Komatsu PC27R-8 Hydraulic Excavator Operation & Maintenance Manual SN F31103 and up – PDF DOWNLOAD

Description

Komatsu PC27R-8 Hydraulic Excavator Operation & Maintenance Manual

TABLE OF CONTENTS:

Komatsu PC27R-8 Hydraulic Excavator Operation & Maintenance Manual

MAIN MENU................................................................................................................................  0
COVER....................................................................................................................................  1
1.1 FOREWORD.............................................................................................................................  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.............................................................................................  9
	1.4.6 CAB SERIAL NUMBER..............................................................................................................  9
	1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS............................................................................................ 10
TABLE OF CONTENTS........................................................................................................................ 11
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................................................................................................. 35
		2.1.3 PICTOGRAMS AND RELEVANT MEANINGS........................................................................................... 37
		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 POWDER................................................................................... 42
		2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT............................................................................ 43
		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 TRAVELLING IN REVERSE........................................................................................... 46
		2.4.4 MOVING THE MACHINE......................................................................................................... 47
		2.4.5 MOVING ON SLOPES........................................................................................................... 48
		2.4.6 WORKING ON 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
		2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES...................................................... 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....................................................................................... 66
		3.2.2 GENERAL VIEW OF 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 WARNING LIGHTS............................................................................................................. 71
		3.3.3 SWITCHES AND PUSH BUTTONS.................................................................................................. 73
		3.3.4 ELECTRICAL ACCESSORIES..................................................................................................... 76
		3.3.5 MACHINE CONTROLS........................................................................................................... 78
	3.4 FUSES AND RELAYS................................................................................................................. 91
		3.4.1 FUSES...................................................................................................................... 91
			3.4.1.1 EQUIPMENT FUSES...................................................................................................... 91
			3.4.1.2 MAIN FUSE............................................................................................................ 92
		3.4.2 RELAYS..................................................................................................................... 93
	3.5 GUARDS AND DRIVER'S SEAT......................................................................................................... 94
		3.5.1 ENGINE HOOD................................................................................................................ 94
		3.5.2 RIGHT COUNTERWEIGHT........................................................................................................ 95
		3.5.3 CANOPY..................................................................................................................... 95
		3.5.4 CAB........................................................................................................................ 96
		3.5.5 VENTILATION AND HEATING.................................................................................................... 99
		3.5.6 SEAT.......................................................................................................................100
		3.5.7 SAFETY BELT................................................................................................................100
		3.5.8 EMERGENCY EXIT.............................................................................................................101
		3.5.9 TECHNICAL DOCUMENTATION CASE...............................................................................................101
		3.5.10 FIRE EXTINGUISHER.........................................................................................................102
		3.5.11 FIRST AID KIT.............................................................................................................102
	3.6 USE OF THE MACHINE...............................................................................................................104
		3.6.1 CHECKS BEFORE STARTING THE ENGINE..........................................................................................104
			3.6.1.1 VISUAL CHECKS........................................................................................................104
			3.6.1.2 DAILY CHECKS.........................................................................................................104
			3.6.1.3 OPERATIONAL CHECKS...................................................................................................105
		3.6.2 STARTING THE ENGINE........................................................................................................106
			3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...................................................................106
			3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES........................................................................107
		3.6.3 WARMING THE ENGINE.........................................................................................................108
		3.6.4 HEATING THE HYDRAULIC OIL..................................................................................................108
		3.6.5 HOW TO MOVE THE MACHINE....................................................................................................108
			3.6.5.1 STEERING (CHANGING DIRECTION)........................................................................................110
			3.6.5.2 MOVING ON SLOPES.....................................................................................................111
			3.6.5.3 MAXIMUM IMMERSION DEPTH..............................................................................................112
	3.7 PARKING THE MACHINE..............................................................................................................113
		3.7.1 PARKING ON LEVEL GROUND....................................................................................................113
		3.7.2 PARKING ON SLOPES..........................................................................................................114
	3.8 STOPPING THE ENGINE..............................................................................................................115
	3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES.......................................................................................116
		3.9.1 LOADING AND UNLOADING THE MACHINE..........................................................................................116
		3.9.2 TRANSPORT..................................................................................................................117
	3.10 LIFTING THE MACHINE.............................................................................................................118
	3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON......................................................................................119
		3.11.1 FUEL AND LUBRICANTS.......................................................................................................119
		3.11.2 COOLANT...................................................................................................................119
		3.11.3 BATTERY...................................................................................................................119
		3.11.4 OTHER PRECAUTIONS.........................................................................................................120
		3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK................................................................................120
	3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON......................................................................................121
	3.13 USING THE WORK EQUIPMENT........................................................................................................122
		3.13.1 ORGANIZING THE WORK AREA..................................................................................................122
		3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS............................................................................123
		3.13.3 DIGGING METHOD............................................................................................................124
		3.13.4 CHANGING THE BUCKET.......................................................................................................125
	3.14 LONG PERIODS OF INACTIVITY......................................................................................................126
		3.14.1 BEFORE THE PERIOD OF INACTIVITY...........................................................................................126
		3.14.2 DURING THE PERIOD OF INACTIVITY...........................................................................................127
		3.14.3 AFTER THE PERIOD OF INACTIVITY............................................................................................127
	3.15 TROUBLESHOOTING.................................................................................................................128
		3.15.1 OCCURENCES THAT ARE NOT FAILURES..........................................................................................128
		3.15.2 HOW TO REMOVE THE MACHINE.................................................................................................128
		3.15.3 AFTER THE FUEL HAS RUN OUT................................................................................................129
		3.15.4 IF THE BATTERY IS DOWN....................................................................................................129
			3.15.4.1 STARTING WITH BOOSTER CABLES........................................................................................130
		3.15.5 OTHER TROUBLES............................................................................................................131
			3.15.5.1 ELECTRICAL CIRCUIT..................................................................................................131
			3.15.5.2 HYDRAULIC SYSTEM....................................................................................................131
			3.15.5.3 ENGINE..............................................................................................................132
MAINTENANCE..............................................................................................................................134
	4.1 GUIDE TO MAINTENANCE.............................................................................................................135
	4.2 MAINTENANCE NOTES................................................................................................................137
		4.2.1 NOTES REGARDING THE ENGINE.................................................................................................137
			4.2.1.1 ENGINE OIL...........................................................................................................137
			4.2.1.2 COOLANT..............................................................................................................137
			4.2.1.3 FUEL.................................................................................................................138
		4.2.2 NOTES REGUARDING THE HYDRAULIC SYSTEM......................................................................................138
		4.2.3 NOTES REGUARDING THE ELECRICAL SYSTEM......................................................................................139
		4.2.4 NOTES REGUARDING LUBRICATION...............................................................................................139
		4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING......................................................................140
	4.3 FUEL, COOLANT AND LUBRICANTS.....................................................................................................141
		4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS........................................................................145
	4.4 NUT AND BOLT TIGHTENING TORQUES..................................................................................................146
		4.4.1 STANDARD TIGHTENING TORQUES................................................................................................146
		4.4.2 SPECIFIC TIGHTENING TORQUES................................................................................................146
	4.5 LUBRICATION......................................................................................................................147
		4.5.1 LUBRICATION DIAGRAM........................................................................................................147
	4.6 PERIODICAL CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY...............................................................148
		4.6.1 CRITICAL PARTS FOR SAFETY..................................................................................................149
	4.7 MAINTENANCE PLAN.................................................................................................................152
		4.7.1 WHEN REQUIRED..............................................................................................................155
			4.7.1.a WASHING THE COOLING CIRCUIT..........................................................................................155
			4.7.1.b DRAINING THE FUEL TANK...............................................................................................156
			4.7.1.c CHECKING THE ELECTRICAL SYSTEM.......................................................................................157
			4.7.1.d CHECKING THE STEEL TRACK TENSION.....................................................................................157
			4.7.1.e CHECKING THE RUBBER TRACKS...........................................................................................159
			4.7.1.f CHECKING THE RUBBER TRACK TENSION....................................................................................161
			4.7.1.g CHANGING THE RUBBER TRACK............................................................................................163
			4.7.1.h CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE.............................................................165
		4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER)....................................................166
			4.7.2.a CHANGING THE HYDRAULIC OIL FILTER....................................................................................166
			4.7.2.b CHANGING THE HYDRAULIC OIL...........................................................................................166
		4.7.3 CHECKS BEFORE STARTING.....................................................................................................167
			4.7.3.a VARIOUS CHECKS.......................................................................................................167
			4.7.3.b CHECKING THE COOLANT LEVEL...........................................................................................167
			4.7.3.c CHECKING THE FUEL LEVEL..............................................................................................168
			4.7.3.d CHECKING THE ENGINE OIL LEVEL........................................................................................168
			4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT......................................................................169
			4.7.3.f CHECKING THE AIR CLEANER CLOGGING INDICATOR..........................................................................170
			4.7.3.g CHECKING THE FUEL FILTER FOR SEDIMENT AND WATER......................................................................170
		4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES....171
		4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION...................................................................................172
			4.7.5.a LUBRICATING THE JOINTS AND THE BALL-BEARING RING.....................................................................172
		4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION.........................................................................174
		4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION...................................................................................174
			4.7.7.a ADJUSTING THE FAN BELT TENSION.......................................................................................174
			4.7.7.b CHECKING THE BATTERY ELECTROLYTE LEVEL...............................................................................175
			4.7.7.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS.................................................................175
			4.7.7.d CHANGING THE HYDRAULIC SYSTEM OIL FILTER.............................................................................176
			4.7.7.e CHANGING THE ENGINE OIL..............................................................................................177
		4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEE....178
		4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION...................................................................................178
			4.7.9.a CHANGING THE OIL FILTER..............................................................................................178
			4.7.9.b CHANGING THE FUEL FILTER.............................................................................................179
			4.7.9.c CHANGING THE FUEL PUMP PRECLEANER....................................................................................180
			4.7.9.d CLEANING THE OUTSIDE OF THE RADIATORS................................................................................181
			4.7.9.e DRAINING THE HYDRAULIC OIL TANK (ONLY FOR MACHINES IN WHICH THE SYNTHETOC BIODEGRADABLE OIL TYPE HEES IS USED).......182
		4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION.................................................................................183
			4.7.10.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS......................................................................183
		4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION.................................................................................184
			4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER...................................................184
			4.7.11.b CHANGING THE COOLANT................................................................................................187
			4.7.11.C CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE...................................................................188
			4.7.11.d CHECKING THE ALTERNATOR AND THE STARTER.............................................................................188
TECHNICAL SPECIFICATIONS.................................................................................................................190
	5.1 TECHNICAL DATA...................................................................................................................191
		5.1.1 STANDARD OVERALL DIMENSIONS................................................................................................191
		5.1.2 TECHNICAL CHARACTERISTICS..................................................................................................193
		5.1.3 LIFTING CAPACITY WITH CAB..................................................................................................194
		5.1.4 LIFTING CAPACITY WITH CANOPY...............................................................................................195
AUTHORIZED OPTIONAL EQUIPMENT............................................................................................................196
	6.1 AUTHORIZED OPTIONAL EQUIPMENT....................................................................................................197
		6.1.1 PRECAUTIONS REGARDING SAFETY...............................................................................................197
		6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT........................................................................198
		6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT..................................................................................199
	6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)..............................................................200
		6.2.1 DESCRIPTION AND CONTROL....................................................................................................200
		6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED......................................................................200
		6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER..............................................................................204
			6.2.3.1 INSTALLING THE HAMMER................................................................................................204
			6.2.3.2 REMOVING THE HAMMER..................................................................................................205
		6.2.4 MAINTENANCE................................................................................................................205
	6.3 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT..............................................................................206
		6.3.1 SELECTION VALVE (1)........................................................................................................206
		6.3.2 CONTROL PEDAL (2)..........................................................................................................207
		6.3.3 ASSEMBLYING AND CONNECTING THE EQUIPMENT...................................................................................208
		6.3.4 MAINTENANCE................................................................................................................209

KOMATSU PC27R-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL SN F31103 AND UP – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC27R-8 Hydraulic Excavator Operation & Maintenance Manual

FOREWORD:

• This manual has been prepared by Komatsu to provide you with all the information you need to operate and maintain your machine in total safety. By complying with the  instructions contained in this manual you will get the best out of your machine and keep it operating at maximum efficiency for many years to come.
•  Make sure that this manual is always readily available to all machine operators and maintenance personnel. Make sure,that they read it carefully. Keep this manual in good condition and where it is easily accessible for rapid consultation (e.g. with the spare parts catalogue). If this manual becomes damaged or lost, request another copy from Komatsu or from your Komatsu dealer.
•  Komatsu machines are constantly being improved. Your machine may therefore differ in some points from ttie illustrations shown in this manual. Consult your Komatsu dealer for the latest information.
•  Make orderly notes immediately any work is done during maintenance checks. This is not only a demonstration of efficient servicing, but also provides a clear record of what work has been done and what still remains to be done at the next service interval. Check the hour counter and the maintenance chart regularly.
•  Your Komatsu dealer has years of experience in dealing with customers’ queries. Do not hesitate to contact your dealer if you need more information. He can help you to get the best out of your machine, and can suggest the most appropriate equipment for a job. You dealer can also provide Technical Assistance for any modifications needed to adapt your machine to comply with safety.
  Your Komatsu dealer also stocks original Komatsu spare parts – the only ones which guarantee safety and interchangeability.
•  Write your machine’s serial numbers on the form provided at the end of this section. Give these details to your dealer whenever you request Technical Assistance or spare parts.

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