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

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the PC25-1, PC30-7, PC40-7, PC45-1 Komatsu Hydraulic Excavator. It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu PC25-1 - S/N: 6471 and up
Komatsu PC30-7 - S/N: 26423 and up
Komatsu PC40-7 - S/N: 24522 - 24994
Komatsu PC45-1 - S/N: 3506 and up


TABLE OF CONTENTS :

- SAFETY
- OPERATION
- MAINTENANCE
- SPECIFICATIONS
- OPTIONS, ATTACHMENTS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEAM006600
Total Pages : 213


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1. FOREWORD
2. SAFETY INFORMATION
3. INTRODUCTION
3.1 INTENDED USE
3.2 FEATURES
3.3 BREAKING IN THE MACHINE
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
4.1 MACHINE SERIAL NO. PLATE POSITION
4.2 ENGINE SERIAL NO. PLATE POSITION
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

CONTENTS

SAFETY
6. GENERAL PRECAUTIONS
7. PRECAUTIONS DURING OPERATION
7.1 BEFORE STARTING ENGINE
7.2 OPERATING MACHINE
7.3 TRANSPORTATION
7.4 BATTERY
7.5 TOWING
7.6 BUCKET WITH HOOK
8. PRECAUTIONS FOR MAINTENANCE
8.1 BEFORE CARRYING OUT MAINTENANCE
8.2 DURING MAINTENANCE
9. POSITION FOR ATTACHING SAFETY LABELS

OPERATION
10. GENERAL VIEW
10.1 GENERAL VIEW OF MACHINE
10.2 GENERAL VIEW OF CONTROLS AND GAUGES
11. EXPLANATION OF COMPONENTS
11.1 MACHINE MONITOR
11.2 SWITCHES
11.3 CONTROL LEVERS AND PEDALS
11.4 ENGINE HOOD
11.5 FRONT WINDOW (MACHINES EQUIPPED WITH CAB)
11.6 DOOR LOCK
11.7 FUSE
11.8 FUSIBLE LINK
11.9 CAP, COVER WITH LOCK
11.10 CANOPY (MACHINES EQUIPPED WITH CANOPY)
12. OPERATION
12.1 CHECK BEFORE STARTING ENGINE
12.2 STARTING ENGINE
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE
12.4 MOVING MACHINE OFF
12.5 STEERING MACHINE
12.6 STOPPING MACHINE
12.7 SWINGING
12.8 OPERATION OF WORK EQUIPMENT
12.9 PROHIBITIONS FOR OPERATION
12.10 PRECAUTIONS FOR OPERATION
12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS
12.12 HOW TO ESCAPE MUD
12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR
12.14 REPLACEMENT OF BUCKET
12.15 PARKING MACHINE
12.16 CHECK AFTER FINISHING WORK
12.17 STOPPING ENGINE
12.18 CHECK AFTER STOPPING ENGINE
12.19 LOCKING
12.20 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)
13. TRANSPORTATION
13.1 LOADING, UNLOADING WORK
13.2 METHOD OF LIFTING MACHINE
13.3 PRECAUTIONS FOR LOADING
13.4 PRECAUTIONS FOR TRANSPORTATION
14. COLD WEATHER OPERATION
14.1 PRECAUTIONS FOR LOW TEMPERATURE
14.2 PRECAUTIONS AFTER COMPLETION OF WORK
14.3 PREPARING THE CAB HEATER (MACHINES EQUIPPED WITH CAB)
14.4 AFTER COLD WEATHER
15. LONG-TERM STORAGE
15.1 BEFORE STORAGE
15.2 DURING STORAGE
15.3 AFTER STORAGE
16. TROUBLESHOOTING
16.1 PHENOMENA THAT ARE NOT FAILURES
16.2 METHOD OF TOWING MACHINE
16.3 PRECAUTIONS ON PARTICULAR JOBSITES
16.4 IF BATTERY IS DISCHARGED
16.5 OTHER TROUBLE

MAINTENANCE
17. GUIDES TO MAINTENANCE
18. OUTLINES OF SERVICE
18.1 OUTLINE OF OIL, FUEL, COOLANT
18.2 OUTLINE OF ELECTRIC SYSTEM
18.3 OUTLINE OF HYDRAULIC SYSTEM
19. WEAR PARTS LIST
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
21.1 INTRODUCTION OF NECESSARY TOOLS
21.2 TORQUE LIST
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
23. MAINTENANCE SCHEDULE CHART
23.1 MAINTENANCE SCHEDULE CHART
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER
24. SERVICE PROCEDURE
24.1 INITIAL 250 HOURS SERVICE
CHECK ENGINE VALVE CLEARANCE, ADJUST
24.2 WHEN REQUIRED
24.2.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
24.2.2 CLEAN INSIDE OF COOLING SYSTEM
24.2.3 DRAIN WATER, SEDIMENT FROM FUEL TANK
24.2.4 CLEAN WATER SEPARATOR ELEMENT
24.2.5 CHECK ELECTRIC WIRINGS
24.2.6 CHECK RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)
24.2.7 CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)
24.2.8 REPLACE RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)
24.2.9 CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH STEEL SHOES)
24.2.10 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)
24.2.11 INSPECTION OF BUCKET PLAY ADJUSTMENT MECHANISM
24.3 CHECK BEFORE STARTING
24.3.1 CHECK COOLANT LEVEL, ADD WATER
24.3.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
24.3.3 CHECK FUEL LEVEL, ADD FUEL
24.3.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
24.3.5 CHECK DUST INDICATOR
24.3.6 CHECK WATER SEPARATOR
24.4 EVERY 100 HOURS SERVICE
24.4.1 LUBRICATING
1. SWING PINION (1POINT)
2. SWING CIRCLE (1POINT)
3. BOOM SWING CYLINDER FOOT PIN (1POINT)
4. BOOM SWING CYLINDER ROD END (1POINT)
5. BOOM CYLINDER FOOT PIN (1POINT)
6. BLADE CYLINDER FOOT PIN (1POINT)
7. BLADE FOOT PIN (2 POINTS)
8. BLADE CYLINDER ROD END (1POINT)
9. BOOM FOOT PIN (2 POINTS)
10. BOOM SWING BRACKET PIN (2 POINTS)
11. ARM CYLINDER FOOT PIN (1POINT)
12. BOOM CYLINDER ROD END (1POINT)
13. BOOM-ARM COUPLING PIN (1POINT)
14. ARM CYLINDER ROD END PIN (1POINT)
15. BUCKET CYLINDER FOOT PIN (1POINT)
16. BUCKET CYLINDER ROD END PIN (1POINT)
17. LINK COUPLING PIN (1POINT)
18. BUCKET-LINK COUPLING PIN (2 POINTS)
19. ARM-BUCKET COUPLING PIN (1POINT)
20. ARM-LINK COUPLING PIN (1POINT)
24.5 EVERY 250 HOURS SERVICE
24.5.1 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
24.5.2 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
24.5.3 CHECK LEVEL OF BATTERY ELECTROLYTE
24.5.4 REPLACE HYDRAULIC FILTER ELEMENT
24.5.5 CHECK FAN BELT TENSION, ADJUST
24.6 EVERY 500 HOURS SERVICE
24.6.1 REPLACE FUEL FILTER CARTRIDGE
24.6.2 CLEAN, CHECK RADIATOR FINS
24.7 EVERY 1000 HOURS SERVICE
24.7.1 CHANGE OIL IN SWING MACHINERY CASE
24.7.2 CHANGE OIL IN FINAL DRIVE CASE
24.8 EVERY 2000 HOURS SERVICE
24.8.1 CHANGE OIL IN HYDRAULIC TANK CLEAN STRAINER
24.8.2 CHECK ALTERNATOR, STARTING MOTOR
24.8.3 CHECK ENGINE VALVE CLEARANCE, ADJUST

SPECIFICATIONS
25. SPECIFICATIONS

OPTIONS, ATTACHMENTS
26. GENERAL PRECAUTIONS
26.1 PRECAUTIONS RELATED TO SAFETY
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS
27. HANDLING BUCKET WITH HOOK
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK
27.2 PROHIBITED OPERATIONS
27.3 PRECAUTIONS DURING OPERATIONS

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