Komatsu Hydraulic Excavator PC15R-8 Operation & Maintenance Manual SN F21803 and up – PDF DOWNLOAD

Description

Komatsu Hydraulic Excavator PC15R-8 Operation & Maintenance Manual

DESCRIPTION:

Komatsu Hydraulic Excavator PC15R-8 Operation & Maintenance Manual 

FOREWORD:

• This manual is supplied by Komatsu in order to provide customers with all the necessary information on the machine and the safety regulations related to it, together with the use and maintenance instructions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over time.
• The operation manual, together with the spare parts catalog, is an integral part of the machine and must accompany it, even when it is resold, until its final disposal.
• The manual must be handled with the greatest care and always kept on board the machine, so that it can be consulted at any moment; it must be placed in the appropriate compartment, where also the ownership documents and the logbook are usually kept.
• This manual must be given to the persons who have to use the machine and carry out the routine maintenance operations; they must read the contents carefully more than once, in such a way as to clearly understand what are the correct operating conditions and the dangerous conditions that must be avoided. In case of loss or damage, request a new copy to Komatsu or to your Komatsu Distributor.
• The illustrations contained in this manual may represent machine configurations that are available on request. Komatsu machines are constantly improved in order to increase their efficiency and reliability; this manual sums up all the information regarding the most recent techniques applied at the moment in which the machine is marketed. For any updated information, contact your Komatsu Distributor.
• Punctual periodic annotations regarding the maintenance operations that have been carried out are important to have a clear prospect of the situation and to know exactly what has been done and what has to be done after the next maintenance interval. Therefore, it is advisable to consult either the hour meter and the maintenance plan frequently.
• Over the years Komatsu Distributors have gathered considerable experience in customer service. If more information is needed, do not hesitate to contact your Komatsu Distributor: he always knows how to get the best performance from the machine, he can suggest the use of the equipment that is most suitable for specific needs and can provide the technical assistance necessary for any change that may be required to conform the machine to the safety standards and traffic rules. Furthermore, Komatsu Distributors also ensure their assistance for the supply of Komatsu genuine spare parts, which alone guarantee safety and interchangeability.
• The table included in this manual must be filled in with the machine data, which are the data that must always be indicated to the Dsrtibutor when requiring assistance and ordering spare parts.

KOMATSU HYDRAULIC EXCAVATOR PC15R-8 OPERATION & MAINTENANCE MANUAL SN F21803 AND UP – PDF DOWNLOAD:

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TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC15R-8 Operation & Maintenance Manual 

MAIN MENU........................................................................................  0
COVER............................................................................................  1
CONTENTS......................................................................................... 11
	1.1 FOREW0RD.................................................................................  2
	1.2 INFORMATION ON SAFETY....................................................................  3
	1.3 INTRODUCTION.............................................................................  5
		1.3.1 INTENDED USES......................................................................  5
		1.3.2 IMPROPER OR UNAUTHORIZED USES......................................................  5
		1.3.3 MAIN CHARACTERISTICS...............................................................  6
		1.3.4 RUNNING-IN.........................................................................  6
	1.4 PRODUCT IDENTIFICATION...................................................................  7
		1.4.1 MACHINE SERIAL NUMBER..............................................................  7
		1.4.2 MACHINE IDENTIFICATION PLATE.......................................................  7
		1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL............................................  8
		1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER................................................  8
		1.4.5 SWING REDUCTION GEAR SERIAL NUMBER.................................................  8
		1.4.6 CAB SERIAL NUMBER..................................................................  9
		1.4.7 SERIAL NUMBERS AND DEALER'S ADDRESS................................................ 10
SAFETY AND ACCIDENT PREVENTION................................................................... 18
	2.1 SAFETY PLATES............................................................................ 19
		2.1.1 POSITION OF THE SAFETY PLATES...................................................... 19
		2.1.2 POSITION OF THE PICTOGRAMS......................................................... 34
		2.1.3 PICTOGRAMS AND RELEVANT MEANINGS................................................... 36
		2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...................................... 38
	2.2 GENERAL PRECAUTIONS...................................................................... 39
		2.2.1 GENERAL SAFETY RULES............................................................... 39
		2.2.2 SAFETY DEVICES AND GUARDS.......................................................... 39
		2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS............................................. 39
		2.2.4 UNAUTHORIZED MODIFICATIONS......................................................... 40
		2.2.5 LEAVING THE OPERATOR'S SEAT........................................................ 40
		2.2.6 GETTING ON AND OFF THE MACHINE .................................................... 41
		2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL............................................... 41
		2.2.8 PREVENTING BURNS................................................................... 42
		2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWER............................................ 42
		2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT.................................... 42
		2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT.............................................. 43
		2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE.......................................... 43
		2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT.............................................. 43
	2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....................................... 44
		2.3.1 SAFETY ON THE WORK SITE............................................................ 44
		2.3.2 FIRE PREVENTION.................................................................... 44
		2.3.3 PRECAUTIONS TO BE TAKEN  FOR THE OPERATOR'S CAB.................................... 44
		2.3.4 ROOM VENTILATION................................................................... 45
		2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS............................................. 45
		2.3.6 CLEANING THE WINDOWS - CHECKING THE WINDSHIELD WIPER BLADES........................ 45
	2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING..................................................... 46
		2.4.1 STARTING THE ENGINE................................................................ 46
		2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE.................................... 46
		2.4.3 CHECKS FOR TRAVELING IN REVERSE.................................................... 46
		2.4.4 MOVING THE MACHINE................................................................. 47
		2.4.5 MOVING THE SLOPES.................................................................. 48
		2.4.6 WORKING THE SLOPES................................................................. 49
		2.4.7 UNAUTHORIZED OPERATIONS............................................................ 49
		2.4.8 PREVENTING ELECTROCUTION........................................................... 50
		2.4.9 VISIBILITY......................................................................... 51
		2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES........................................... 51
		2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT.................................... 51
		2.4.12 WORKING ON LOOSE GROUND........................................................... 51
		2.4.13 PARKING THE MACHINE............................................................... 52
	2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES............................................... 53
		2.5.1 LOADING AND UNLOADING.............................................................. 53
		2.5.2 TRANSPORT.......................................................................... 53
	2.6 BATTERY.................................................................................. 54
		2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY.................................... 54
		2.6.2 STARTING WITH BOOSTER CABLES....................................................... 54
	2.7 PRECAUTIONS FOR EMERGENCY RECOVERY....................................................... 55
	2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE............................................... 56
		2.8.1 WARNING PLATES..................................................................... 56
		2.8.2 TOOLS.............................................................................. 56
		2.8.3 PERSONNEL.......................................................................... 57
		2.8.4 EQUIPMENT.......................................................................... 57
		2.8.5 WORKING UNDER THE MACHINE.......................................................... 57
		2.8.6 CLEANING THE MACHINE............................................................... 57
		2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS.................................... 58
		2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY........................ 58
		2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION........ 58
		2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP................................ 59
		2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR........................................ 59
		2.8.12 USING LAMPS....................................................................... 59
		2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR............................. 60
		2.8.14 PRECAUTIONS CONCERNING THE STARTER................................................ 60
		2.8.15 HANDLING HIGH-PRESSURE PIPES...................................................... 61
		2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH PRESSURE OIL........................... 61
		2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE..... 61
		2.8.18 COOLING FAN AND BELT.............................................................. 62
		2.8.19 WASTE MATERIALS................................................................... 62
THE MACHINE AND ITS OPERATIONS................................................................... 64
	3.1 SAFETY LOCKS............................................................................. 65
		3.1.1 MACHINE LOCKS...................................................................... 65
	3.2 GENERAL VIEWS............................................................................ 66
		3.2.1 GENERAL VIEW OF THE MACHINE WITH CAB (OPTIONAL).................................... 66
		3.2.2 GENERAL VIEW OF THE MACHINE WITH CANOPY............................................ 67
		3.2.3 GENERAL VIEW OF THE DRIVER'S SEAT.................................................. 68
	3.3. INSTRUMENTS AND CONTROLS................................................................ 69
		3.3.1 INSTRUMENTS........................................................................ 69
		3.3.2 WARNINGS LIGHTS.................................................................... 70
		3.3.3 SWITCHES AND PUSH BUTTONS.......................................................... 72
		3.3.4 ELECTRICAL ACCESSORIES............................................................. 75
		3.3.5 MACHINE CONTROLS................................................................... 77
	3.4 FUSES AND RELAYS......................................................................... 86
		3.4.1 FUSES.............................................................................. 86
		3.4.2 RELAYS............................................................................. 87
	3.5 GUARDS AND DRIVER'S SEAT................................................................. 88
		3.5.1 ENGINE HOOD........................................................................ 88
		3.5.2 CANOPY............................................................................. 89
		3.5.3 CAB (OPTIONAL)..................................................................... 89
			3.5.3.1 SLIDING DOOR................................................................. 90
			3.5.3.2 FRONT OPENING WINDSHEILD..................................................... 91
			3.5.3.3 FRONT WINDSHEILD (LOWER PART)................................................ 92
			3.5.3.4 SIDE OPENING WINDOW.......................................................... 93
		3.5.4 VENTILATION AND HEATING (ONLY ON MACHINES WITH CAB)................................ 94
		3.5.5 SEAT............................................................................... 94
		3.5.6 SAFETY BELT........................................................................ 95
		3.5.7 EMERGENCY EXIT (ONLY ON MACHINES WITH CAB)......................................... 95
		3.5.8 TECHNICAL DOCUMENTATION CASE....................................................... 96
		3.5.9 FIRE EXTINGUISHER.................................................................. 96
		3.5.10 FIRST AID KIT..................................................................... 96
	3.6 USE OF THE MACHINE....................................................................... 98
		3.6.1 CHECKS BEFORE STARTING THE ENGINE.................................................. 98
			3.6.1.1 VISUAL CHECKS................................................................ 98
			3.6.1.2 DAILY CHECKS................................................................. 98
			3.6.1.3 OPERATIONAL CHECKS........................................................... 99
		3.6.2 STARTING THE ENGINE................................................................100
			3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...........................100
			3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES................................101
		3.6.3 WARMING THE ENGINE.................................................................102
		3.6.4 HEATING THE HYDRAULIC OIL..........................................................102
		3.6.5 HOW TO MOVE THE MACHINE............................................................102
			3.6.5.1 STEERING (CHANGING DIRECTION)................................................104
			3.6.5.2 MOVING ON SLOPES.............................................................105
			3.6.5.3 MAXIMUM IMMERSION DEPTH......................................................106
	3.7 PARKING THE MACHINE......................................................................107
		3.7.1 PARKING ON LEVEL GROUND............................................................107
		3.7.2 PARKING ON SLOPES..................................................................108
	3.8 STOPPING THE ENGINE......................................................................109
	3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES...............................................110
		3.9.1 LOADING AND UNLOADING THE MACHINE..................................................110
		3.9.2 TRANSPORT..........................................................................111
	3.10 LIFTING THE MACHINE.....................................................................112
	3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON..............................................113
		3.11.1 FUEL AND LUBRICANTS...............................................................113
		3.11.2 COOLANT...........................................................................113
		3.11.3 BATTERY...........................................................................113
		3.11.4 OTHER PRECAUTIONS.................................................................114
		3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF THE END OF WORK.............................114
	3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON..............................................115
	3.13 USING THE WORK EQUIPMENT................................................................116
		3.13.1 ORGANIZING THE WORK AREA..........................................................116
		3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS....................................117
		3.13.3 DIGGING METHOD....................................................................118
		3.13.4 CHANING THE BUCKET................................................................119
	3.14 USING THE MACHINE WITH VARIABLE TRACK GAUGE.............................................120
		3.14.1 HOW TO SEE THE VARIABLE TRACK GAUGE...............................................120
		3.14.2 ADJUSTING THE BLADE...............................................................121
	3.15 LONG PERIODS OF INACTIVITY..............................................................122
		3.15.1 BEFORE THE PERIOD OF INACTIVITY...................................................122
		3.15.2 DURING THE PERIOD OF INACTIVITY...................................................123
		3.15.3 AFTER THE PERIOD OF INACTIVITY....................................................123
	3.16 TROUBLESHOOTING.........................................................................124
		3.16.1 OCCURRENCES THAT ARE NOT FAILURES.................................................124
		3.16.2 HOW TO REMOVE THE MACHINE.........................................................124
		3.16.3 AFTER THE FUEL HAS RUN OUT........................................................125
		3.16.4 IF THE BATTERY IS DOWN............................................................125
			3.16.4.1 STARTING WITH BOOSTER CABLES................................................126
		3.16.5 OTHER TROUBLES....................................................................127
			3.16.5.1 ELECTRICAL CIRCUT...........................................................127
			3.16.5.2 HYDRAULIC SYSTEM............................................................127
			3.16.5.3 ENGINE......................................................................128
MAINTENANCE......................................................................................130
	4.1 GUIDE TO MAINTENANCE.....................................................................131
	4.2 MAINTENANCE NOTES........................................................................133
		4.2.1 NOTES REGARDING THE ENGINE.........................................................133
			4.2.1.1  ENGINE OIL..................................................................133
			4.2.1.2 COOLANT......................................................................133
			4.2.1.3 FUEL.........................................................................134
		4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM...............................................134
		4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM..............................................135
		4.2.4 NOTES REGARDING LUBRICATION........................................................135
		4.2.5 PARTS SUJECT TO WEAR THAT PERIODICALLY NEED CHANGING...............................136
	4.3 FUEL, COOLANT AND LUBRICANTS.............................................................137
	4.4 NUT AND BOLT TIGHTEN TOU.................................................................141
		4.4.1 STANDARD TIGHTENING TORQUES........................................................141
		4.4.2 SPECIFIC TIGHTENING TORQUES........................................................141
	4.5 LUBRICATION..............................................................................142
		4.5.1 LUBRICATION DIAGRAM................................................................142
		4.5.2 LUBRICATION DIAGRAM (VARIABLE TRACK GAUGE).........................................143
	4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY................................144
		4.6.1 CRITICAL PARTS FOR SAFETY..........................................................145
	4.7 MAINTENANCE PLAN.........................................................................147
		4.7.1 WHEN REQUIRED......................................................................150
			4.7.1.A WASHING THE COOLING CIRCUIT..................................................150
			4.7.1.B DRAINING THE FUEL TANK.......................................................151
			4.7.1.C CHECKING THE ELECTRICAL SYSTEM...............................................151
			4.7.1.D CHECKING THE STEEL TRACK TENSION.............................................152
			4.7.1.E CHECKING THE RUBBER TRACKS...................................................154
			4.7.1.F CHECKING THE RUBBER TRACK TENSION............................................156
			4.7.1.G CHANGING THE RUBBER TRACK....................................................158
		4.7.2 MAINTENANCE INTERVALS IN CASE OF THE DEMOLITION HAMMER (BREAKER)...................160
			4.7.2 A CHANGING THE HYDRAULIC OIL FILTER............................................160
			4.7.2.B CHANGING THE HYDRAULIC OIL...................................................160
		4.7.3 CHECKS BEFORE STARTING.............................................................161
			4.7.3.A VARIOUS CHECKS...............................................................161
			4.7.3.B CHECKING THE COOLANT LEVEL...................................................161
			4.7.3 C CHECKING THE FUEL LEVEL......................................................162
			4.7.3.D CHECKING THE ENGINE OIL LEVEL................................................162
			4.7.3.E CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT..............................163
		4.7.4 MAINTENANCE EVERY 100 HOURS OF OPERATION...........................................164
			4.7.4.A LUBRICATING THE JOINTS AND THE BALL - BEARING RING...........................164
			4.7.4.B LUBRICATING THE VARIABLE TRACK GAUGE SLIDING GUIDES (ONLY <<HS>> VERSION)....165
			4.7.4.C. CLEANING THE AIR CLEANER CARTRIDGE..........................................166
		4.7.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION.................................167
		4.7.6 MAINTENANCE EVERY N250 HOURS OF OPERATION..........................................167
			4.7.6.A ADJUSTING THE FAN BELT TENSION...............................................167
			4.7.6.B CHECKING THE BATTERY ELECTROLYTE LEVEL.......................................168
			4.7.6.C CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS.........................169
			4.7.6.D CHANGING THE HYDRAULIC SYSTEM OIL FILTER.....................................170
			4.7.6.E CHANGING THE ENGINE OIL......................................................171
		4.7.7 MAINTENANCE EVERY 500 HOURS OF OPERATION...........................................172
			4.7.7.A CHANGING THE ENGINE OIL FILTER...............................................172
			4.7.7.B CHANGING THE FUEL FILTER.....................................................173
			4.7.7.C CHANGING THE FUEL PUMP PRECLEANER............................................174
			4.7.7.D CHANGING THE AIR CLEANER CARTRIDGE...........................................175
			4.7.7.E CLEANING THE OUTSIDE OF THE RADIATORS........................................175
		4.7.8 MAINTENANCE EVERY 1000 HOURS OF OPERATION..........................................176
			4.7.8.A CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS...............................176
		4.7.9 MAINTENANCE EVERY 2000 HOURS OF OPERATION..........................................177
			4.7.9.A CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER............177
			4.7.9.B CHANGING THE COOLANT.........................................................179
			4.7.9.C CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE............................179
			4.7.9.D CHECKING THE ALTERNATOR AND THE STARTER......................................179
TECHNICAL SPECIFICATIONS.........................................................................180
	5.1 TECHNICAL DATA...........................................................................181
		5.1.1 STANDARD OVERALL DIMENSIONS........................................................181
		5.1.2 TECHNICAL CHARACTERISTICS..........................................................182
		5.1.3 OVERALL DIMENSIONS (ONLY <<HS>> VERSION)...........................................183
		5.1.4 TECHNICAL CHARACTERISTICS (ONLY <<HS>> VERSION)....................................184
		5.1.5 LIFTING CAPACITY...................................................................185
		5.1.6 LIFTING CAPACITY (ONLY <<HS>> VERSION).............................................186
AUTHORIZED OPTIONAL EQUIPMENT....................................................................188
	6.1 AUTHORIZED OPTIONAL EQUIPMENT............................................................189
		6.1.1 PRECAUTIONS REGARDING SAFETY.......................................................189
		6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT................................190
		6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT..........................................191
	6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)......................192
		6.2.1 DESCRIPTION AND CONTROL............................................................192
		6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED..............................192
		6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER......................................196
			6.2.3.1 INSTALLING THE HAMMER........................................................196
			6.2.3.2 REMOVING THE HAMMER..........................................................197
		6.2.4 MAINTENANCE........................................................................197

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