Komatsu Hydraulic Excavator PC25-1 PC30-7 PC40-7 PC45-1 Operator & Maintenance Manual – PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC25-1 PC30-7 PC40-7 PC45-1 Operator & Maintenance Manual

FILE DETAILS:

Komatsu Hydraulic Excavator PC25-1 PC30-7 PC40-7 PC45-1 Operator & Maintenance Manual

Size: 9.23 MB
Fomat: PDF
Language: English
Brand: Komatsu
Type of machine: Hydraulic Excavator
Type of document: Operator & Maintenance Manual
Model: PC25_30_40_45
Serial: 6471 264423 and up 24522-24994 3506 and up
Number of Page: 213

KOMATSU HYDRAULIC EXCAVATOR PC25-1 PC30-7 PC40-7 PC45-1 OPERATOR & MAINTENANCE MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu Hydraulic Excavator PC25-1 PC30-7 PC40-7 PC45-1 Operator & Maintenance Manual

FOREWORD:

• This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
• if you sell the machine, be sure to give this manual to the new owners. ‘ Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual.
• Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult Komatsu or your Komatsu distributor for those items you may require.

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC25-1 PC30-7 PC40-7 PC45-1 Operator & Maintenance Manual

MAIN MENU.................................................................................  0
COVER.....................................................................................  1
1. FOREWORD...............................................................................  2
2. SAFETY INFORMATION.....................................................................  3
3. INTRODUCTION...........................................................................  4
	3.1 INTENDED USE......................................................................  4
	3.2 FEATURES..........................................................................  4
	3.3 BREAKING IN THE MACHINE...........................................................  4
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR..........................  5
	4.1 MACHINE SERIAL NO. PLATE  POSITION................................................  5
	4.2 ENGINE SERIAL NO. PLATE POSITION..................................................  5
	4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.........................................  5
CONTENTS..................................................................................  6
SAFETY.................................................................................... 10
	6. GENERAL PRECAUTIONS................................................................ 11
	7. PRECAUTIONS DURING OPERATION....................................................... 16
		7.1 BEFORE STARTING ENGINE........................................................ 16
		7.2 OPERATING MACHINE............................................................. 18
		7.3 TRANSPORTATION................................................................ 23
		7.4 BATTERY....................................................................... 24
		7.5 TOWING........................................................................ 25
		7.6 BUCKET WITH HOOK.............................................................. 26
	8. PRECAUTIONS FOR MAINTENANCE........................................................ 29
		8.1 BEFORE CARRYING OUT MAINTENANCE............................................... 29
		8.2 DURING MAINTENANCE............................................................ 32
	9. POSITION FOR ATTACHING SAFETY LABELS............................................... 36
OPERATION................................................................................. 40
	10. GENERAL VIEW...................................................................... 41
		10.1 GENERAL VIEW OF MACHINE...................................................... 41
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES.......................................... 42
	11. EXPLANATION OF COMPONENTS......................................................... 43
		11.1 MACHINE MONITOR.............................................................. 43
		11.2 SWITCHES..................................................................... 48
		11.3 CONTROL LEVERS AND PEDALS.................................................... 51
		11.4 ENGINE HOOD.................................................................. 55
		11.5 FRONT WINDOW (MACHINES EQUIPPED WITH CAB).................................... 56
		11.6 DOOR LOCK.................................................................... 58
		11.7 FUSE......................................................................... 59
		11.8 FUSIBLE LINK................................................................. 59
		11.9 CAP, COVER WITH LOCK......................................................... 60
		11.10 CANOPY (MACHINES EQUIPPED WITH CANOPY)...................................... 61
	12. OPERATION......................................................................... 62
		12.1 CHECK BEFORE STARTING ENGINE................................................. 62
		12.2 STARTING ENGINE.............................................................. 70
		12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................. 72
		12.4 MOVING MACHINE OFF........................................................... 74
		12.5 STEERING MACHINE............................................................. 77
		12.6 STOPPING MACHINE............................................................. 79
		12.7 SWINGING..................................................................... 80
		12.8 OPERATION OF WORK EQUIPMENT.................................................. 81
		12.9 PROHIBITIONS FOR OPERATION................................................... 82
		12.10 PRECAUTIONS FOR OPERATION................................................... 85
		12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS................................. 86
		12.12 HOW TO ESCAPE MUD........................................................... 88
		12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR..................................... 89
		12.14 REPLACEMENT OF BUCKET....................................................... 91
		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....................................................................102
		13.1 LOADING, UNLOADING WORK......................................................102
		13.2 METHOD OF LIFTING MACHINE....................................................104
		13.3 PRECAUTIONS FOR LOADING......................................................106
		13.4 PRECAUTIONS FOR TRANSPORTATION...............................................107
	14. COLD WEATHER OPERATION............................................................108
		14.1 PRECAUTIONS FOR LOW TEMPERATURE..............................................108
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK.........................................110
		14.3 PREPARING THE CAB HEATER (MACHINES EQUIPPED WITH CAB)........................110
		14.4 AFTER COLD WEATHER...........................................................110
	15. LONG-TERM STORAGE.................................................................111
		15.1 BEFORE STORAGE...............................................................111
		15.2 DURING STORAGE...............................................................112
		15.3 AFTER STORAGE................................................................112
	16. TROUBLESHOOTING...................................................................113
		16.1 PHENOMENA THAT ARE NOT FAILURES..............................................113
		16.2 METHOD OF TOWING MACHINE.....................................................113
		16.3 PRECAUTIONS ON PARTICULAR JOBSITES...........................................113
		16.4 IF BATTERY IS DISCHARGED.....................................................114
		16.5 OTHER TROUBLE................................................................119
MAINTENANCE...............................................................................124
	17. GUIDES TO MAINTENANCE.............................................................125
	18. OUTLINES OF SERVICE...............................................................127
		18.1 OUTLINE OF OIL, FUEL, COOLANT................................................127
		18.2 OUTLINE OF ELECTRIC SYSTEM...................................................130
		18.3 OUTLINE OF HYDRAULIC SYSTEM..................................................131
	19. WEAR PARTS LIST...................................................................132
	20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE..............133
	21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....................................137
		21.1 INTRODUCTION OF NECESSARY TOOLS..............................................137
		21.2 TORQUE LIST..................................................................138
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....................................139
	23. MAINTENANCE SCHEDULE CHART........................................................141
		23.1 MAINTENANCE SCHEDULE CHART...................................................141
		23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER............................143
	24. SERVICE PROCEDURE.................................................................144
		24.1 INITIAL 250 HOURS SERVICE....................................................144
			CHECK ENGINE VALVE CLEARANCE, ADJUST..........................................191
		24.2 WHEN REQUIRED................................................................145
			24.2.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...........................145
			24.2.2 CLEAN INSIDE OF COOLING SYSTEM.........................................148
			24.2.3 DRAIN WATER, SEDIMENT FROM FUEL TANK...................................152
			24.2.4 CLEAN WATER SEPARATOR ELEMENT..........................................152
			24.2.5 CHECK ELECTRIC WIRINGS.................................................153
			24.2.6 CHECK RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)................154
			24.2.7 CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)....156
			24.2.8 REPLACE RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)..............158
			24.2.9 CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH STEEL SHOES).....161
			24.2.10 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)..............................164
			24.2.11 INSPECTION OF BUCKET PLAY ADJUSTMENT MECHANISM........................167
		24.3 CHECK BEFORE STARTING........................................................168
			24.3.1 CHECK COOLANT LEVEL, ADD WATER.........................................168
			24.3.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL.............................168
			24.3.3 CHECK FUEL LEVEL, ADD FUEL.............................................169
			24.3.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.............................170
			24.3.5 CHECK DUST INDICATOR...................................................171
			24.3.6 CHECK WATER SEPARATOR..................................................171
		24.4 EVERY 100 HOURS SERVICE......................................................172
			24.4.1 LUBRICATING............................................................172
				1. SWING PINION (1POINT)..................................................172
				2. SWING CIRCLE (1POINT)..................................................172
				3. BOOM SWING CYLINDER FOOT PIN (1POINT)..................................172
				4. BOOM SWING CYLINDER ROD END (1POINT)...................................172
				5. BOOM CYLINDER FOOT PIN (1POINT)........................................172
				6. BLADE CYLINDER FOOT PIN (1POINT).......................................172
				7. BLADE FOOT PIN (2 POINTS)..............................................172
				8. BLADE CYLINDER ROD END (1POINT)........................................172
				9. BOOM FOOT PIN (2 POINTS)...............................................172
				10. BOOM SWING BRACKET PIN (2 POINTS).....................................172
				11. ARM CYLINDER FOOT PIN (1POINT)........................................173
				12. BOOM CYLINDER ROD END (1POINT)........................................173
				13. BOOM-ARM COUPLING PIN (1POINT)........................................173
				14. ARM CYLINDER ROD END PIN (1POINT).....................................173
				15. BUCKET CYLINDER FOOT PIN (1POINT).....................................173
				16. BUCKET CYLINDER ROD END PIN (1POINT)..................................173
				17. LINK COUPLING PIN (1POINT)............................................173
				18. BUCKET-LINK COUPLING PIN (2 POINTS)...................................173
				19. ARM-BUCKET COUPLING PIN (1POINT)......................................173
				20. ARM-LINK COUPLING PIN (1POINT)........................................173
		24.5 EVERY 250 HOURS SERVICE......................................................174
			24.5.1 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE......174
			24.5.2 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...........................176
			24.5.3 CHECK LEVEL OF BATTERY ELECTROLYTE.....................................178
			24.5.4 REPLACE HYDRAULIC FILTER ELEMENT.......................................179
			24.5.5 CHECK FAN BELT TENSION, ADJUST.........................................180
		24.6 EVERY 500 HOURS SERVICE......................................................181
			24.6.1 REPLACE FUEL FILTER CARTRIDGE..........................................181
			24.6.2 CLEAN, CHECK RADIATOR FINS.............................................183
		24.7 EVERY 1000 HOURS SERVICE.....................................................184
			24.7.1 CHANGE OIL IN SWING MACHINERY CASE.....................................184
			24.7.2 CHANGE OIL IN FINAL DRIVE CASE.........................................185
		24.8 EVERY 2000 HOURS SERVICE.....................................................187
			24.8.1 CHANGE OIL IN HYDRAULIC TANK CLEAN STRAINER............................187
			24.8.2 CHECK ALTERNATOR, STARTING MOTOR.......................................191
			24.8.3 CHECK ENGINE VALVE CLEARANCE, ADJUST...................................191
SPECIFICATIONS............................................................................192
	25. SPECIFICATIONS....................................................................193
OPTIONS, ATTACHMENTS......................................................................210
	26. GENERAL PRECAUTIONS...............................................................211
		26.1 PRECAUTIONS RELATED TO SAFETY................................................211
		26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS......................................212
	27. HANDLING BUCKET WITH HOOK.........................................................213
		27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK......................................213
		27.2 PROHIBITED OPERATIONS........................................................213
		27.3 PRECAUTIONS DURING OPERATIONS................................................213

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]