Komatsu PC110R-1 Hydraulic Excavator Operation & Maintenance Manual (SN :2265010001 and up) - WEAM00

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the PC110R-1 Komatsu Hydraulic Excavator (2265010001 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu PC110R-1 Hydraulic Excavator
Serial Numbers : 2265010001 and up


TABLE OF CONTENTS :

- SAFETY AND ACCIDENT PREVENTION
- DESCRIPTION AND USE OF THE MACHINE
- MAINTENANCE
- TECHNICAL SPECIFICATIONS
- AUTHORIZED OPTIONAL EQUIPMENT


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : WEAM000402
Total Pages : 212


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.

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1.1 FOREWORD
1.2 INFORMATION ON SAFETY
1.3 INTRODUCTION
-1.3.1 INTENDED USES
-1.3.2 IMPROPER OR UNAUTHORIZED USE
-1.3.3 MAIN CHARACTERISTICS
-1.3.4 RUNNING-IN
1.4 PRODUCT IDENTIFICATION
-1.4.1 MACHINE SERIAL NUMBER
-1.4.2 MACHINE IDENTIFICATION PLATE
-1.4.3 NGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
-1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER
-1.4.5 SWING REDUCTION GEAR SERIAL NUMBER
-1.4.6 CAB SERIAL NUMBER
-1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS

CONTENTS

2.1 SAFETY, NOISE AND VIBRATION PLATES
-2.1.1 POSITION OF THE SAFETY PLATES
-2.1.2 PICTOGRAMS AND RELEVANT MEANINGS
-2.1.3 POSITION OF THE NOISE PLATES
-2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
2.2 GENERAL PRECAUTIONS
-2.2.1 GENERAL SAFETY RULES
-2.2.2 SAFETY DEVICES AND GUARDS
-2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS
-2.2.4 UNAUTHORIZED MODIFICATIONS
-2.2.5 LEAVING THE OPERATOR’S SEAT
-2.2.6 GETTING ON AND OFF THE MACHINE
-2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL
-2.2.8 PREVENTING BURNS
-2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER
-2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
-2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT
-2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE
-2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE
-2.3.1 SAFETY ON THE WORK SITE
-2.3.2 FIRE PREVENTION
-2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB
-2.3.4 ROOM VENTILATION
-2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS
-2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WINDSHIELD WIPER BLADES
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING
-2.4.1 STARTING THE ENGINE
-2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE
-2.4.3 CHECKS FOR TRAVELLING IN REVERSE
-2.4.4 MOVING THE MACHINE
-2.4.5 MOVING ON SLOPES
-2.4.6 WORKING ON SLOPES
-2.4.7 UNAUTHORIZED OPERATIONS
-2.4.8 PREVENTING ELECTROCUTION
-2.4.9 VISIBILITY
-2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES
-2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
-2.4.12 WORKING ON LOOSE GROUND
-2.4.13 PARKING THE MACHINE
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES
-2.5.1 LOADING AND UNLOADING THE MACHINE
-2.5.2 SHIPPING
2.6 BATTERY
-2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES
-2.6.2 STARTING WITH BOOSTER CABLES
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
-2.8.1 WARNING PLATES
-2.8.2 TOOLS
-2.8.3 PERSONNEL
-2.8.4 EQUIPMENT
-2.8.5 WORKING UNDER THE MACHINE
-2.8.6 KEEPING THE MACHINE CLEAN
-2.8.7 USE OF THE ENGINE DURING MAINTENANCE
-2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY
-2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION
-2.8.10 RULES FOR REFUELLING AND ADDING OIL
-2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR
-2.8.12 USING LAMPS
-2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR
-2.8.14 PRECAUTIONS CONCERNING THE STARTER
-2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES
-2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMSE
-2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES
-2.8.18 COOLING FAN AND FAN BELT
-2.8.19 WASTE MATERIALS
-2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES

3.1 SAFETY LOCKS
-3.1.1 MACHINE LOCKS
3.2 GENERAL VIEWS
-3.2.1 FRONT GENERAL VIEW (MONOBOOM)
-3.2.2 FRONT GENERAL VIEW (TWO-PIECE BOOM)
-3.2.3 CAB INSIDE GENERAL VIEW
3.3 INSTRUMENTS AND CONTROLS
-3.3.1 INSTRUMENTS
-3.3.2 WARNING LIGHTS
-3.3.3 SWITCHES AND PUSH BUTTONS
-3.3.4 ELECTRICAL ACCESSORIES
-3.3.5 MACHINE CONTROLS
3.4 FUSES AND RELAYS
-3.4.1 CENTRAL UNIT FUSES AND RELAYS
--3.4.1.1 CENTRAL UNIT FUSES
--3.4.1.2 CENTRAL UNIT RELAYS
-3.4.2 ENGINE LINE FUSES AND RELAYS
--3.4.2.1 ENGINE LINE FUSES
--3.4.2.2 ENGINE LINE RELAYS
-3.4.3 FUSES AND RELAYS OF THE AIR CONDITIONING SYSTEM (if provided)
--FUSES
--RELAYS
--FUSES
--RELAYS
3.5 GUARDS AND DRIVER’S SEAT
-3.5.1 ENGINE HOOD
-3.5.2 SIDE COVER
-3.5.3 CAB
-3.5.4 VENTILATION AND HEATING
-3.5.5 AIR CONDITIONER (if provided)
-3.5.6 SEAT
-3.5.7 SAFETY BELT
-3.5.8 EMERGENCY EXIT
-3.5.9 TECHNICAL DOCUMENTATION CASE
-3.5.10 FIRE EXTINGUISHER
-3.5.11 FIRST AID KIT
3.6 USE OF THE MACHINE
-3.6.1 CHECKS BEFORE STARTING THE ENGINE
--3.6.1.1 VISUAL CHECKS
--3.6.1.2 DAILY CHECKS
--3.6.1.3 OPERATIONAL CHECKS
-3.6.2 STARTING THE ENGINE
--3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES
--3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES
-3.6.3 WARMING THE ENGINE
-3.6.4 HEATING THE HYDRAULIC OIL
-3.6.5 HOW TO MOVE THE MACHINE
--3.6.5.1 STEERING (CHANGING DIRECTION)
--3.6.5.2 MOVING ON SLOPES
--3.6.5.3 MAXIMUM IMMERSION DEPTH
3.7 PARKING THE MACHINE
-3.7.1 PARKING ON LEVEL GROUND
-3.7.2 PARKING ON SLOPES
3.8 STOPPING THE ENGINE
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES
-3.9.1 LOADING AND UNLOADING THE MACHINE
-3.9.2 TRANSPORT
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON
-3.10.1 FUEL AND LUBRICANTS
-3.10.2 COOLANT
-3.10.3 BATTERY
-3.10.4 OTHER PRECAUTIONS
-3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON
3.12 USING THE WORK EQUIPMENT
-3.12.1 ORGANIZING THE WORK AREA
-3.12.2 POSITIONING THE BUCKET ACCORDING TO THE WORK TO BE CARRIED OUT
-3.12.3 POSITIONING THE MACHINE FOR DIGGING OPERATIONS
-3.12.4 DIGGING METHOD
-3.12.5 CHANGING THE BUCKET
3.13 LONG PERIODS OF INACTIVITY
-3.13.1 BEFORE THE PERIOD OF INACTIVITY
-3.13.2 DURING THE PERIOD OF INACTIVITY
-3.13.3 AFTER THE PERIOD OF INACTIVITY
3.14 TROUBLESHOOTING
-3.14.1 HOW TO REMOVE THE MACHINE
-3.14.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED
-3.14.3 IF THE BATTERY IS DEPLETED
--3.14.3.1 STARTING WITH BOOSTER CABLES
-3.14.4 OTHER TROUBLES
--3.14.4.1 ELECTRICAL CIRCUIT
--3.14.4.2 HYDRAULIC SYSTEM
--3.14.4.3 ENGINE

4.1 GUIDE TO MAINTENANCE
4.2 MAINTENANCE NOTES
-4.2.1 NOTES REGARDING THE ENGINE
--4.2.1.1 ENGINE OIL
--4.2.1.2 COOLANT
--4.2.1.3 FUEL
-4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM
-4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM
-4.2.4 NOTES REGARDING LUBRICATION
-4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING
4.3 FUEL, COOLANT AND LUBRICANTS
-LUBRICATION WITH GREASE
-4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS
4.4 DRIVING TORQUES FOR SCREWS AND NUTS
-4.4.1 STANDARD DRIVING TORQUES
-4.4.2 SPECIFIC DRIVING TORQUES
4.5 LUBRICATION
-4.5.1 LUBRICATION DIAGRAM
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY
-4.6.1 CRITICAL PARTS FOR SAFETY
4.7 MAINTENANCE PLAN
-4.7.1 WHEN REQUIRED
--4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE
--4.7.1.b CHECKING AND CLEANING THE CAB AIR FILTER
--4.7.1.c CHECKING AND CLEANING THE AIR RECIRCULATION FILTER (only for machines equipped with air c...
--4.7.1.d CLEANING THE WATER SEPARATOR
--4.7.1.e CHECKING THE STEEL TRACK TENSION
---CHECK
---ADJUSTMENT
--4.7.1.f CHECKING THE SHOE FASTENING
-4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER
--4.7.2.a CHANGING THE HYDRAULIC OIL FILTER
--4.7.2.b CHANGING THE HYDRAULIC OIL
-4.7.3 CHECKS BEFORE STARTING
--4.7.3.a VARIOUS CHECKS
--4.7.3.b CHECKING THE COOLANT LEVEL
--4.7.3.c CHECKING THE FUEL LEVEL
--4.7.3.d CHECKING THE ENGINE OIL LEVEL
--4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT
--4.7.3.f DRAINING THE WATER SEPARATOR
-4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION
--4.7.4.a LUBRICATING THE JOINTS
---BLADE LUBRICATION POINTS
---EQUIPMENT LUBRICATION POINTS (MONOBOOM)
---EQUIPMENT LUBRICATION POINTS (TWO-PIECE BOOM)
-4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic...
-4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION
--4.7.6.a CHECKING THE RADIATOR FLUID LEVEL
--4.7.6.b LUBRICATING THE SWING JOINT
--4.7.6.c CHECKING THE ELECTRICAL SYSTEM
-4.7.7 MAINTENANCE EVERY 100 HOURS OF OPERATION
--4.7.7.a LUBRICATING THE BALL-BEARING RING
-4.7.8 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION
-4.7.9 MAINTENANCE EVERY 250 HOURS OF OPERATION
--4.7.9.a ADJUSTING THE FAN BELT TENSION
--4.7.9.b ADJUSTING THE TENSION OF THE A/C COMPRESSOR BELT (only for machines equipped with air con...
--4.7.9.c CHECKING THE BATTERY ELECTROLYTE LEVEL
--4.7.9.d CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS
--4.7.9.e CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR
-4.7.10 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the synthet...
-4.7.11 MAINTENANCE EVERY 500 HOURS OF OPERATION
--4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL FILTER
--4.7.11.b CHANGING THE SERVO CONTROL FILTER
--4.7.11.c CHANGING THE ENGINE OIL
--4.7.11.d CHANGING THE ENGINE OIL FILTER
--4.7.11.e CHANGING THE FUEL FILTER
--4.7.11.f DRAINING THE FUEL TANK
--4.7.11.g CLEANING THE OUTSIDE OF THE RADIATORS
--4.7.11.h CLEANING THE OUTSIDE OF THE A/C CONDENSER (only for machines equipped with air conditioner)
--4.7.11.j CHECKING THE BALL-BEARING RING PINION LUBRICANT LEVEL
--4.7.11.k DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable ...
-4.7.12 MAINTENANCE EVERY 1000 HOURS OF OPERATION
--4.7.12.a CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE
-4.7.13 MAINTENANCE EVERY 2000 HOURS OF OPERATION
--4.7.13.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS
--4.7.13.b CHANGING THE OIL IN THE SWING REDUCTION GEAR
--4.7.13.c CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER
--4.7.13.d CHANGING THE COOLANT
--4.7.13.e CHANGING THE BALL-BEARING RING PINION LUBRICANT
--4.7.13.f CHECKING THE ALTERNATOR AND THE STARTER
--4.7.13.g CHECKING THE A/C COOLING GAS QUANTITY (only for machines equipped with air conditioner)
-4.7.14 MAINTENANCE EVERY 4000 HOURS OF OPERATION
--4.7.14.a CHANGING THE A/C DEHYDRATOR FILTER (only for machines equipped with air conditioner)
--4.7.14.b CHECKING THE CORRECT OPERATION OF THE A/C COMPRESSOR (only for machines equipped with ai...

5.1 TECHNICAL DATA
-5.1.1 STANDARD OVERALL DIMENSIONS
--OVERALL DIMENSIONS WITH MONOBOOM
--OVERALL DIMENSIONS WITH TWO-PIECE BOOM
-5.1.2 TECHNICAL CHARACTERISTICS
-5.1.3 LIFTING CAPACITIES (Only for machines with overload alarm device)
--5.1.3.1 LIFTING CAPACITY TABLE
--5.1.3.2 LIFTING CAPACITY WITH MONOBOOM
--5.1.3.3 LIFTING CAPACITY WITH TWO-PIECE BOOM

6.1 AUTHORIZED OPTIONAL EQUIPMENT
-6.1.1 PRECAUTIONS REGARDING SAFETY
-6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT
-6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER
-6.2.1 DESCRIPTION AND OPERATION
-6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED
--FOR A CORRECT USE, IT IS NECESSARY TO:
-ALWAYS AVOID THE FOLLOWING INCORRECT USES:
-6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER
--6.2.3.1 INSTALLING THE HAMMER
--6.2.3.2 REMOVING THE HAMMER
-6.2.4 MAINTENANCE
6.3 CLAMSHELL BUCKET
-6.3.1 DESCRIPTION AND OPERATION
-6.3.2 INSTALLING THE CLAMSHELL BUCKET
-6.3.3 MAINTENANCE

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