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Komatsu Hydraulic Excavator PC60-7 Operator & Maintenance Manual SN 59869 and up – PDF DOWNLOAD
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Komatsu Hydraulic Excavator PC60-7 Operator & Maintenance Manual
Book Code : SEAM034106T
SERIAL NUMBERS : PC60-59869 and UP
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Description
Komatsu Hydraulic Excavator PC60-7 Operator & Maintenance Manual
FILE DETAILS:
Komatsu Hydraulic Excavator PC60-7 Operator & Maintenance Manual
Size: 9.01 MB
Fomat: PDF
language: English
Brand: Komatsu
Type of machine: Hydraulic Excavator
Type of document: Operator & Maintenance Manual
Model: PC60-7
Serial: 59869 and up
Number of Page: 289
KOMATSU HYDRAULIC EXCAVATOR PC60-7 OPERATOR & MAINTENANCE MANUAL SN 59869 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Hydraulic Excavator PC60-7 Operator & Maintenance Manual
FOREWORD:
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu Hydraulic Excavator PC60-7 Operator & Maintenance Manual
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 SERVICE METER LOCATION................................................................. 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR............................................ 10 CONTENTS....................................................................................... 11 FOREWORD................................................................................... 11 SAFETY..................................................................................... 11 OPERATION.................................................................................. 11 MAINTENANCE................................................................................ 13 SPECIFICATIONS............................................................................. 14 ATTACHMENTS AND OPTIONS.................................................................... 14 SAFETY......................................................................................... 16 SAFETY INFORMATION......................................................................... 17 WARNING LABELS AND PICTOGRAMS.............................................................. 19 WARNING LABELS AND PICTOGRAMS - LOCATION............................................... 20 WARNING LABELS AND PICTOGRAMS - ACTUAL................................................. 21 SAFETY INFORMATION......................................................................... 26 Safety Rules........................................................................... 26 If Abnormalities are Found............................................................. 26 Working Wear and Personal Protective Items............................................. 26 Fire Extinguisher and First Aid Kit.................................................... 26 Safety Equipment....................................................................... 27 Keep Machine Clean..................................................................... 27 Keep Operator's Compartment Clean...................................................... 27 Leaving Operator's Seat with Lock...................................................... 27 Handrails and Steps.................................................................... 28 Mounting and Dismounting............................................................... 29 No Persons on Attachments.............................................................. 29 Burn Prevention........................................................................ 29 Fire Prevention and Explosion Prevention............................................... 30 Action If Fire Occurs.................................................................. 31 Windshield Washer Fluid................................................................ 31 Falling Objects, Flying Objects a and Intruding Objects Prevention..................... 31 Attachment Installation................................................................ 31 Attachment Combinations................................................................ 32 Cab Widow Glasses...................................................................... 32 Unauthorized Modifications............................................................. 32 Safety at Jobsite...................................................................... 32 Working on Loose Ground................................................................ 32 Distance to High Voltage Cables........................................................ 33 Ensure Good Visibility................................................................. 33 Ventilation for Enclosed Area.......................................................... 34 Signalman's Signal and Signs........................................................... 34 Emergency Exit from Operator's Cab..................................................... 34 Asbestos Dust Hazard Prevention........................................................ 34 SAFETY MACHINE OPERATION................................................................... 35 BEFORE STARTING ENGINE................................................................. 35 Checks Before Starting Engine...................................................... 35 Safety Rules for Starting Engine................................................... 36 Starting Engine in Cold Weather.................................................... 36 AFTER STARTING ENGINE.................................................................. 37 Checks After Starting Engine....................................................... 37 Safety Rules for Changing Machine Directions....................................... 37 Safety Rules for Traveling......................................................... 38 Traveling on Slopes................................................................ 39 Operations on Slopes............................................................... 40 Prohibited Operations.............................................................. 40 Operations on Snow................................................................. 41 Parking Machine.................................................................... 42 TRANSPORTATION......................................................................... 43 Loading and Unloading.............................................................. 43 Shipping the Machine............................................................... 44 BATTERY................................................................................ 45 Battery Hazard Prevention.......................................................... 45 Starting Engine with Booster Cables................................................ 46 TOWING................................................................................. 47 Safety Rules for Towing............................................................ 47 LIFTING OBJECTS WITH BUCKET............................................................ 48 Safety Rules for Lifting Objects................................................... 48 SAFETY MAINTENANCE INFORMATION............................................................. 49 Warning Tag............................................................................ 49 Keep Work Place Clean and Tidy......................................................... 49 Appoint Leader when Working with Others................................................ 49 Stop Engine Before Carrying Out Maintenance............................................ 50 Two Workers for Maintenance when Engine is Running..................................... 51 Proper Tools........................................................................... 51 Accumulator............................................................................ 51 Personnel.............................................................................. 52 Attachments............................................................................ 52 Work Under the Machine................................................................. 52 Noise.................................................................................. 52 When Using Hammer...................................................................... 53 Welding Works.......................................................................... 53 Removing Battery Terminals............................................................. 53 Safety First when Using High-pressure Grease to Adjust Track Tension................... 53 Do Not Disassemble Recoil Springs...................................................... 54 Safety Rules for High-pressure Oil..................................................... 54 Safety Handling High-pressure Hoses.................................................... 54 Waste Materials........................................................................ 55 Air Conditioner Maintenance............................................................ 55 Compressed Air......................................................................... 55 Periodic Replacement of Safety Critical Parts.......................................... 55 OPERATION...................................................................................... 56 MACHINE VIEW ILLUSTRATIONS................................................................. 57 OVERALL MACHINE VIEW................................................................... 57 CONTROLS AND GAUGES.................................................................... 58 DETAILED CONTROLS AND GAUGES............................................................... 59 MONITORING SYSTEM...................................................................... 59 Caution Monitors................................................................... 60 Emergency Monitors................................................................. 62 Gauges and Meter................................................................... 63 SWITCHES............................................................................... 65 Starting Switch.................................................................... 65 Travel Speed Selector Switch....................................................... 66 Swing Lock Switch.................................................................. 66 Windshield Wiper Switch............................................................ 66 Lamp Switch........................................................................ 67 Cab Heater Switch.................................................................. 67 Horn Switch........................................................................ 67 Swift Deceleration Switch.......................................................... 68 Room Lamp Switch................................................................... 68 Swing Brake Cancel Switch.......................................................... 69 Fuel Control Dial.................................................................. 69 CONTROL LEVERS AND PEDALS.............................................................. 70 Safety Lock Lever.................................................................. 71 Work Equipment Control Lever....................................................... 71 Blade Control Lever................................................................ 72 Travel Levers...................................................................... 73 SUN ROOF............................................................................... 75 Opening............................................................................ 75 Closing............................................................................ 75 ENGINE HOOD............................................................................ 76 WINDSHIELD............................................................................. 77 Opening............................................................................ 77 Closing............................................................................ 79 Lower Windshield................................................................... 80 EMERGENCY EXIT FROM OPERATOR'S CAB..................................................... 80 DOOR LOCK.............................................................................. 80 CAP WITH LOCK.......................................................................... 81 Opening and Closing Caps with Lock................................................. 81 Opening and Closing Covers with Lock............................................... 81 ASHTRAY................................................................................ 82 RADIO.................................................................................. 83 Control Panel...................................................................... 83 Controls Of Radio.................................................................. 85 Use Radio With Care................................................................ 86 FUSE................................................................................... 87 Fuse Capacities and Circuit Names.................................................. 87 FUSIBLELINK............................................................................ 87 CONTROLLERS............................................................................ 88 OPERATION MANUAL STORAGE............................................................... 88 TOOL BOX............................................................................... 88 GREASE GUN HOLDER...................................................................... 88 MACHINE OPERATIONS AND CONTROLS............................................................ 89 BEFORE STARTING ENGINE................................................................. 89 Walk-Around Checks................................................................. 89 Checks Before Starting............................................................. 91 Adjustment......................................................................... 97 Seat Belt.......................................................................... 98 Operations Before Starting Engine..................................................100 STARTING ENGINE........................................................................102 Normal Starting....................................................................102 Starting Engine In Cold Weather....................................................103 AFTER STARTING ENGINE..................................................................105 Breaking-In The New Machine........................................................105 Warming-Up Operation...............................................................106 STOPPING THE ENGINE....................................................................108 CHECK AFTER SHUT OFF ENGINE............................................................108 MACHINE OPERATION......................................................................109 Preparations For Moving The Machine Off............................................109 Moving Machine Forward.............................................................110 Moving Machine Backward............................................................111 Stopping Machine...................................................................112 STEERING THE MACHINE...................................................................113 Steering...........................................................................113 SWINGING...............................................................................115 WORK EQUIPMENT CONTROLS AND OPERATIONS.................................................116 PROHIBITED OPERATIONS..................................................................118 Operations Using Swing Force.......................................................118 Operations Using Travel Force......................................................118 Operations Using Hydraulic Cylinder Stroke Ends....................................118 Operations Using Bucket Dropping Force.............................................119 Operations Using Machine Dropping Force............................................119 Digging Hard Rocky Ground..........................................................119 Sudden Lever Shifting High Speed Travel............................................119 Avoid Hitting Blade................................................................120 Folding in Work Equipment..........................................................120 Support Blade on Both Sides........................................................120 Blade During Backhoe Operations....................................................121 GENERAL OPERATION INFORMATION..........................................................122 Traveling..........................................................................122 High Speed Travel..................................................................122 Permissible Water Depth............................................................122 TRAVELING ON SLOPES....................................................................123 Traveling Downhill.................................................................124 If shoes slip......................................................................124 Engine Stopped on Slope............................................................124 Cab Doors on Slope.................................................................124 ESCAPE FROM MUD........................................................................125 Stuck One Side Of Track............................................................125 Stuck Both Sides Of Tracks.........................................................125 RECOMMENDED APPLICATIONS...............................................................126 Backhoe Work.......................................................................126 Shovel Work........................................................................126 Ditching Work......................................................................126 Loading Work.......................................................................127 BUCKET REPLACEMENT AND INVERSION.......................................................128 Replacement........................................................................128 Inversion..........................................................................129 PARKING MACHINE........................................................................131 MACHINE INSPECTION AFTER DAILY WORK....................................................132 LOCKING................................................................................133 RUBBER SHOES AND ROAD LINERS...........................................................134 Rubber Shoes And Road Liners Information...........................................134 Warranty For Rubber Shoes And Road Liners..........................................134 Using Rubber Shoes And Road Liners.................................................135 Long Life Operations...............................................................135 TRANSPORTATION.............................................................................139 TRANSPORTATION PROCEDURE...............................................................139 LOADING AND UNLOADING WITH TRAILER.....................................................140 Loading............................................................................141 Securing Machine...................................................................143 Unloading..........................................................................144 LIFTING MACHINE........................................................................146 Standard Specification Machine.....................................................146 Machines With Lifting Hook.........................................................147 COLD WEATHER OPERATION.....................................................................149 COLD WEATHER OPERATION INFORMATION.....................................................149 Fuel And Lubricants................................................................149 Cooling System Coolant.............................................................149 Battery............................................................................150 Grease For Automatic Greasing System...............................................150 Preparing The Cab Heater...........................................................151 AFTER DAILY WORK COMPLETION............................................................151 AFTER COLD WEATHER SEASON..............................................................152 LONG TERM STORAGE..........................................................................153 BEFORE STORAGE.........................................................................153 DURING STORAGE.........................................................................153 AFTER STORAGE..........................................................................154 STARTING MACHINE AFTER LONG-TERM STORAGE...............................................154 TROUBLES AND ACTIONS.......................................................................155 RUNNING OUT OF FUEL....................................................................155 PHENOMENA THAT ARE NOT FAILURES........................................................155 TOWING THE MACHINE.....................................................................156 LIGHTWEIGHT TOWING HOOK................................................................156 SEVERE JOB CONDITION...................................................................156 DISCHARGED BATTERY.....................................................................157 Battery Removal And Installation...................................................158 Battery Charges....................................................................158 Starting Engine With Booster Cables................................................159 OTHER TROUBLE..........................................................................161 Electrical System..................................................................161 Chassis............................................................................162 Engine.............................................................................163 Automatic greasing system..........................................................165 MAINTENANCE....................................................................................166 MAINTENANCE INFORMATION....................................................................167 Service Meter Reading..................................................................167 Komatsu Genuine Replacement Parts......................................................167 Komatsu Genuine Lubricants.............................................................167 Windshield Washer Fluid................................................................167 Fresh and Clean Lubricants.............................................................167 Check Drained Oil and Used Filter......................................................167 Fuel Strainer..........................................................................167 Welding Instructions...................................................................167 Do Not Drop Things Inside Machine......................................................168 Dusty Jobsite..........................................................................168 Avoid Mixing Lubricants................................................................168 Locking the Inspection Covers..........................................................168 Hydraulic System - Air Bleeding........................................................168 Hydraulic Hose Installation............................................................168 Checks After Inspection and Maintenance Works..........................................169 OUTLINE OF SERVICE.........................................................................170 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................170 Oil................................................................................170 Fuel...............................................................................171 Coolant and Water for Dilution.....................................................171 Grease.............................................................................172 CARRYING OUT KOWA (Komatsu Oil Wear Analysis)......................................172 OIL AND FUEL STORAGE...............................................................173 Filters............................................................................173 ELECTRIC SYSTEM MAINTENANCE............................................................174 WEAR PARTS.................................................................................175 WEAR PARTS LIST........................................................................175 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................176 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................177 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....178 TIGHTENING TORQUE SPECIFICATIONS...........................................................179 TIGHTENING TORQUE LIST.................................................................179 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................180 SAFETY CRITICAL PARTS..................................................................180 MAINTENANCE SCHEDULE.......................................................................181 MAINTENANCE SCHEDULE CHART.............................................................181 Initial 250 Hours Maintenance (Only after the first 250 hours).....................181 When Required......................................................................181 Checks Before Starting.............................................................182 Every 50 Hours Maintenance.........................................................182 Every 100 Hours Maintenance........................................................182 Every 250 Hours Maintenance........................................................182 Every 500 Hours Maintenance........................................................182 Every 1000 Hours Maintenance.......................................................182 Every 2000 Hours Maintenance.......................................................182 Every 4000 Hours Maintenance.......................................................182 Every 5000 Hours Maintenance.......................................................182 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.............................................183 Hydraulic Oil Filter Element - Replace.............................................183 Hydraulic Oil - Change.............................................................183 Breaker Circuit Additional Oil Filter Element - Replace............................183 MAINTENANCE PROCEDURE......................................................................184 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS).........................184 WHEN REQUIRED..........................................................................185 Air Cleaner Element - Check/Clean/Replace..........................................185 Cooling System Coolant - Clean/Change..............................................189 Track Shoe Bolts - Check/Tighten...................................................192 Track Tension - Check/Adjust.......................................................193 Rubber Shoes or Road Liners - Check................................................195 Rubber Shoe Tension - Check/Adjust.................................................197 Road Liners - Replace..............................................................201 Steel Shoes or Road Liners to Rubber Shoes - Change................................202 Electrical Intake Air Heater - Inspect.............................................202 Bucket Teeth (Vertical Pin Type) - Replace.........................................203 Bucket Teeth (Horizontal Pin Type) - Replace.......................................206 Bucket Clearance - Adjust..........................................................207 Windshield Washer Fluid Level - Check/Add..........................................208 Breaker Circuit Additional Oil Filter Element - Replace............................209 Wash Washable Floor................................................................210 Hydraulic System - Bleed Air.......................................................213 CHECK BEFORE STARTING..................................................................216 EVERY 50 HOURS MAINTENANCE.............................................................217 Fuel Tank - Drain..................................................................217 EVERY 100 HOURS MAINTENANCE............................................................218 Lubricating........................................................................218 Swing Machinery Case Oil - Check/Add...............................................220 EVERY 250 HOURS MAINTENANCE............................................................221 Final Drive Case Oil Level - Check/Add.............................................221 Battery Electrolyte Level - Check..................................................222 Cooling Fan Belt Tension - Inspect/Adjust..........................................224 EVERY 500 HOURS MAINTENANCE............................................................226 Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge..................226 Fuel Filter Cartridge - Replace....................................................228 Swing Pinion Gear Oil Level - Check/Add............................................229 Swing Circle - Lubricate...........................................................229 Clean And Inspect Radiator Fins, Oil Cooler Fins And Condenser Fins................230 Hydraulic Oil Filter Element - Replace.............................................231 EVERY 1000 HOURS MAINTENANCE...........................................................232 Swing Machinery Case Oil - Change..................................................232 Final Drive Case Oil - Change......................................................233 EVERY 2000 HOURS MAINTENANCE...........................................................234 PTO Gear Case Oil Level - Check/Add................................................234 Alternator And Starting Motor - Inspect............................................235 Engine Valve Clearances - Inspect..................................................235 EVERY 4000 HOURS MAINTENENCE...........................................................236 Water Pump - Inspect...............................................................236 EVERY 5000 HOURS MAINTENANCE...........................................................237 Change Oil In Hydraulic Tank, Clean Strainer.......................................237 SPECIFICATIONS.................................................................................240 SPECIFICATIONS.............................................................................241 ATTACHMENTS AND OPTIONS........................................................................244 ATTACHMENTS AND OPTIONS - GENERAL INFORAMTION..............................................245 SAFETY FIRST...........................................................................245 ATTACHMENT INSTALLATION................................................................247 BUCKET WITH HOOK...........................................................................248 HOOK CONDITION.........................................................................248 PROHIBITED OPERATIONS..................................................................248 Operations with Care...............................................................248 AIR CONDITIONER............................................................................249 CONTROL PANEL..........................................................................249 Temperature Control Switch.........................................................249 Air Flow Selector Switch...........................................................250 Vent Selector Switch...............................................................251 Fresh/Recirculate Selection Switch.................................................252 Air Conditioner Switch.............................................................253 Box................................................................................253 AIR CONDITIONER CONTROLS...............................................................253 Cooling............................................................................253 Cooling with Care..................................................................253 AIR CONDITIONER MAINTENANCE............................................................254 When Required......................................................................255 Every 250 Hours Maintenance........................................................257 Every 500 Hours Maintenance........................................................259 MACHINE READY FOR ATTACHMENT...............................................................260 LOCATIONS..............................................................................260 Stop Valve.........................................................................261 Selector Valve.....................................................................261 Attachment Control Pedal...........................................................261 Lock Pin...........................................................................261 Breaker Circuit Additional Oil Filter..............................................262 Accumulator (For Attachment Circuit)...............................................262 HYDRAULIC CIRCUIT......................................................................263 Hydraulic Circuit Connection.......................................................263 ATTACHMENT OPERATIONS..................................................................266 When Using Breaker.................................................................266 When Using General Attachment Such As Crusher......................................267 ACCUMULATOR............................................................................268 Hydraulic System - Pressure Release................................................269 LONG TERM STORAGE......................................................................269 SPECIFICATIONS.........................................................................270 CHANGING MACHINE CONTROLL PATERN (IF PATTERN CHANGE VALVE EQUIPPED)........................271 CONTROL PATTERN CHANGE PROCEDURE.......................................................271 MACHINE CONTROL PATTERNS...............................................................272 ATTACHMENT GUIDE...........................................................................273 ATTACHMENT COMBINATIONS................................................................273 SELECTION OF TRACK SHOES...............................................................274 METHOD OF SELECTING SHOES..........................................................274 AUTOMATIC GREASING SYSTEM..................................................................275 CONTROLLER.............................................................................275 Setting Greasing Interval..........................................................275 Method of Setting (Changing) Greasing Interval.....................................276 CHECK BEFORE STARTING..............................................................278 Every 100 Hours Service............................................................280 RECOMMENDED ATTACHMENT OPERATIONS..........................................................281 HYDRAULIC BREAKER......................................................................281 Main Applications..................................................................281 Prohibited Works...................................................................283 INDEX..........................................................................................286 A..........................................................................................286 B..........................................................................................286 C..........................................................................................286 D..........................................................................................286 E..........................................................................................286 F..........................................................................................286 G..........................................................................................286 H..........................................................................................286 I..........................................................................................286 L..........................................................................................286 M..........................................................................................287 O..........................................................................................287 P..........................................................................................287 R..........................................................................................287 S..........................................................................................287 T..........................................................................................287 W..........................................................................................287 Y..........................................................................................287
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