Komatsu PC800-8 PC800LC-8 Hydraulic Excavator Operation & Maintenance Manual – PDF Download

Description

Komatsu PC800-8 PC800LC-8 Hydraulic Excavator Operation & Maintenance Manual

Description:

Komatsu PC800-8 PC800LC-8 Hydraulic Excavator Operation & Maintenance Manual

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 for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.

Table of Contents:

Komatsu PC800-8 PC800LC-8 Hydraulic Excavator Operation & Maintenance Manual

FOREWORD..............................................................................................................................................................................  3
	FOREWORD..........................................................................................................................................................................  4
	SAFETY INFORMATION................................................................................................................................................................  5
		Noise emission levels.........................................................................................................................................................  7
		Vibration levels..............................................................................................................................................................  8
			Guide to Reduce Vibration Levels on Machine...............................................................................................................................  8
		BREAKING-IN THE NEW MACHINE................................................................................................................................................... 10
	INTRODUCTION...................................................................................................................................................................... 11
		DIRECTIONS OF MACHINE......................................................................................................................................................... 11
		VISIBILITY FROM OPERATOR'S SEAT............................................................................................................................................... 12
			PROXIMITY VISIBILITY...................................................................................................................................................... 12
			12M CIRCUMFERENCE VISIBILITY.............................................................................................................................................. 12
	PRODUCT INFORMATION............................................................................................................................................................... 13
		PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.................................................................................................................. 13
		EPA REGULATIONS, ENGINE NUMBER PLATE.......................................................................................................................................... 13
		SERVICE METER LOCATION........................................................................................................................................................ 14
		YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR................................................................................................................................... 14
		MACHINE SERIAL PLATE.......................................................................................................................................................... 15
		FOREWORD...................................................................................................................................................................... 17
		SAFETY........................................................................................................................................................................ 17
		OPERATION..................................................................................................................................................................... 18
		MAINTENANCE................................................................................................................................................................... 20
		SPECIFICATIONS................................................................................................................................................................ 22
		ATTACHMENTS AND OPTIONS....................................................................................................................................................... 23
		INDEX......................................................................................................................................................................... 23
		COLOPHON...................................................................................................................................................................... 23
SAFETY................................................................................................................................................................................ 25
	SAFETY INFORMATION................................................................................................................................................................ 26
	SAFETY LABELS..................................................................................................................................................................... 28
		LOCATION OF SAFETY LABELS..................................................................................................................................................... 29
		SAFETY LABELS................................................................................................................................................................. 30
	SAFETY INFORMATION................................................................................................................................................................ 37
	SAFETY MACHINE OPERATION.......................................................................................................................................................... 46
		STARTING ENGINE............................................................................................................................................................... 46
		OPERATION..................................................................................................................................................................... 47
		TRANSPORTATION................................................................................................................................................................ 53
		BATTERY....................................................................................................................................................................... 54
		TOWING........................................................................................................................................................................ 55
		LIFTING OBJECTS WITH BUCKET................................................................................................................................................... 56
	SAFETY MAINTENANCE INFORMATION.................................................................................................................................................... 57
OPERATION............................................................................................................................................................................. 65
	MACHINE VIEW ILLUSTRATIONS........................................................................................................................................................ 66
		OVERALL MACHINE VIEW.......................................................................................................................................................... 66
		CONTROLS AND GAUGES........................................................................................................................................................... 67
	DETAILED CONTROLS AND GAUGES...................................................................................................................................................... 69
		MONITORING SYSTEM............................................................................................................................................................. 69
			Basic Operation of Machine Monitor........................................................................................................................................ 70
			Emergency Monitors........................................................................................................................................................ 73
			Caution Monitors.......................................................................................................................................................... 75
			Basic Check Monitors...................................................................................................................................................... 77
			Meter Display Portion..................................................................................................................................................... 79
			Monitor Switches Portion.................................................................................................................................................. 83
		SWITCHES...................................................................................................................................................................... 98
		CONTROL LEVERS AND PEDALS.....................................................................................................................................................105
		SUN ROOF......................................................................................................................................................................107
			Opening...................................................................................................................................................................108
			Closing...................................................................................................................................................................108
		WINDSHIELD....................................................................................................................................................................108
		EMERGENCY EXIT FROM OPERATOR'S CAB............................................................................................................................................113
		DOOR LOCK.....................................................................................................................................................................113
		CAP WITH LOCK.................................................................................................................................................................113
		HOT AND COOL BOX..............................................................................................................................................................115
		MAGAZINE BOX..................................................................................................................................................................115
		ASHTRAY.......................................................................................................................................................................115
		AIR CONDITIONER CONTROLS......................................................................................................................................................116
			Air Conditioner Control Panel.............................................................................................................................................116
			Method of Operation.......................................................................................................................................................120
			Use Air Conditioner with Care.............................................................................................................................................126
			Air Conditioner Maintenance...............................................................................................................................................127
			Other Functions...........................................................................................................................................................127
		RADIO-CASSETTE (OPTION).......................................................................................................................................................129
			Use Radio with Care.......................................................................................................................................................129
		AUXILIARY ELECTRIC POWER......................................................................................................................................................130
			24V power source..........................................................................................................................................................130
			12V power source..........................................................................................................................................................131
		FUSE..........................................................................................................................................................................132
		CIRCUIT BREAKER...............................................................................................................................................................133
		CONTROLLER....................................................................................................................................................................134
		TOOL BOX......................................................................................................................................................................134
		GREASE PUMP...................................................................................................................................................................135
			Method of Use.............................................................................................................................................................135
			Precautions when Using....................................................................................................................................................136
			Supplying Grease..........................................................................................................................................................137
		ACCUMULATOR HANDLING..........................................................................................................................................................139
			RELEASING PRESSURE IN THE CONTROL CIRCUIT ON MACHINES EQUIPPED WITH AN ACCUMULATOR........................................................................................139
	MACHINE OPERATIONS AND CONTROLS...................................................................................................................................................140
		BEFORE STARTING ENGINE........................................................................................................................................................140
			Walk-around Checks........................................................................................................................................................140
			Checks Before Starting....................................................................................................................................................141
			Adjustment................................................................................................................................................................149
			Seat Belt.................................................................................................................................................................152
			Operations Before Starting Engine.........................................................................................................................................153
		STARTING ENGINE...............................................................................................................................................................156
		AFTER STARTING ENGINE.........................................................................................................................................................159
			Engine Warm Up............................................................................................................................................................159
			Hydraulic Equipment Warm Up...............................................................................................................................................161
			Operation After Completion Of Warm-Up Operation...........................................................................................................................166
		STOPPING THE ENGINE...........................................................................................................................................................168
		MACHINE OPERATION.............................................................................................................................................................169
			Preparations for Moving the Machine.......................................................................................................................................169
			Moving Machine Forward....................................................................................................................................................170
			Moving Machine Backward...................................................................................................................................................171
			Stopping Machine..........................................................................................................................................................172
		STEERING THE MACHINE..........................................................................................................................................................173
			Steering..................................................................................................................................................................173
		SWINGING......................................................................................................................................................................175
		WORK EQUIPMENT CONTROLS AND OPERATIONS........................................................................................................................................176
		WORKING MODE..................................................................................................................................................................178
		PROHIBITED OPERATIONS.........................................................................................................................................................179
		GENERAL OPERATION INFORMATION.................................................................................................................................................181
		TRAVELING ON SLOPES...........................................................................................................................................................182
		ESCAPE FROM MUD...............................................................................................................................................................184
			Track on One Side Stuck...................................................................................................................................................184
			Tracks on Both Sides Stuck................................................................................................................................................184
		RECOMMENDED APPLICATIONS......................................................................................................................................................185
			Backhoe Work..............................................................................................................................................................185
			Ditching Work.............................................................................................................................................................185
			Loading Work..............................................................................................................................................................185
		BUCKET REPLACEMENT............................................................................................................................................................186
			Replacement...............................................................................................................................................................186
		PARKING MACHINE...............................................................................................................................................................188
		MACHINE INSPECTION AFTER DAILY WORK...........................................................................................................................................190
		LOCKING.......................................................................................................................................................................190
	TRANSPORTATION....................................................................................................................................................................191
		TRANSPORTATION PROCEDURE......................................................................................................................................................191
		LIFTING MACHINE...............................................................................................................................................................191
		SHIPPING MACHINE INFORMATION..................................................................................................................................................193
		TRANSPORTATION POSTURE........................................................................................................................................................194
		PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE........................................................................................................................199
	COLD WEATHER OPERATION............................................................................................................................................................201
		COLD WEATHER OPERATION INFORMATION............................................................................................................................................201
			Fuel and Lubricants.......................................................................................................................................................201
			Cooling System Coolant....................................................................................................................................................201
			Battery...................................................................................................................................................................202
			Monitor...................................................................................................................................................................202
		AFTER DAILY WORK COMPLETION...................................................................................................................................................204
		AFTER COLD WEATHER SEASON.....................................................................................................................................................204
	LONG TERM STORAGE.................................................................................................................................................................205
		BEFORE STORAGE................................................................................................................................................................205
		DURING STORAGE................................................................................................................................................................206
		AFTER STORAGE.................................................................................................................................................................206
		STARTING MACHINE AFTER LONG-TERM STORAGE......................................................................................................................................206
	TROUBLES AND ACTIONS..............................................................................................................................................................207
		RUNNING OUT OF FUEL...........................................................................................................................................................207
		PHENOMENA THAT ARE NOT FAILURES...............................................................................................................................................208
		TOWING THE MACHINE............................................................................................................................................................208
		SEVERE JOB CONDITION..........................................................................................................................................................209
		DISCHARGED BATTERY............................................................................................................................................................210
			Battery Removal and Installation..........................................................................................................................................210
			Battery Charges...........................................................................................................................................................211
			Starting Engine with Booster Cables.......................................................................................................................................212
		OTHER TROUBLE.................................................................................................................................................................214
			Electrical System.........................................................................................................................................................214
			Chassis...................................................................................................................................................................215
			Engine....................................................................................................................................................................216
			Electronic Control System.................................................................................................................................................218
			Point of Contact to Telephone when Error Occurs...........................................................................................................................219
MAINTENANCE...........................................................................................................................................................................221
	MAINTENANCE INFORMATION...........................................................................................................................................................222
	OUTLINE OF SERVICE................................................................................................................................................................224
		HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC........................................................................................................................224
			OIL.......................................................................................................................................................................224
			FUEL......................................................................................................................................................................225
			COOLANT AND WATER FOR DILUTION............................................................................................................................................225
			GREASE....................................................................................................................................................................226
			CARRYING OUT KOWA (Komatsu Oil Wear Analysis).............................................................................................................................226
			STORING OIL AND FUEL......................................................................................................................................................227
			FILTERS...................................................................................................................................................................227
		ELECTRIC SYSTEM MAINTENANCE...................................................................................................................................................228
		EXPLANATION OF LUBRICATION CHART DECAL........................................................................................................................................229
	WEAR PARTS........................................................................................................................................................................231
		WEAR PARTS LIST...............................................................................................................................................................231
	RECOMMENDED FUEL, COOLANT, AND LUBRICANT..........................................................................................................................................232
		RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...........................................................................................234
	TIGHTENING TORQUE SPECIFICATIONS..................................................................................................................................................235
		TIGHTENING TORQUE LIST........................................................................................................................................................235
	SAFETY CRITICAL PARTS.............................................................................................................................................................236
		SAFETY CRITICAL PARTS LIST....................................................................................................................................................236
	MAINTENANCE SCHEDULE..............................................................................................................................................................237
		MAINTENANCE SCHEDULE CHART....................................................................................................................................................237
	MAINTENANCE PROCEDURE.............................................................................................................................................................239
		INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)................................................................................................................239
		INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)................................................................................................................239
		WHEN REQUIRED.................................................................................................................................................................239
			CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..............................................................................................................................239
			CLEAN INSIDE OF COOLING SYSTEM............................................................................................................................................244
			CHECK AND TIGHTEN TRACK SHOE BOLTS........................................................................................................................................247
			CHECK AND ADJUST TRACK TENSION............................................................................................................................................248
			REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)................................................................................................................................250
			REPLACE BUCKET TEETH (KMAX)...............................................................................................................................................251
			ADJUST BUCKET CLEARANCE...................................................................................................................................................252
			CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID................................................................................................................................254
			CHECK AND MAINTENANCE AIR CONDITIONER.....................................................................................................................................255
			CLEAN LINE FILTER, REMOVE DIRT............................................................................................................................................256
			CHECK GAS SPRING..........................................................................................................................................................256
			BLEEDING AIR FROM HYDRAULIC SYSTEM........................................................................................................................................257
		CHECK BEFORE STARTING.........................................................................................................................................................260
		EVERY 10 HOURS MAINTENANCE....................................................................................................................................................261
			LUBRICATING...............................................................................................................................................................261
		EVERY 100 HOURS MAINTENANCE...................................................................................................................................................263
			LUBRICATING SWING CIRCLE..................................................................................................................................................263
		EVERY 250 HOURS MAINTENANCE...................................................................................................................................................264
			CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL..............................................................................................................................264
			CHECK LEVEL OF BATTERY ELECTROLYTE........................................................................................................................................264
			CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS...................................................................................................................266
			CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST...............................................................................................................................267
			CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.....................................................................................................................268
		EVERY 500 HOURS MAINTENANCE...................................................................................................................................................269
			REPLACE FUEL PRE-FILTER CARTRIDGE.........................................................................................................................................269
			CHECK SWING PINION GREASE LEVEL, ADD GREASE...............................................................................................................................271
			CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (only machines equipped with air conditioner)....272
			CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER).......................................................................273
			REPLACE PILOT FILTER......................................................................................................................................................274
			CLEAN STRAINER OF COUPLING LUBRICATING OIL FILTER.........................................................................................................................275
			REPLACE DRAIN FILTER CARTRIDGE............................................................................................................................................275
			CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.........................................................................................................276
		EVERY 1000 HOURS MAINTENANCE..................................................................................................................................................278
			REPLACE FUEL MAIN FILTER CARTRIDGE........................................................................................................................................278
			REPLACE BREATHER ELEMENT IN HYDRAULIC TANK................................................................................................................................281
			REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT........................................................................................................................282
			REPLACE HYDRAULIC OIL FILTER ELEMENT......................................................................................................................................282
			CHANGE OIL IN SWING MACHINERY CASE........................................................................................................................................283
			CHANGE OIL IN COUPLING CASE...............................................................................................................................................285
			REPLACE CORROSION RESISTOR CARTRIDGE......................................................................................................................................286
			CHECK WELDED STRUCTURE....................................................................................................................................................286
			CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)...........................................................................................................288
		EVERY 2000 HOURS MAINTENANCE..................................................................................................................................................289
			CHANGE OIL IN FINAL DRIVE CASE............................................................................................................................................289
			CLEAN HYDRAULIC TANK STRAINER.............................................................................................................................................290
			CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT).............................................................................................291
			CHECK ALTERNATOR..........................................................................................................................................................294
			CHECK ENGINE VALVE CLEARANCE, ADJUST......................................................................................................................................294
			CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS.................................................................................................................294
		EVERY 4000 HOURS MAINTENANCE..................................................................................................................................................295
			CHECK WATER PUMP..........................................................................................................................................................295
			REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT).................................................................................................................................295
			CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER....................................................................................................296
			CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER..........................................................................................................296
			CHECK OPERATING CONDITION OF COMPRESSOR...................................................................................................................................297
			CHECK STARTING MOTOR......................................................................................................................................................297
		EVERY 5000 HOURS MAINTENANCE..................................................................................................................................................298
			CHANGE OIL IN HYDRAULIC TANK..............................................................................................................................................298
		EVERY 8000 HOURS MAINTENANCE..................................................................................................................................................300
			REPLACE HIGH-PRESSURE PIPING CLAMP........................................................................................................................................300
			REPLACE FUEL SPRAY PREVENTION CAP.........................................................................................................................................300
SPECIFICATIONS........................................................................................................................................................................301
	SPECIFICATIONS....................................................................................................................................................................302
ATTACHMENTS AND OPTIONS...............................................................................................................................................................305
	GENERAL PRECAUTIONS FOR SAFETY....................................................................................................................................................306
		PRECAUTIONS WHEN SELECTING....................................................................................................................................................306
		READ THE INSTRUCTION MANUAL THOROUGHLY........................................................................................................................................306
		PRECAUTIONS WHEN REMOVING OR INSTALLING.......................................................................................................................................306
		PRECAUTIONS WHEN USING........................................................................................................................................................307
	ATTACHMENT GUIDE..................................................................................................................................................................308
		COMBINATIONS OF WORK EQUIPMENT................................................................................................................................................309
			Working Range Diagram.....................................................................................................................................................310
		TRACK SHOES SELECTION.........................................................................................................................................................311
	HANDLING MACHINES EQUIPPED WITH KOMTRAX...........................................................................................................................................312
		BASIC PRECAUTIONS.............................................................................................................................................................312
INDEX.................................................................................................................................................................................313
	<A>...............................................................................................................................................................................315
	<B>...............................................................................................................................................................................315
	<C>...............................................................................................................................................................................315
	<D>...............................................................................................................................................................................315
	<E>...............................................................................................................................................................................315
	<F>...............................................................................................................................................................................315
	<G>...............................................................................................................................................................................315
	<H>...............................................................................................................................................................................315
	<I>...............................................................................................................................................................................315
	<L>...............................................................................................................................................................................315
	<M>...............................................................................................................................................................................315
	<O>...............................................................................................................................................................................315
	<P>...............................................................................................................................................................................315
	<R>...............................................................................................................................................................................316
	<S>...............................................................................................................................................................................316
	<T>...............................................................................................................................................................................316
	<V>...............................................................................................................................................................................316
	<W>...............................................................................................................................................................................316
	<Y>...............................................................................................................................................................................316
COLOPHON..............................................................................................................................................................................317

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KOMATSU PC800-8 PC800LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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