooting…643
Sequence of events in troubleshooting…644
Checks before troubleshooting…645
Classification and procedures of troubleshooting…646
Connection table for connector pin numbers…649
T- branch box and T- branch adapter table…685
200 Troubleshooting of electrical system (E-mode)…690
Before carrying out troubleshooting for electrical system (E-mode)…691
Information contained in troubleshooting table…693
E-1 Engine does not start…694
E-2 Engine does not stop…701
E-3 When starting switch is turned ON, any item does not operate…703
E-4 When starting switch is turned ON, some items do not operate…705
E-5 Alarm buzzer is abnormal…706
E-6 Engine oil pressure caution is turned ON…708
E-7 Charge level caution is turned ON…709
E-8 Preheating system does not operate or preheater does not become hot…711
E-9 Coolant temperature gauge is abnormal…713
E-10 Fuel level gauge is abnormal…717
E-11 Service meter does not operate while engine is running…721
E-12 2nd travel speed is not selected…724
E-13 Working lamp does not light up…727
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves…729
E-15 Blade/Variable gauge selector system does not operate normally…732
300 Troubleshooting of hydraulic and mechanical system (H-mode)…736
Information contained in troubleshooting table…738
H-1 Speed or power of whole work equipment, travel, swing, and blade is low…739
H-2 Engine speed lowers extremely or engine stalls…740
H-3 Whole work equipment, travel system, swing system, and blade do not move…741
H-4 Abnormal sound comes out from around hydraulic pump…742
H-5 Fine control performance or response is low…742
H-6 Speed or power of boom is low…743
H-7 Speed or power of arm is low…744
H-8 Speed or power of bucket is low…745
H-9 Speed or power of boom swing is low…746
H-10 Work equipment does not move singly…746
H-11 Work equipment hydraulic drift is large…747
H-12 Time lag of work equipment is large…748
H-13 In compound operation of work equipment, speed of part loaded more is low…748
H-14 Machine deviates during travel…749
H-15 Travel speed or travel power is low…751
H-16 Machine is not steered well or steering power is low…751
H-17 Travel speed does not change…752
H-18 Travel motor does not work (one side only)…752
H-19 Speed or power of swing is low…753
H-20 Machine does not swing…755
H-21 Swing acceleration performance is low…757
H-22 Machine overruns when it stops swinging…758
H-23 Large shock is made when machine stops swinging…759
H-24 When upper structure stops swinging, it makes large sound…759
H-25 Hydraulic drift of swing is large…760
H-26 Speed or power of blade is low…761
H-27 Blade does not move…762
H-28 Hydraulic drift of blade is large…762
H-29 Variable gauge does not move…763
H-30 Troubleshooting for hydraulic breaker…764
400 Troubleshooting of engine (S-mode)…768
Troubleshooting chart…769
50 Disassembly and assembly…0
100 General information on disassembly and assembly…774
How to read this manual…775
Coating materials list…777
Special tool list…780
Sketches of special tools…782
200 Engine and cooling system…786
Removal and installation of fuel injection pump assembly…787
Removal and installation of radiator assembly…788
Removal and installation of hydraulic oil cooler assembly…790
Removal and installation of engine and hydraulic pump assembly…791
300 Power train…798
Removal and installation of swing circle assembly…799
400 Undercarriage and frame…802
Removal and installation of track shoe assembly…803
Disassembly and assembly of idler assembly…804
Disassembly and assembly of recoil spring…806
Disassembly and assembly of track roller assembly…808
Assembly of travel motor assembly…810
Removal and installation of floor frame assembly…819
Removal and installation of revolving frame…823
500 Hydraulic system…828
Disassembly and assembly of hydraulic pump assembly…829
Disassembly and assembly of control valve assembly…839
Removal and installation of hydraulic system and center swivel joint assembly…845
Disassembly and assembly of center swivel joint assembly…847
Removal and installation of swing motor assembly…849
Disassembly and assembly of swing motor assembly…850
Disassembly and assembly of hydraulic cylinder assembly…857
Disassembly and assembly of hydraulic breaker assembly…861
600 Work equipment…870
Removal and installation of work equipment assembly…871
700 Cab and its attachments…874
Removal and installation of canopy…875
800 Electrical system…878
Removal and installation of KOMTRAX terminal…879
90 Diagrams and drawings…0
100 Hydraulic diagrams and drawings…882
Hydraulic circuit diagram…884
200 Electrical diagrams and drawings…887
Electrical circuit diagram…889
Connector list and stereogram…890
TEN00052-01 – Hydraulic Excavator GALEO PC18MR-2 Operation & Maintenance Manual…893
COVER…893
FOREWORD…894
FOREWORD…895
SAFETY INFORMATION…898
INTRODUCTION…900
DIRECTIONS OF MACHINE…900
PRODUCT INFORMATION…901
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…901
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…901
EPA NAMEPLATE…902
SERVICE METER LOCATION…902
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…903
CONTENTS…904
SAFETY…908
SAFETY INFORMATION…909
SAFETY LABELS…911
LOCATION OF SAFETY LABELS…911
SAFETY LABELS…912
SAFETY INFORMATION…917
SAFETY MACHINE OPERATION…926
STARTING ENGINE…926
OPERATION…928
TRANSPORTATION…934
BATTERY…935
TOWING…937
LIFTING OBJECTS WITH BUCKET…938
SAFETY MAINTENANCE INFORMATION…939
OPERATION…946
MACHINE VIEW ILLUSTRATIONS…947
OVERALL MACHINE VIEW…947
CONTROLS AND GAUGES…948
DETAILED CONTROLS AND GAUGES…949
MONITORING SYSTEM…949
SWITCHES…955
CONTROL LEVERS AND PEDALS…959
COVER WITH LOCK…964
ENGINE REAR COVER…965
COOLING COVER…966
BATTERY COVER…967
METHOD OF OPENING (TILTING) FLOOR…968
FUSE…972
BLOCK FUSE…972
OPERATION MANUAL STORAGE…973
TOOL BOX…973
MACHINE OPERATIONS AND CONTROLS…974
BEFORE STARTING ENGINE…974
STARTING ENGINE…987
AFTER STARTING ENGINE…991
STOPPING THE ENGINE…994
MACHINE OPERATION…995
STEERING THE MACHINE…1000
SWINGING…1002
WORK EQUIPMENT CONTROLS AND OPERATIONS…1003
PROHIBITED OPERATIONS…1006
GENERAL OPERATION INFORMATION…1008
TRAVELING ON SLOPES…1010
ESCAPE FROM MUD…1012
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1013
BUCKET REPLACEMENT…1015
PARKING MACHINE…1016
MACHINE INSPECTION AFTER DAILY WORK…1017
LOCKING…1018
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1019
TRANSPORTATION…1024
TRANSPORTATION PROCEDURE…1024
LOADING AND UNLOADING WITH TRAILER…1024
LIFTING MACHINE…1030
COLD WEATHER OPERATION…1033
COLD WEATHER OPERATION INFORMATION…1033
AFTER DAILY WORK COMPLETION…1035
AFTER COLD WEATHER SEASON…1035
LONG TERM STORAGE…1036
BEFORE STORAGE…1036
DURING STORAGE…1036
AFTER STORAGE…1036
TROUBLES AND ACTIONS…1037
RUNNING OUT OF FUEL…1037
PHENOMENA THAT ARE NOT FAILURES…1037
TOWING THE MACHINE…1038
SEVERE JOB CONDITION…1038
DISCHARGED BATTERY…1039
OTHER TROUBLE…1043
MAINTENANCE…1046
MAINTENANCE INFORMATION…1047
OUTLINE OF SERVICE…1049
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1049
ELECTRIC SYSTEM MAINTENANCE…1052
HANDLING HYDRAULIC SYSTEM…1052
WEAR PARTS…1053
WEAR PARTS LIST…1053
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1054
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…1056
TIGHTENING TORQUE SPECIFICATIONS…1057
TIGHTENING TORQUE LIST…1057
SAFETY CRITICAL PARTS…1058
SAFETY CRITICAL PARTS LIST…1058
MAINTENANCE SCHEDULE…1059
MAINTENANCE SCHEDULE CHART…1059
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1060
MAINTENANCE PROCEDURE…1061
WHEN REQUIRED…1061
CHECK BEFORE STARTING…1083
EVERY 500 HOURS MAINTENANCE…1084
EVERY 1000 HOURS MAINTENANCE…1091
EVERY 2000 HOURS MAINTENANCE…1094
SPECIFICATIONS…1096
SPECIFICATIONS…1097
ATTACHMENTS AND OPTIONS…1100
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1101
SAFETY FIRST…1101
ATTACHMENT INSTALLATION…1102
BUCKET WITH HOOK…1103
PROHIBITED OPERATIONS…1103
MACHINE READY FOR ATTACHMENT…1104
LOCATIONS…1104
HYDRAULIC CIRCUIT…1106
ATTACHMENT OPERATIONS…1108
LONG TERM STORAGE…1109
SPECIFICATIONS…1109
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1110
CONTROL PATTERN CHANGE PROCEDURE…1110
MACHINE CONTROL PATTERNS…1111
ATTACHMENT GUIDE…1112
ATTACHMENT COMBINATIONS…1112
RECOMMENDED ATTACHMENT OPERATIONS…1113
HYDRAULIC BREAKER…1113
INDEX…1118
TEN00292-03 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual…1122
COVER…1122
FOREWORD…1123
FOREWORD…1124
SAFETY INFORMATION…1125
INTRODUCTION…1127
DIRECTIONS OF MACHINE…1127
PRODUCT INFORMATION…1128
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1128
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1128
EPA NAMEPLATE…1129
SERVICE METER LOCATION…1129
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1130
CONTENTS…1131
SAFETY…1135
SAFETY…1136
SAFETY LABELS…1138
LOCATION OF SAFETY LABELS…1138
SAFETY LABELS…1139
GENERAL PRECAUTIONS…1144
SAFETY MACHINE OPERATION…1153
STARTING ENGINE…1153
OPERATION…1155
TRANSPORTATION…1161
BATTERY…1162
TOWING…1164
LIFTING OBJECTS WITH BUCKET…1165
SAFETY MAINTENANCE INFORMATION…1166
OPERATION…1175
MACHINE VIEW ILLUSTRATIONS…1176
OVERALL MACHINE VIEW…1176
CONTROLS AND GAUGES…1177
DETAILED CONTROLS AND GAUGES…1178
MONITORING SYSTEM…1178
SWITCHES…1184
CONTROL LEVERS AND PEDALS…1187
COVER WITH LOCK…1193
ENGINE REAR COVER…1194
COOLING COVER…1195
BATTERY COVER…1196
METHOD OF OPENING (TILTING) FLOOR…1197
AUXILIARY ELECTRIC POWER…1201
FUSE…1201
BLOCK FUSE…1202
OPERATION MANUAL STORAGE…1202
TOOL BOX…1203
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1204
MACHINE OPERATIONS AND CONTROLS…1205
BEFORE STARTING ENGINE…1205
STARTING ENGINE…1218
AFTER STARTING ENGINE…1222
STOPPING THE ENGINE…1225
MACHINE OPERATION…1226
STEERING THE MACHINE…1231
SWINGING…1233
WORK EQUIPMENT CONTROLS AND OPERATIONS…1234
PROHIBITED OPERATIONS…1237
GENERAL OPERATION INFORMATION…1239
TRAVELING ON SLOPES…1241
ESCAPE FROM MUD…1243
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1244
BUCKET REPLACEMENT…1246
PARKING MACHINE…1247
MACHINE INSPECTION AFTER DAILY WORK…1248
LOCKING…1249
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1250
TRANSPORTATION…1255
TRANSPORTATION PROCEDURE…1255
LOADING AND UNLOADING WITH TRAILER…1256
LIFTING MACHINE…1262
COLD WEATHER OPERATION…1265
COLD WEATHER OPERATION INFORMATION…1265
AFTER DAILY WORK COMPLETION…1267
AFTER COLD WEATHER SEASON…1267
LONG TERM STORAGE…1268
BEFORE STORAGE…1268
DURING STORAGE…1268
AFTER STORAGE…1268
TROUBLES AND ACTIONS…1270
RUNNING OUT OF FUEL…1270
PHENOMENA THAT ARE NOT FAILURES…1270
TOWING THE MACHINE…1271
SEVERE JOB CONDITION…1271
DISCHARGED BATTERY…1272
OTHER TROUBLE…1276
MAINTENANCE…1279
MAINTENANCE INFORMATION…1280
OUTLINE OF SERVICE…1282
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1282
ELECTRIC SYSTEM MAINTENANCE…1286
HANDLING HYDRAULIC SYSTEM…1286
WEAR PARTS…1287
WEAR PARTS LIST…1287
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1288
TIGHTENING TORQUE SPECIFICATIONS…1290
TIGHTENING TORQUE LIST…1290
SAFETY CRITICAL PARTS…1291
SAFETY CRITICAL PARTS LIST…1291
MAINTENANCE SCHEDULE…1292
MAINTENANCE SCHEDULE CHART…1292
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1293
MAINTENANCE PROCEDURE…1294
WHEN REQUIRED…1294
CHECK BEFORE STARTING…1317
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…1317
EVERY 500 HOURS MAINTENANCE…1318
EVERY 1000 HOURS MAINTENANCE…1326
EVERY 1500 HOURS MAINTENANCE…1329
EVERY 2000 HOURS MAINTENANCE…1330
SPECIFICATIONS…1335
SPECIFICATIONS…1336
ATTACHMENTS, OPTIONS…1339
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1340
SAFETY FIRST…1340
ATTACHMENT INSTALLATION…1341
BUCKET WITH HOOK…1342
HOOK CONDITION…1342
PROHIBITED OPERATIONS…1342
MACHINE READY FOR ATTACHMENT…1343
LOCATIONS…1343
HYDRAULIC CIRCUIT…1346
ATTACHMENT OPERATIONS…1347
LONG TERM STORAGE…1348
SPECIFICATIONS…1348
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1349
CONTROL PATTERN CHANGE PROCEDURE…1349
MACHINE CONTROL PATTERNS…1350
ATTACHMENT GUIDE…1351
ATTACHMENT COMBINATIONS…1351
HANDLING ARM WITH BUILT-IN BREAKER…1352
REMOVING AND INSTALLING CHISEL…1352
PROCEDURE FOR BREAKER OPERATIONS…1355
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS…1356
INSTALLATION OF BUCKET…1357
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS…1359
STOWING CHISEL, DUMMY CHISEL…1359
CHECK BEFORE STARTING…1360
SPECIFICATIONS…1361
RECOMMENDED ATTACHMENT OPERATIONS…1362
HYDRAULIC BREAKER…1362
INDEX…1367
TEN00514-01 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual…1371
COVER…1371
FOREWORD…1372
FOREWORD…1373
SAFETY INFORMATION…1374
INTRODUCTION…1376
DIRECTIONS OF MACHINE…1376
PROTECTIVE STRUCTURE…1376
PRODUCT INFORMATION…1377
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1377
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1377
EPA NAMEPLATE…1378
SERVICE METER LOCATION…1378
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1379
CONTENTS…1380
SAFETY…1384
SAFETY…1385
SAFETY LABELS…1387
LOCATION OF SAFETY LABELS…1387
SAFETY LABELS…1388
GENERAL PRECAUTIONS…1393
SAFETY MACHINE OPERATION…1402
STARTING ENGINE…1402
OPERATION…1404
TRANSPORTATION…1410
BATTERY…1411
TOWING…1413
LIFTING OBJECTS WITH BUCKET…1414
SAFETY MAINTENANCE INFORMATION…1415
OPERATION…1424
MACHINE VIEW ILLUSTRATIONS…1425
OVERALL MACHINE VIEW…1425
CONTROLS AND GAUGES…1426
DETAILED CONTROLS AND GAUGES…1427
MONITORING SYSTEM…1427
SWITCHES…1433
CONTROL LEVERS AND PEDALS…1436
COVER WITH LOCK…1442
ENGINE REAR COVER…1443
COOLING COVER…1444
BATTERY COVER…1445
METHOD OF OPENING (TILTING) FLOOR…1446
AUXILIARY ELECTRIC POWER…1450
FUSE…1450
OPERATION MANUAL STORAGE…1451
TOOL BOX…1452
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1453
MACHINE OPERATIONS AND CONTROLS…1454
BEFORE STARTING ENGINE…1454
STARTING ENGINE…1467
AFTER STARTING ENGINE…1471
STOPPING THE ENGINE…1474
MACHINE OPERATION…1475
STEERING THE MACHINE…1480
SWINGING…1482
WORK EQUIPMENT CONTROLS AND OPERATIONS…1483
PROHIBITED OPERATIONS…1486
GENERAL OPERATION INFORMATION…1488
TRAVELING ON SLOPES…1490
ESCAPE FROM MUD…1492
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1493
BUCKET REPLACEMENT…1495
PARKING MACHINE…1496
MACHINE INSPECTION AFTER DAILY WORK…1497
LOCKING…1498
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1499
TRANSPORTATION…1504
TRANSPORTATION PROCEDURE…1504
LOADING AND UNLOADING WITH TRAILER…1505
LIFTING MACHINE…1511
COLD WEATHER OPERATION…1514
COLD WEATHER OPERATION INFORMATION…1514
AFTER DAILY WORK COMPLETION…1516
AFTER COLD WEATHER SEASON…1516
LONG TERM STORAGE…1517
BEFORE STORAGE…1517
DURING STORAGE…1517
AFTER STORAGE…1517
TROUBLES AND ACTIONS…1518
RUNNING OUT OF FUEL…1518
PHENOMENA THAT ARE NOT FAILURES…1518
TOWING THE MACHINE…1519
SEVERE JOB CONDITION…1519
DISCHARGED BATTERY…1520
OTHER TROUBLE…1524
MAINTENANCE…1528
MAINTENANCE INFORMATION…1529
OUTLINE OF SERVICE…1531
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1531
ELECTRIC SYSTEM MAINTENANCE…1534
HANDLING HYDRAULIC SYSTEM…1535
WEAR PARTS…1536
WEAR PARTS LIST…1536
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1537
TIGHTENING TORQUE SPECIFICATIONS…1539
TIGHTENING TORQUE LIST…1539
SAFETY CRITICAL PARTS…1540
SAFETY CRITICAL PARTS LIST…1540
MAINTENANCE SCHEDULE…1541
MAINTENANCE SCHEDULE CHART…1541
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1542
MAINTENANCE PROCEDURE…1543
WHEN REQUIRED…1543
CHECK BEFORE STARTING…1565
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…1565
EVERY 500 HOURS MAINTENANCE…1566
EVERY 1000 HOURS MAINTENANCE…1574
EVERY 1500 HOURS MAINTENANCE…1577
EVERY 2000 HOURS MAINTENANCE…1578
SPECIFICATIONS…1584
SPECIFICATIONS…1585
ATTACHMENTS, OPTIONS…1588
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1589
SAFETY FIRST…1589
ATTACHMENT INSTALLATION…1590
BUCKET WITH HOOK…1591
HOOK CONDITION…1591
PROHIBITED OPERATIONS…1591
MACHINE READY FOR ATTACHMENT…1592
LOCATIONS…1592
HYDRAULIC CIRCUIT…1595
ATTACHMENT OPERATIONS…1596
LONG TERM STORAGE…1597
SPECIFICATIONS…1597
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1598
CONTROL PATTERN CHANGE PROCEDURE…1598
MACHINE CONTROL PATTERNS…1599
ATTACHMENT GUIDE…1600
ATTACHMENT COMBINATIONS…1600
HANDLING ARM WITH BUILT-IN BREAKER…1601
REMOVING AND INSTALLING CHISEL…1601
PROCEDURE FOR BREAKER OPERATIONS…1604
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS…1605
INSTALLATION OF BUCKET…1606
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS…1608
STOWING CHISEL, DUMMY CHISEL…1608
CHECK BEFORE STARTING…1609
SPECIFICATIONS…1610
RECOMMENDED ATTACHMENT OPERATIONS…1611
HYDRAULIC BREAKER…1611
INDEX…1616
TEN00549-00 – Hydraulic Excavator PC18MR-3 Operation & Maintenance Manual…1620
COVER…1620
FOREWORD…1621
FOREWORD…1622
SAFETY INFORMATION…1623
INTRODUCTION…1625
DIRECTIONS OF MACHINE…1625
PROTECTIVE STRUCTURE…1625
PRODUCT INFORMATION…1626
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1626
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1626
EPA NAMEPLATE…1627
SERVICE METER LOCATION…1627
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1628
CONTENTS…1629
SAFETY…1633
SAFETY…1634
SAFETY LABELS…1636
LOCATION OF SAFETY LABELS…1636
SAFETY LABELS…1637
GENERAL PRECAUTIONS…1642
SAFETY MACHINE OPERATION…1651
STARTING ENGINE…1651
OPERATION…1653
TRANSPORTATION…1659
BATTERY…1660
TOWING…1662
LIFTING OBJECTS WITH BUCKET…1663
SAFETY MAINTENANCE INFORMATION…1664
OPERATION…1673
MACHINE VIEW ILLUSTRATIONS…1674
OVERALL MACHINE VIEW…1674
CONTROLS AND GAUGES…1675
DETAILED CONTROLS AND GAUGES…1676
MONITORING SYSTEM…1676
SWITCHES…1682
CONTROL LEVERS AND PEDALS…1685
COVER WITH LOCK…1691
ENGINE REAR COVER…1692
COOLING COVER…1693
BATTERY COVER…1694
METHOD OF OPENING (TILTING) FLOOR…1695
AUXILIARY ELECTRIC POWER…1699
FUSE…1699
BLOCK FUSE…1700
OPERATION MANUAL STORAGE…1700
TOOL BOX…1701
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1702
MACHINE OPERATIONS AND CONTROLS…1703
BEFORE STARTING ENGINE…1703
STARTING ENGINE…1716
AFTER STARTING ENGINE…1720
STOPPING THE ENGINE…1723
MACHINE OPERATION…1724
STEERING THE MACHINE…1729
SWINGING…1731
WORK EQUIPMENT CONTROLS AND OPERATIONS…1732
PROHIBITED OPERATIONS…1735
GENERAL OPERATION INFORMATION…1737
TRAVELING ON SLOPES…1739
ESCAPE FROM MUD…1741
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1742
BUCKET REPLACEMENT…1744
PARKING MACHINE…1745
MACHINE INSPECTION AFTER DAILY WORK…1746
LOCKING…1747
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…1748
TRANSPORTATION…1753
TRANSPORTATION PROCEDURE…1753
LOADING AND UNLOADING WITH TRAILER…1754
LIFTING MACHINE…1760
COLD WEATHER OPERATION…1763
COLD WEATHER OPERATION INFORMATION…1763
AFTER DAILY WORK COMPLETION…1765
AFTER COLD WEATHER SEASON…1765
LONG TERM STORAGE…1766
BEFORE STORAGE…1766
DURING STORAGE…1766
AFTER STORAGE…1766
TROUBLES AND ACTIONS…1767
RUNNING OUT OF FUEL…1767
PHENOMENA THAT ARE NOT FAILURES…1767
TOWING THE MACHINE…1768
SEVERE JOB CONDITION…1768
DISCHARGED BATTERY…1769
OTHER TROUBLE…1773
MAINTENANCE…1777
MAINTENANCE INFORMATION…1778
OUTLINE OF SERVICE…1780
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1780
ELECTRIC SYSTEM MAINTENANCE…1783
HANDLING HYDRAULIC SYSTEM…1784
WEAR PARTS…1785
WEAR PARTS LIST…1785
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1786
TIGHTENING TORQUE SPECIFICATIONS…1788
TIGHTENING TORQUE LIST…1788
SAFETY CRITICAL PARTS…1789
SAFETY CRITICAL PARTS LIST…1789
MAINTENANCE SCHEDULE…1790
MAINTENANCE SCHEDULE CHART…1790
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1791
MAINTENANCE PROCEDURE…1792
WHEN REQUIRED…1792
CHECK BEFORE STARTING…1814
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…1814
EVERY 500 HOURS MAINTENANCE…1815
EVERY 1000 HOURS MAINTENANCE…1823
EVERY 1500 HOURS MAINTENANCE…1826
EVERY 2000 HOURS MAINTENANCE…1827
SPECIFICATIONS…1833
SPECIFICATIONS…1834
ATTACHMENTS, OPTIONS…1837
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1838
SAFETY FIRST…1838
ATTACHMENT INSTALLATION…1839
BUCKET WITH HOOK…1840
HOOK CONDITION…1840
PROHIBITED OPERATIONS…1840
MACHINE READY FOR ATTACHMENT…1841
LOCATIONS…1841
HYDRAULIC CIRCUIT…1844
ATTACHMENT OPERATIONS…1845
LONG TERM STORAGE…1846
SPECIFICATIONS…1846
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1847
CONTROL PATTERN CHANGE PROCEDURE…1847
MACHINE CONTROL PATTERNS…1848
ATTACHMENT GUIDE…1849
ATTACHMENT COMBINATIONS…1849
HANDLING ARM WITH BUILT-IN BREAKER…1850
REMOVING AND INSTALLING CHISEL…1850
PROCEDURE FOR BREAKER OPERATIONS…1853
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS…1854
INSTALLATION OF BUCKET…1855
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS…1857
STOWING CHISEL, DUMMY CHISEL…1857
CHECK BEFORE STARTING…1858
SPECIFICATIONS…1859
RECOMMENDED ATTACHMENT OPERATIONS…1860
HYDRAULIC BREAKER…1860
INDEX…1865

Komatsu Hydraulic Excavators PC18MR Repair Service Manual

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC15MR-1, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC15MR-1 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.

SEAM044900T – Hydraulic Excavator PC15MRX-1 Operation & Maintenance Manual.pdf
SEBM019002 – Hydraulic Excavator PC15MR-1 Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 613 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
COVER…1
CONTENTS…2
01 GENERAL…25
GENERAL ASSEMBLY DRAWING…26
SPECIFICATIONS…27
WEIGHT TABLE…30
LIST OF LUBRICANT AND WATER…32
10 STRUCTURE AND FUNCTION…34
SWING CIRCLE…35
TRACK FRAME, RECOIL SPRING…36
HYDRAULIC EQUIPMENT LAYOUT…37
HYDRAULIC TANK…38
HYDRAULIC PUMP…39
CONTROL VALVE…43
CLSS…51
CENTER SWIVEL JOINT…68
SWING MOTOR…70
TRAVEL MOTOR…72
VALVE CONTROL…78
PPC VALVE…79
PPC LOCK SOLENOID VALVE…83
TRAVEL 2-SPEED SELECTER VALVE…85
ELECTRIC WIRING DIAGRAM…86
MONITOR SYSTEM…88
20 TESTING AND ADJUSTING…91
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…92
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…93
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…101
TESTING AND ADJUSTING…103
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…104
MEASURING ENGINE SPEED…105
MEASURING EXHAUST COLOR…106
ADJUSTING VALVE CLEARANCE…107
MEASURING COMPRESSION PRESSURE…108
TESTING AND ADJUSTING FUEL INJECTION TIMING…109
MEASURING ENGINE OIL PRESSURE…110
TESTING AND ADJUSTING FAN BELT TENSION…111
ADJUSTING FUEL CONTROL LEVER…112
MEASURING SPROCKET WEAR…113
TESTING AND ADJUSTING TRACK SHOE TENSION…114
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…115
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE…117
ADJUSTING PC VALVE SPRING…119
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE…120
TESTING PPC LOCK VALVE…121
TESTING PPC VALVE OUTPUT PRESSURE AND SWING HOLDING BRAKE INLET PORT PRESSURE…122
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE…124
TESTING AND ADJUSTING TRAVEL DEVIATION…125
MEASURING OIL LEAKAGE INSIDE WORK EQUIPMENT CYLINDER…126
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…127
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK…128
PRESSURIZING HYDRAULIC TANK…128
BLEEDING AIR…129
TROUBLESHOOTING…131
POINTS TO REMEMBER WHEN TROUBLESHOOTING…132
SEQUENCE OF EVENTS IN TROUBLESHOOTING…133
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…134
CHECKS BEFORE TROUBLESHOOTING…142
CONNECTOR TYPES AND MOUNTING LOCATIONS…143
CONNECTOR PIN ALLOCATION DRAWING…144
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…146
METHOD OF USING TROUBLESHOOTING CHARTS…156
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…158
E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…159
E-1 ENGINE DOES NOT START…161
a) WHEN STARTING MOTOR DOES NOT TURN (STARTING SYSTEM)…161
b) WHEN STARTING MOTOR TURNS (ENGINE STOP SOLENOID SYSTEM)…163
E-2 ENGINE DOES NOT STOP…165
E-3 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS CANCELED…166
E-4 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED…168
E-5 TRAVEL ALARM DOES NOT SOUND…169
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…170
TABLE OF FAILURE MODES AND CAUSES…171
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER…173
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…174
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE…174
H-4 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)…175
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…175
H-6 BOOM IS SLOW OR LACKS POWER…176
H-7 ARM IS SLOW OR LACKS POWER…176
H-8 BUCKET IS SLOW OR LACKS POWER…177
H-9 BOOM SWING IS SLOW OR LACKS POWER…177
H-10 BLADE IS SLOW OR LACKS POWER…178
H-11 BOOM, ARM, BUCKET DO NOT MOVE (BOOM SWING, BLADE, TRAVEL AND SWING ARE NORMAL)…178
H-12 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET, BOOM SWING, BLADE)…179
a) BOOM, BUCKET, BOOM SWING, BLADE…179
b) ARM…179
H-13 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)…179
a) BOOM, ARM…179
b) BUCKET…179
H-14 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW…180
H-15 TRAVEL DEVIATION…181
a) DEVIATION IN NORMAL TRAVEL…181
b) DEVIATION WHEN STARTING…181
H-16 TRAVEL SPEED IS SLOW OR LACKS POWER…182
H-17 STEERING DOES NOT TURN EASILY…182
H-18 TRAVEL SPEED DOES NOT SWITCH…182
H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…183
H-20 SWING SPEED IS SLOW OR LACKS POWER…183
a) SPEED IS SLOW OR LACKS POWER IN BOTH DIRECTIONS…183
b) SPEED IS SLOW OR LACKS POWER IN ONE DIRECTION ONLY…183
H-21 DOES NOT SWING…184
a) DOES NOT SWING IN EITHER DIRECTION…184
b) DOES NOT SWING IN ONE DIRECTION ONLY…184
H-22 SWING ACCELERATION IS POOR…185
a) ACCELERATION IS POOR IN BOTH DIRECTIONS…185
b) ACCELERATION IS POOR IN ONE DIRECTION ONLY…185
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING…186
a) OVERRUN WHEN STOPPING IS EXCESSIVE IN BOTH DIRECTIONS…186
b) OVERRUN WHEN STOPPING IS EXCESSIVE IN ONE DIRECTION ONLY…186
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (IN ONE DIRECTION ONLY)…186
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…187
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING…187
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…188
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE RELATED PARTS…189
M-1 ABNORMALITY IN ENGINE OIL PRESSURE CAUTION LAMP SYSTEM…190
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON…190
b) LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)…190
M-2 ABNORMALITY IN CHARGE CAUTION LAMP SYSTEM…192
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON…192
b) LAMP LIGHTS UP WHEN ENGINE IS RUNNING (BATTERY CHARGE IS NORMAL)…192
M-3 ABNORMALITY IN ENGINE WATER TEMPERATURE CAUTION LAMP SYSTEM…194
a) LAMP DOES NOT STAY LIGHTED UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON…194
b) LAMP DOES NOT GO OUT AFTER STARTING SWITCH HAS BEEN AN ON FOR 3 SECONDS…194
c) LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE WATER TEMPERATURE IS NORMAL)…195
M-4 ABNORMALITY IN PREHEATING PILOT LAMP…196
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED TO HEAT…196
b) LAMP DOES NOT GO OUT WHEN STARTING SWITCH IS AT HEAT AND PREHEATING TIME (APPROX. 18 SEC.) IS COMPLETED…196
c) LAMP LIGHTS UP WHEN STARTING SWITCH IS AT POSITION OTHER THAN HEAT…197
M-5 ABNORMALITY IN FUEL GAUGE SYSTEM…198
a) GAUGE DOES NOT GO UP FROM E WHEN FUEL IS ADDED TO FUEL TANK…198
b) GAUGE DOES NOT GO DOWN FROM F EVEN WHEN THERE IS NO FUEL IN FUEL TANK…198
c) FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY…199
M-6 ABNORMALITY IN SERVICE METER SYSTEM…200
a) SERVICE METER DOES NOT ADVANCE WHEN STARTING SWITCH IS AT ON…200
b) SERVICE METER ADVANCES WHEN STARTING SWITCH IS AT OFF…200
c) PILOT LAMP DOES NOT FLASH WHEN SERVICE METER IS ADVANCING…200
M-7 ABNORMALITY IN NIGHT LIGHTING SYSTEM…202
a) NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON…202
b) NIGHT LIGHTING LIGHTS UP WHEN LAMP SWITCH IS TURNED OFF…202
30 DISASSEMBLY AND ASSEMBLY…204
METHOD OF USING MANUAL…205
PRECAUTIONS WHEN CARRYING OUT OPERATION…206
SPECIAL TOOL LIST…208
ENGINE AND HYDRAULIC PUMP…209
REMOVAL…209
INSTALLATION…213
CENTER SWIVEL JOINT…214
REMOVAL…214
INSTALLATION…214
DISASSEMBLY…215
ASSEMBLY…215
SWING MOTOR…216
REMOVAL…216
INSTALLATION…216
REVOLVING FRAME…217
REMOVAL…217
INSTALLATION…218
SWING CIRCLE…219
REMOVAL…219
INSTALLATION…219
IDLER…220
ASSEMBLY…220
TRACK ROLLER…221
ASSEMBLY…221
RUBBER SHOE…222
REMOVAL…222
INSTALLATION…222
CONTROL VALVE…223
DISASSEMBLY…223
ASSEMBLY…228
HYDRAULIC CYLINDER…235
ASSEMBLY…235
40 MAINTENANCE STANDARD…238
SWING CIRCLE…239
TRACK FRAME, RECOIL SPRING…240
IDLER…241
TRACK ROLLER…242
TRACK SHOE…243
HYDRAULIC PUMP…245
CONTROL VALVE…246
CENTER SWIVEL JOINT…250
SWING MOTOR…251
TRAVEL MOTOR…252
PPC VALVE…253
HYDRAULIC CYLINDER…254
WORK EQUIPMENT…255
90 OTHERS…257
HYDRAULIC CIRCUIT DIAGRAM (VARIABLE GAUGE TYPE)…258
HYDRAULIC CIRCUIT DIAGRAM (FIXED GAUGE TYPE)…259
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO.: 10001-10634)…260
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO.: 10635 AND UP)…261

COVER…1
FOREWORD…2
FOREWORD…3
SAFETY INFORMATION…6
INTRODUCTION…8
DIRECTIONS OF MACHINE…8
PRODUCT INFORMATION…9
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…9
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…9
EMISSION CONTROL INFORMATION LABEL…10
SERVICE METER LOCATION…10
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…10
CONTENTS…11
SAFETY…15
SAFETY INFORMATION…16
POSITION FOR ATTACHING SAFETY LABELS…18
POSITION FOR ATTACHING SAFETY LABELS…19
SAFETY LABELS…20
SAFETY INFORMATION…24
SAFETY RULES…24
IF ABNORMALITIES ARE FOUND…24
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…24
FIRE EXTINGUISHER AND FIRST AID KIT…24
SAFETY EQUIPMENT…25
KEEP MACHINE CLEAN…25
KEEP OPERATOR'S COMPARTMENT CLEAN…25
LEAVING OPERATOR'S SEAT WITH LOCK…25
HANDRAILS AND STEPS…26
CRUSHING OR CUTTING PREVENTION…26
MOUNTING AND DISMOUNTING…27
NO PERSONS ON ATTACHMENTS…27
BURN PREVENTION…27
FIRE PREVENTION AND EXPLOSION PREVENTION…28
ACTION IF FIRE OCCURS…29
WINDSHIELD WASHER FLUID…29
FALLING OBJECTS,FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…29
ATTACHMENT INSTALLATION…29
ATTACHMENT COMBINATIONS…30
CAB WIDOW GLASSES…30
UNAUTHORIZED MODIFICATIONS…30
SAFETY AT JOBSITE…30
WORKING ON LOOSE GROUND…30
DISTANCE TO HIGH VOLTAGE CABLES…31
ENSURE GOOD VISIBILITY…31
VENTILATION FOR ENCLOSED AREA…32
SIGNALMAN'S SIGNAL AND SIGNS…32
ASBESTOS DUST HAZARD PREVENTION…32
SAFETY MACHINE OPERATION…33
STARTING ENGINE…33
CHECKS BEFORE STARTING ENGINE…33
SAFETY RULES FOR STARTING ENGINE…34
STARTING ENGINE IN COLD WEATHER…34
OPERATION…35
CHECKS AFTER STARTING ENGINE…35
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…35
SAFETY RULES FOR TRAVELING…36
TRAVELING ON SLOPES…37
OPERATIONS ON SLOPES…38
PROHIBITED OPERATIONS…38
OPERATIONS ON SNOW…40
PARKING MACHINE…40
TRANSPORTATION…41
LOADING AND UNLOADING…41
SHIPPING THE MACHINE…42
BATTERY…43
BATTERY HAZARD PREVENTION…43
STARTING ENGINE WITH BOOSTER CABLES…44
TOWING…45
SAFETY RULES FOR TOWING…45
LIFTING OBJECTS WITH BUCKET…46

Komatsu Hydraulic Excavator PC15MR Repair Service Manual (SEBM019002)

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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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

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC09-1, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC09-1 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.

SEBM026105 – Hydraulic Excavator PC09-1 Shop Manual.pdf
SEAM044501T – Hydraulic Excavator GALEO PC09-1 Operation & Maintenance Manual.pdf
SEAM044502 – Hydraulic Excavator PC09-1 Operation & Maintenance Manual.pdf
TEN00062-04 – Hydraulic Excavator PC09-1 Operation & Maintenance Manual.pdf
TEN00555-00 – Hydraulic Excavator PC09-1 Operation & Maintenance Manual.pdf

Total Pages: 1,027 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
SEAM044501T – Hydraulic Excavator GALEO PC09-1 Operation & Maintenance Manual….2
COVER….2
FOREWORD….3
FOREWORD….4
SAFETY INFORMATION….7
INTRODUCTION….9
DIRECTIONS OF MACHINE….9
PRODUCT INFORMATION….10
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION….10
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….10
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION….11
SERVICE METER LOCATION….11
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….12
CONTENTS….13
SAFETY….16
SAFETY INFORMATION….17
SAFETY LABELS….19
LOCATION OF SAFETY LABELS….19
SAFETY LABELS….20
SAFETY INFORMATION….23
SAFETY RULES….23
IF ABNORMALITIES ARE FOUND….23
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….23
FIRE EXTINGUISHER AND FIRST AID KIT….23
SAFETY EQUIPMENT….23
KEEP MACHINE CLEAN….24
OPERATOR'S SEAT EQUIPMENT….24
LEAVING OPERATOR'S SEAT WITH LOCK….24
HANDRAILS AND STEPS….25
MOUNTING AND DISMOUNTING….25
NO PERSONS ON ATTACHMENTS….25
BURN PREVENTION….26
FIRE PREVENTION AND EXPLOSION PREVENTION….27
ACTION IF FIRE OCCURS….27
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….28
ATTACHMENT INSTALLATION….28
ATTACHMENT COMBINATIONS….28
UNAUTHORIZED MODIFICATIONS….28
SAFETY AT JOBSITE….29
WORKING ON LOOSE GROUND….29
DISTANCE TO HIGH VOLTAGE CABLES….29
ENSURE GOOD VISIBILITY….30
VENTILATION FOR ENCLOSED AREA….30
SIGNALMAN'S SIGNAL AND SIGNS….30
ASBESTOS DUST HAZARD PREVENTION….30
SAFETY MACHINE OPERATION….31
STARTING ENGINE….31
CHECKS BEFORE STARTING ENGINE….31
SAFETY RULES FOR STARTING ENGINE….31
SAFETY ENGINE IN COLD WEATHER….31
OPERATION….32
CHECKS BEFORE OPERATION….32
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….32
SAFETY RULES FOR TRAVELING….33
TRAVELING ON SLOPES….34
OPERATIONS ON SLOPES….35
PROHIBITED OPERATIONS….35
OPERATIONS ON SNOW….37
PARKING MACHINE….37
TRANSPORTATION….39
LOADING AND UNLOADING….39
SHIPPING THE MACHINE….39
BATTERY….40
BATTERY HAZARD PREVENTION….40
STARTING ENGINE WITH BOOSTER CABLES….41
TOWING….42
SAFETY RULES FOR TOWING….42
LIFTING OBJECTS WITH BUCKET….43
SAFETY RULES FOR LIFTING OBJECTS….43
SAFETY MAINTENANCE INFORMATION….44
WARNING TAG….44
KEEP WORK PLACE CLEAN AND TIDY….44
APPOINT LEADER WHEN WORKING WITH OTHERS….44
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….45
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….46
PROPER TOOLS….46
PERSONNEL….46
ATTACHMENTS….47
WORK UNDER THE MACHINE….47
NOISE….47
WHEN USING HAMMER….47
WELDING WORKS….47
REMOVING BATTERY TERMINALS….48
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….48
SAFETY RULES FOR HIGH-PRESSURE OIL….48
SAFETY HANDLING HIGH-PRESSURE HOSES….49
WASTE MATERIALS….49
COMPRESSED AIR….49
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….49
OPERATION….50
MACHINE VIEW ILLUSTRATIONS….51
OVERALL MACHINE VIEW….51
CONTROLS AND GAUGES….52
DETAILED CONTROLS AND GAUGES….53
METERS,LAMPS….53
SWITCHES….55
CONTROL LEVERS AND PEDALS….57
VARIABLE BLADE….64
ENGINE HOOD….64
FUSE….65
BLOCK FUSE….65
OPERATION MANUAL STORAGE….66
MACHINE OPERATIONS AND CONTROLS….67
BEFORE STARTING ENGINE….67
STARTING ENGINE….78
AFTER STARTING ENGINE….81
STOPPING THE ENGINE….84
CHECK AFTER SHUT OFF ENGINE….84
MACHINE OPERATION….85
STEERING THE MACHINE….89
SWINGING….91
WORK EQUIPMENT CONTROLS AND OPERATIONS….92
PROHIBITED OPERATIONS….94
GENERAL OPERATION INFORMATION….97
TRAVELING ON SLOPES….98
ESCAPE FROM MUD….100
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR….101
BUCKET REPLACEMENT….103
PARKING MACHINE….105
MACHINE INSPECTION AFTER DAILY WORK….106
RUBBER SHOES(MACHINE WITH RUBBER SHOES ONLY)….107
TRANSPORTATION….112
TRANSPORTATION PROCEDURE….112
LOADING AND UNLOADING WITH TRAILER….112
LIFTING MACHINE….114
SHIPPING MACHINE INFORMATION….116
COLD WEATHER OPERATION….117
COLD WEATHER OPERATION INFORMATION….117
AFTER DAILY WORK COMPLETION….119
AFTER COLD WEATHER SEASON….119
LONG TERM STORAGE….120
BEFORE STORAGE….120
DURING STORAGE….120
AFTER STORAGE….120
STARTING MACHINE AFTER LONG-TERM STORAGE….120
TROUBLES AND ACTIONS….121
RUNNING OUT OF FUEL….121
PHENOMENA THAT ARE NOT FAILURES….121
TOWING THE MACHINE….122
SEVERE JOB CONDITION….122
DISCHARGED BATTERY….123
OTHER TROUBLE….127
MAINTENANCE….131
MAINTENANCE INFORMATION….132
LUBRICANTS, COOLANT AND FILTERS….134
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….134
ELECTRIC SYSTEM MAINTENANCE….136
WEAR PARTS….137
WEAR PARTS LIST….137
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….138
PROPER SELECTION….138
TIGHTENING TORQUE SPECIFICATIONS….142
TIGHTENING TORQUE LIST….142
SAFETY CRITICAL PARTS….143
SAFETY CRITICAL PARTS LIST….143
MAINTENANCE SCHEDULE….144
MAINTENANCE SCHEDULE CHART….144
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….145
MAINTENANCE SCHEDULE….146
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….146
WHEN REQUIRED….147
CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT….147
CLEAN INSIDE OF COOLING SYSTEM….149
CHECK LEVEL OF BATTERY ELECTROLYTE….152
CHECK RUBBER SHOES….155
CHECK AND ADJUST RUBBER SHOE TENSION….157
REPLACE RUBBER SHOES….159
DRAIN WATER AND SEDIMENT FROM FUEL TANK….162
CHECKS BEFORE STARTING….163
EVERY 100 HOURS MAINTENANCE….164
LUBRICATING….164
EVERY 250 HOURS MAINTENANCE….165
LUBRICATING….165
REPLACE ENGINE OIL IN ENGINE OIL PAN….166
CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL….167
REPLACE HYDRAULIC OIL FILTER CARTRIDGE….168
CHECK AND ADJUST COOLINE FAN BELT TENSION….169
EVERY 500 HOURS MAINTENANCE….170
LUBRICATING….170
REPLACE ENGINE OIL FILTER CARTRIDGE….171
REPLACE FUEL FILTER ELEMENT….172
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS….174
REPLACE FUEL FEED PUMP PRE-FILTER….175
EVERY 1000 HOURS MAINTENANCE….176
CHANGE OIL IN FINAL DRIVE CASE….176
EVERY 2000 HOURS MAINTENANCE….177
CHANGE OIL IN HYDRAULIC TANK,CLEAN STRAINER….177
CHECK ALTERNATOR,STARTING MOTOR….178
CHECK ENGINE VALVE CLEARANCE,ADJUST….178
SPECIFICATIONS….179
SPECIFICATIONS….180
ATTACHMENTS, OPTIONS….182
ATTACHMENTS AND OPTIONS-GENERAL INFORAMTION….183
SAFETY FIRST….183
ATTACHMENT INSTALLATION….184
BUCKET WITH HOOK….185
HOOK CONDITION….185
PROHIBITED OPERATIONS….185
ATTACHMENT GUIDE….186
ATTACHMENT COMBINATIONS….186
HANDLING ARM WITH BUILT-IN BREAKER….187
BUCKET POSTURE….187
REMOVING AND INSTALLING CHISEL….187
PROCEDURE FOR BREAKER OPERATIONS….188
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS….189
STOWING CHISEL,DUMMY CHISEL….190
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS….190
HANDLING DUMMY LINK….191
CHECK BEFORE STARTING….192
SPECIFICATIONS….193
HANDLING BUCKET COUPLER….194
PROCEDURE FOR REMOVING BUCKET….194
PROCEDURE FOR INSTALLING BUCKET….196
RECOMMENDED ATTACHMENT OPERATIONS….198
HYDRAULIC BREAKER….198
INDEX….202
SEAM044502 – Hydraulic Excavator PC09-1 Operation & Maintenance Manual….205
COVER….205
FOREWARD….206
FOREWORD….207
SAFETY INFORMATION….210
INTRODUCTION….212
DIRECTIONS OF MACHINE….212
PRODUCT INFORMATION….213
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….213
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….213
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION….214
SERVICE METER LOCATION….214
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….215
CONTENTS….216
SAFETY….220
SAFETY INFORMATION….221
SAFETY LABELS….223
LOCATION OF SAFETY LABELS….223
SAFETY LABELS….224
SAFETY INFORMATION….227
SAFETY RULES….227
IF ABNORMALITIES ARE FOUND….227
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….227
FIRE EXTINGUISHER AND FIRST AID KIT….227
SAFETY EQUIPMENT….227
KEEP MACHINE CLEAN….228
OPERATOR'S SEAT EQUIPMENT….228
LEAVING OPERATOR'S SEAT WITH LOCK….228
HANDRAILS AND STEPS….229
MOUNTING AND DISMOUNTING….229
NO PERSONS ON ATTACHMENTS….229
BURN PREVENTION….230
FIRE PREVENTION AND EXPLOSION PREVENTION….231
ACTION IF FIRE OCCURS….231
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….232
ATTACHMENT INSTALLATION….232
ATTACHMENT COMBINATIONS….232
UNAUTHORIZED MODIFICATIONS….232
SAFETY AT JOBSITE….233
WORKING ON LOOSE GROUND….233
DISTANCE TO HIGH VOLTAGE CABLES….233
ENSURE GOOD VISIBILITY….234
VENTILATION FOR ENCLOSED AREA….234
SIGNALMAN'S SIGNAL AND SIGNS….234
ASBESTOS DUST HAZARD PREVENTION….234
SAFETY MACHINE OPERATION….235
STARTING ENGINE….235
CHECKS BEFORE STARTING ENGINE….235
SAFETY RULES FOR STARTING ENGINE….235
STARTING ENGINE IN COLD WEATHER….235
OPERATION….236
CHECKS BEFORE OPERATION….236
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….236
SAFETY RULES FOR TRAVELING….237
TRAVELING ON SLOPES….238
OPERATIONS ON SLOPES ….239
PROHIBITED OPERATIONS….239
OPERATIONS ON SNOW….241
PARKING MACHINE….241
TRANSPORTATION….243
LOADING AND UNLOADING….243
SHIPPING THE MACHINE….243
BATTERY….244
BATTERY HAZARD PREVENTION….244
STARTING ENGINE WITH BOOSTER CABLES….245
TOWING….246
SAFETY RULES FOR TOWING….246
LIFTING OBJECTS WITH BUCKET….247
SAFETY RULES FOR LIFTING OBJECTS….247
SAFETY MAINTENANCE INFORMATION….248
WARNING TAG….248
KEEP WORK PLACE CLEAN AND TIDY….248
APPOINT LEADER WHEN WORKING WITH OTHERS….248
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….249
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….250
PROPER TOOLS….250
PERSONNEL….250
ATTACHMENTS….251
WORK UNDER THE MACHINE….251
NOISE….251
WHEN USING HAMMER….251
WELDING WORKS….251
REMOVING BATTERY TERMINALS….252
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….252
SAFETY RULES FOR HIGH-PRESSURE OIL….252
SAFETY HANDLING HIGH-PRESSURE HOSES….253
WASTE MATERIALS….253
COMPRESSED AIR….253
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….253
OPERATION….254
MACHINE VIEW ILLUSTRATIONS….255
OVERALL MACHINE VIEW….255
CONTROLS AND GAUGES….256
DETAILED CONTROLS AND GAUGES….257
METERS,LAMPS….257
SWITCHES….259
CONTROL LEVERS AND PEDALS….261
VARIABLE BLADE….268
ENGINE HOOD….268
FUSE….269
BLOCK FUSE….269
OPERATION MANUAL STORAGE….270
MACHINE OPERATIONS AND CONTROLS….271
BEFORE STARTING ENGINE….271
STARTING ENGINE….282
AFTER STARTING ENGINE….285
STOPPING THE ENGINE….288
CHECK AFTER SHUT OFF ENGINE….288
MACHINE OPERATION….289
STEERING THE MACHINE….293
SWINGING….295
WORK EQUIPMENT CONTROLS AND OPERATIONS….296
PROHIBITED OPERATIONS….298
GENERAL OPERATION INFORMATION….301
TRAVELING ON SLOPES….302
ESCAPE FROM MUD….304
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR….305
BUCKET REPLACEMENT….307
PARKING MACHINE….309
MACHINE INSPECTION AFTER DAILY WORK….310
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)….311
TRANSPORTATION….316
TRANSPORTATION PROCEDURE….316
LOADING AND UNLOADING WITH TRAILER….316
LIFTING MACHINE….318
SHIPPING MACHINE INFORMATION….320
COLD WEATHER OPERATION….321
COLD WEATHER OPERATION INFORMATION….321
AFTER DAILY WORK COMPLETION….323
AFTER COLD WEATHER SEASON….323
LONG TERM STORAGE….324
BEFORE STORAGE….324
DURING STORAGE….324
AFTER STORAGE….324
STARTING MACHINE AFTER LONG-TERM STORAGE….324
TROUBLES AND ACTIONS….325
RUNNING OUT OF FUEL….325
PHENOMENA THAT ARE NOT FAILURES….325
TOWING THE MACHINE….326
SEVERE JOB CONDITION….326
DISCHARGED BATTERY….327
OTHER TROUBLE….331
MAINTENANCE….336
MAINTENANCE INFORMATION….337
LUBRICANTS, COOLANT AND FILTERS….339
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….339
ELECTRIC SYSTEM MAINTENANCE….341
WEAR PARTS….342
WEAR PARTS LIST….342
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….343
PROPER SELECTION….343
TIGHTENING TORQUE SPECIFICATIONS….347
TIGHTENING TORQUE LIST….347
SAFETY CRITICAL PARTS….348
SAFETY CRITICAL PARTS LIST….348
MAINTENANCE SCHEDULE….349
MAINTENANCE SCHEDULE CHART….349
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….350
MAINTENANCE PROCEDURE….351
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….351
REPLACE FUEL FILTER ELEMENT….376
REPLACE ENGINE OIL FILTER CARTRIDGE….375
CHECK ENGINE VALVE CLEARANCE, ADJUST….382
WHEN REQUIRED….352
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….352
CLEAN INSIDE OF COOLING SYSTEM….354
CHECK LEVEL OF BATTERY ELECTROLYTE….357
CHECK RUBBER SHOES….360
CHECK AND ADJUST RUBBER SHOE TENSION….362
REPLACE RUBBER SHOES….364
DRAIN WATER AND SEDIMENT FROM FUEL TANK….366
CHECK BEFORE STARTING….367
EVERY 100 HOURS MAINTENANCE….368
LUBRICATING….368
EVERY 250 HOURS MAINTENANCE….369
LUBRICATING….369
REPLACE ENGINE OIL IN ENGINE OIL PAN….370
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….371
REPLACE HYDRAULIC OIL FILTER CARTRIDGE….372
CHECK AND ADJUST COOLING FAN BELT TENSION….373
EVERY 500 HOURS MAINTENANCE….374
LUBRICATING….374
REPLACE ENGINE OIL FILTER CARTRIDGE….375
REPLACE FUEL FILTER ELEMENT….376
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS….378
REPLACE FUEL FEED PUMP PRE-FILTER….379
EVERY 1000 HOURS MAINTENANCE….380
CHANGE OIL IN FINAL DRIVE CASE….380
EVERY 2000 HOURS MAINTENANCE….381
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….381
CHECK ALTERNATOR, STARTING MOTOR….382
CHECK ENGINE VALVE CLEARANCE, ADJUST….382
SPECIFICATIONS….384
SPECIFICATIONS….385
ATTACHMENTS, OPTIONS….388
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….389
SAFETY FIRST….389
ATTACHMENT INSTALLATION….390
BUCKET WITH HOOK….391
HOOK CONDITION….391
PROHIBITED OPERATIONS….391
ATTACHMENT GUIDE….392
ATTACHMENT COMBINATIONS….392
HANDLING ARM WITH BUILT-IN BREAKER….393
BUCKET POSTURE….393
REMOVING AND INSTALLING CHISEL….393
PROCEDURE FOR BREAKER OPERATIONS….394
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS….395
STOWING CHISEL, DUMMY CHISEL….396
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS….396
HANDLING DUMMY LINK….397
CHECK BEFORE STARTING….398
SPECIFICATIONS….399
HANDLING BUCKET COUPLER….400
PROCEDURE FOR REMOVING BUCKET….400
PROCEDURE FOR INSTALLING BUCKET….402
RECOMMENDED ATTACHMENT OPERATIONS….404
HYDRAULIC BREAKER….404
INDEX….408
SEBM026105 – Hydraulic Excavator PC09-1 Shop Manual….412
COVER….412
CONTENTS….413
01 GENERAL….436
GENERAL ASSEMBLY DRAWING….437
SPECIFICATIONS….438
WEIGHT TABLE….444
LIST OF LUBRICANT AND WATER….446
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD….447
RADIATOR….448
ENGINE CONTROL….450
PTO….452
POWER TRAIN DIAGRAM….453
SWING CIRCLE….454
TRACK FRAME….455
IDLER CUSHION….457
IDLER….458
TRACK ROLLER….459
TRACK SHOE….460
HYDRAULIC EQUIPMENT LAYOUT….461
VALVE CONTROL….462
HYDRAULIC TANK….463
HYDRAULIC PUMP….464
10-SPOOL CONTROL VALVE….466
CENTER SWIVEL JOINT….468
SWING MOTOR….469
TRAVEL MOTOR….470
HYDRAULIC CYLINDER….476
WORK EQUIPMENT….478
DIMENSION OF WORK EQUIPMENT….480
MACHINE MONITOR SYSTEM….484
20 TESTING AND ADJUSTING….486
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS….487
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS….489
TESTING AND ADJUSTING….497
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING….498
MEASUREMENT ENGINE SPEED….499
MASURING EXHAUST COLOR….501
ADJUSTMENT VALVE CLEARANCE….503
MEASURING COMPRESSION PRESSURE….504
MEASURING ENGINE OIL PRESSURE….505
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING….506
ADJUSTMENT OF FUEL CONTROL CABLE….508
BLEEDING AIR FROM FUEL CIRCUIT….510
TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION….511
TESTING AND ADJUSTING TRACK SHOE TENSION….512
INSPECTION AND ADJUSTMENT OF HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUITS….513
IDENTIFICATION OF SPOT CAUSING WORK EQUIPMENT HYDRAULIC DRIFT….516
MEASUREMENT OF OIL LEAK AMOUNT INSIDE WORK EQUIPMENT CYLINDER….517
BLEEDING AIR FROM HYDRAULIC CIRCUITS….517
PRESSURIZING HYDRAULIC TANK….518
TROUBLESHOOTING….519
POINTS TO REMEMBER WHEN TROUBLESHOOTING….520
SEQUENCE OF EVENTS IN TROUBLESHOOTING….521
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ….522
CHECKS BEFORE TROUBLESHOOTING….530
METHOD OF USING TROUBLESHOOTING….531
CONNECTOR MOUNTING LOCATIONS AND ELECTRICAL CIRCUITS….532
CONNECTOR PIN ALLOCATION DRAWING….533
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE START, STOP, PREHEATING AND CHARGING SYSTEMS (E CIRCUIT)….535
ELECTRICAL CIRCUIT DIAGRAM FOR PANEL SYSTEMS (P CIRCUIT)….536
CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS….537
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)….539
INFORMATION IN TROUBLESHOOTING TABLE….540
E-1 ENGINE DOES NOT START….541
E-2 ENGINE DOES NOT STOP….545
E-3 ENGINE OIL PRESSURE LAMP DOES NOT WORK PROPERLY….546
E-4 ENGINE COOLING WATER TEMPERATURE LAMP DOES NOT WORK PROPERLY….548
E-5 ENGINE PREHEATING SYSTEM DOES NOT WORK….550
E-6 SERVICE METER DOES NOT ADVANCE….552
E-7 HORN DOES NOT SOUND, OR DOES NOT STOP SOUNDING….553
E-8 WORKING LAMP DOES NOT LIGHT UP, OR DOES NOT GO OFF….555
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H-MODE)….557
METHOD OF USING TROUBLESHOOTING CHARTS….558
H-1 ALL WORK EQUIPMENT, TRAVEL AND SWING SHOW SLOW SPEED OR LACK IN POWER….560
H-2 ENGINE RUNNING SPEED DROPS SHARPLY OR ENGINE STAALS.MOREOVER, ALL WORK EQUIPMENT, TRAVEL AND SWING DO NOT MOVE AT ALL OR MOVE EXTREMELY SLOWLY…..560
H-3 THERE IS NOISE FROM AROUND HYDRAULIC PUMP….561
H-4 CONTROL LEVERS AND PEDALS ARE HARD TO OPERATE….561
H-5 BOOM MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT….562
H-6 ARM MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT….562
H-7 BUCKET MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT….563
H-8 SWING IS SLOW, LACKS IN POWER AND HAS BIG HYDRAULIC DRIFT….563
H-9 BLADE MOVES SLOWLY, LACKS IN POWER, HAS LONG TIME LAG AND BIG HYDRAULIC DRIFT….563
H-10 MACHINE DEVIATES FROM TRAVEL PATH IN TRAVELING….564
a) THE MACHINE DEVIATES IN THE SAME DIRECTION BOTH IN FORWARD AND IN REVERSE DIRECTIONS ….564
b) THE DEVIATION DIRECTION CHANGES DEPENDING ON FORWARD OR REVERSE TRAVEL….564
H-11 NO POWER OR SLOW IN TRAVELING….566
H-12 UNDERCARRIAGE DOES NOT MOVE (ONE SIDE ONLY)….566
H-13 TRAVEL SPEED CANNOT BE CHANGED….567
H-14 UPPER STRUCTURE DOES NOT SWING….567
H-15 SWING SPEED IS SLOW OR ACCELERATION IS POOR….568
H-16 OVERRUN WHEN STOPPING WING IS BIG….568
H-17 THERE IS BIG SHOCK WHEN STOPPING SWING….569
H-18 THERE IS BIG NOISE WHEN STOPPING SWING….569
H-19 HYDRAULIC DRIFT OF SWING IS BIG….570
H-20 TROUBLESHOOTING OF HYDRAULIC BREAKER….571
30 DISASSEMBLY AND ASSEMBLY….572
METHOD OF USING MANUAL….573
PRECAUTIONS WHEN CARRYING OUT OPERATION….574
SPECIAL TOOL LIST….576
SWING MOTOR….577
REMOVAL AND INSTALLATION….577
CENTER SWIVEL JOINT….578
REMOVAL AND INSTALLATION….577
DISASSEMBLY AND ASSEMBLY….579
ENGINE AND HYDRAULIC PUMP….580
REMOVAL….580
INSTALLATION….583
REVOLVING FRAME….584
REMOVAL ….584
INSTALLATION….585
SWING CIRCLE….586
REMOVAL AND INSTALLATION….586
IDLER….587
ASSEMBLY….587
TRACK ROLLER….588
ASSEMBLY….588
RUBBER SHOE….588
REMOVAL AND INSTALLATION….588
CONTROL VALVE….589
ASSEMBLY….589
HYDRAULIC CYLINDER….590
ASSEMBLY….590
HYDRAULIC BREAKER….593
DISASSEMBLY….594
ASSEMBLY….597
90 OTHERS….601
HYDRAULIC CIRCUIT DIAGRAM….602
FIXED GAUGE TYPE (STD)….602
VARIABLE GAUGE TYPE (IF EQUIPPED)….603
ELECTRICAL CIRCUIT DIAGRAM….604
STANDERD SPECIFICATION….604
TRAVEL ALREM SPECIFICATION (IF EQUIPPED)….605
TEN00062-04 – Hydraulic Excavator PC09-1 Operation & Maintenance Manual….606
COVER….606
FOREWORD….607
FOREWORD….608
SAFETY INFORMATION….611
INTRODUCTION….613
DIRECTIONS OF MACHINE….613
PRODUCT INFORMATION….614
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….614
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….614
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION….615
SERVICE METER LOCATION….615
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….616
CONTENTS….617
SAFETY….621
SAFETY….622
SAFETY LABELS….624
LOCATION OF SAFETY LABELS….624
SAFETY LABELS….625
GENERAL PRECAUTIONS….628
SAFETY MACHINE OPERATION….636
STARTING ENGINE….636
OPERATION….637
TRANSPORTATION….644
BATTERY….645
TOWING….647
LIFTING OBJECTS WITH BUCKET….648
SAFETY MAINTENANCE INFORMATION….649
OPERATION….655
MACHINE VIEW ILLUSTRATIONS….656
OVERALL MACHINE VIEW….656
CONTROLS AND GAUGES….657
DETAILED CONTROLS AND GAUGES….658
METERS, LAMPS….658
SWITCHES….660
CONTROL LEVERS AND PEDALS….662
VARIABLE BLADE….669
ENGINE HOOD….669
FUSE….670
BLOCK FUSE….670
OPERATION MANUAL STORAGE….671
MACHINE OPERATIONS AND CONTROLS….672
BEFORE STARTING ENGINE….672
STARTING ENGINE….683
AFTER STARTING ENGINE….686
STOPPING THE ENGINE….689
CHECK AFTER SHUT OFF ENGINE….689
MACHINE OPERATION….690
STEERING THE MACHINE….694
SWINGING….696
WORK EQUIPMENT CONTROLS AND OPERATIONS….697
PROHIBITED OPERATIONS….699
GENERAL OPERATION INFORMATION….702
TRAVELING ON SLOPES….703
ESCAPE FROM MUD….705
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR….706
BUCKET REPLACEMENT….708
PARKING MACHINE….710
MACHINE INSPECTION AFTER DAILY WORK….711
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)….712
TRANSPORTATION….717
TRANSPORTATION PROCEDURE….717
LOADING AND UNLOADING WITH TRAILER….717
LIFTING MACHINE….719
SHIPPING MACHINE INFORMATION….721
COLD WEATHER OPERATION….722
COLD WEATHER OPERATION INFORMATION….722
AFTER DAILY WORK COMPLETION….724
AFTER COLD WEATHER SEASON….724
LONG TERM STORAGE….725
BEFORE STORAGE….725
DURING STORAGE….725
AFTER STORAGE….725
STARTING MACHINE AFTER LONG-TERM STORAGE….725
TROUBLES AND ACTIONS….726
RUNNING OUT OF FUEL….726
PHENOMENA THAT ARE NOT FAILURES….726
TOWING THE MACHINE….727
SEVERE JOB CONDITION….727
DISCHARGED BATTERY….728
OTHER TROUBLE….732
MAINTENANCE….737
MAINTENANCE INFORMATION….738
OUTLINE OF SERVICE….740
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….740
ELECTRIC SYSTEM MAINTENANCE….743
WEAR PARTS….744
WEAR PARTS LIST….744
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….745
PROPER SELECTION….745
TIGHTENING TORQUE SPECIFICATIONS….749
TIGHTENING TORQUE LIST….749
SAFETY CRITICAL PARTS….750
SAFETY CRITICAL PARTS LIST….750
MAINTENANCE SCHEDULE….751
MAINTENANCE SCHEDULE CHART….751
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….752
MAINTENANCE PROCEDURE….753
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….753
WHEN REQUIRED….754
CHECK BEFORE STARTING….769
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE….769
EVERY 100 HOURS MAINTENANCE….770
EVERY 250 HOURS MAINTENANCE….771
EVERY 500 HOURS MAINTENANCE….776
EVERY 1000 HOURS MAINTENANCE….783
EVERY 2000 HOURS MAINTENANCE….784
SPECIFICATIONS….787
SPECIFICATIONS….788
ATTACHMENTS, OPTIONS….791
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….792
SAFETY FIRST….792
ATTACHMENT INSTALLATION….793
BUCKET WITH HOOK….794
HOOK CONDITION….794
PROHIBITED OPERATIONS….794
ATTACHMENT GUIDE….795
ATTACHMENT COMBINATIONS….795
HANDLING ARM WITH BUILT-IN BREAKER….796
BUCKET POSTURE….796
REMOVING AND INSTALLING CHISEL….796
PROCEDURE FOR BREAKER OPERATIONS….797
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS….798
STOWING CHISEL, DUMMY CHISEL….799
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS….799
HANDLING DUMMY LINK….800
CHECK BEFORE STARTING….801
SPECIFICATIONS….802
HANDLING BUCKET COUPLER….803
PROCEDURE FOR REMOVING BUCKET….803
PROCEDURE FOR INSTALLING BUCKET….805
HANDLING FOLDING TOPS CANOPY….807
RECOMMENDED ATTACHMENT OPERATIONS….809
HYDRAULIC BREAKER….809
INDEX….813
TEN00555-00 – Hydraulic Excavator PC09-1 Operation & Maintenance Manual….817
COVER….817
FOREWORD….818
FOREWORD….819
SAFETY INFORMATION….822
INTRODUCTION….824
DIRECTIONS OF MACHINE….824
PRODUCT INFORMATION….825
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….825
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….825
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION….826
SERVICE METER LOCATION….826
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….827
CONTENTS….828
SAFETY….832
SAFETY….833
SAFETY LABELS….835
LOCATION OF SAFETY LABELS….835
SAFETY LABELS….836
GENERAL PRECAUTIONS….839
SAFETY MACHINE OPERATION….847
STARTING ENGINE….847
OPERATION….848
TRANSPORTATION….855
BATTERY….856
TOWING….858
LIFTING OBJECTS WITH BUCKET….859
SAFETY MAINTENANCE INFORMATION….860
OPERATION….866
MACHINE VIEW ILLUSTRATIONS….867
OVERALL MACHINE VIEW….867
CONTROLS AND GAUGES….868
DETAILED CONTROLS AND GAUGES….869
METERS, LAMPS….869
SWITCHES….871
CONTROL LEVERS AND PEDALS….873
VARIABLE BLADE….880
ENGINE HOOD….880
FUSE….881
BLOCK FUSE….881
OPERATION MANUAL STORAGE….882
MACHINE OPERATIONS AND CONTROLS….883
BEFORE STARTING ENGINE….883
STARTING ENGINE….894
AFTER STARTING ENGINE….897
STOPPING THE ENGINE….900
CHECK AFTER SHUT OFF ENGINE….900
MACHINE OPERATION….901
STEERING THE MACHINE….905
SWINGING….907
WORK EQUIPMENT CONTROLS AND OPERATIONS….908
PROHIBITED OPERATIONS….910
GENERAL OPERATION INFORMATION….913
TRAVELING ON SLOPES….914
ESCAPE FROM MUD….916
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR….917
BUCKET REPLACEMENT….919
PARKING MACHINE….921
MACHINE INSPECTION AFTER DAILY WORK….922
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)….923
TRANSPORTATION….928
TRANSPORTATION PROCEDURE….928
LOADING AND UNLOADING WITH TRAILER….928
LIFTING MACHINE….930
SHIPPING MACHINE INFORMATION….932
COLD WEATHER OPERATION….933
COLD WEATHER OPERATION INFORMATION….933
AFTER DAILY WORK COMPLETION….935
AFTER COLD WEATHER SEASON….935
LONG TERM STORAGE….936
BEFORE STORAGE….936
DURING STORAGE….936
AFTER STORAGE….936
STARTING MACHINE AFTER LONG-TERM STORAGE….936
TROUBLES AND ACTIONS….937
RUNNING OUT OF FUEL….937
PHENOMENA THAT ARE NOT FAILURES….937
TOWING THE MACHINE….938
SEVERE JOB CONDITION….938
DISCHARGED BATTERY….939
OTHER TROUBLE….943
MAINTENANCE….948
MAINTENANCE INFORMATION….949
OUTLINE OF SERVICE….951
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….951
ELECTRIC SYSTEM MAINTENANCE….954
WEAR PARTS….955
WEAR PARTS LIST….955
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….956
PROPER SELECTION….956
TIGHTENING TORQUE SPECIFICATIONS….960
TIGHTENING TORQUE LIST….960
SAFETY CRITICAL PARTS….961
SAFETY CRITICAL PARTS LIST….961
MAINTENANCE SCHEDULE….962
MAINTENANCE SCHEDULE CHART….962
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….963
MAINTENANCE PROCEDURE….964
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….964
WHEN REQUIRED….965
CHECK BEFORE STARTING….980
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE….980
EVERY 100 HOURS MAINTENANCE….981
EVERY 250 HOURS MAINTENANCE….982
EVERY 500 HOURS MAINTENANCE….987
EVERY 1000 HOURS MAINTENANCE….994
EVERY 2000 HOURS MAINTENANCE….995
SPECIFICATIONS….998
SPECIFICATIONS….999
ATTACHMENTS, OPTIONS….1002
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….1003
SAFETY FIRST….1003
ATTACHMENT INSTALLATION….1004
BUCKET WITH HOOK….1005
HOOK CONDITION….1005
PROHIBITED OPERATIONS….1005
ATTACHMENT GUIDE….1006
ATTACHMENT COMBINATIONS….1006
HANDLING ARM WITH BUILT-IN BREAKER….1007
BUCKET POSTURE….1007
REMOVING AND INSTALLING CHISEL….1007
PROCEDURE FOR BREAKER OPERATIONS….1008
PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS….1009
STOWING CHISEL, DUMMY CHISEL….1010
PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS….1010
HANDLING DUMMY LINK….1011
CHECK BEFORE STARTING….1012
SPECIFICATIONS….1013
HANDLING BUCKET COUPLER….1014
PROCEDURE FOR REMOVING BUCKET….1014
PROCEDURE FOR INSTALLING BUCKET….1016
HANDLING FOLDING TOPS CANOPY….1018
RECOMMENDED ATTACHMENT OPERATIONS….1020
HYDRAULIC BREAKER….1020
INDEX….1024

Komatsu Hydraulic Excavator PC09 Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Excavator PC05, PC07, PC10, PC10, PC15, 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

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