Komatsu PC80MR-3 excavator pdf operation and maintenance manual

Table of Contents for KOMATSU-WEAM009700 manual

• 1.1 FOREWORD
• 1.2 INFORMATION ON SAFETY
• 1.3 INTRODUCTION
  • 1.3.1 INTENDED USE OF THE MACHINE
  • 1.3.2 IMPROPER OR UNAUTHORIZED USES
  • 1.3.3 RUNNING-IN
  • 1.3.4 POSITIONS AND DIRECTIONS OF THE MACHINE
• 1.4 PRODUCT IDENTIFICATION
  • 1.4.1 MACHINE SERIAL NUMBER
  • 1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
  • 1.4.3 ENGINE 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
• 1.5 KOMTRAX SYSTEM
  • 1.5.1 GENERAL PRECAUTIONS
• TABLE OF 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 SAFETY RULES
  • 2.2.2 HOW TO BEHAVE IN CASE OF ANOMALIES
  • 2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS
  • 2.2.4 FIRE EXTINGUISHERS AND FIRST AID KIT
  • 2.2.5 SAFETY DEVICES AND GUARDS
  • 2.2.6 CLEANING THE MACHINE
  • 2.2.7 INSIDE OF THE CAB
  • 2.2.8 LEAVING THE OPERATOR SEAT
  • 2.2.9 GETTING ON AND OFF THE MACHINE
  • 2.2.10 IT IS FORBIDDEN TO CLIMB ON THE EQUIPMENT
  • 2.2.11 ARTICULATED PARTS
  • 2.2.12 PREVENTING BURNS
  • 2.2.13 PREVENTING FIRES DUE TO FUEL AND OIL
  • 2.2.14 HOW TO BEHAVE IN CASE OF FIRE
  • 2.2.15 DETERGENT FOR THE WINDOWS
  • 2.2.16 PROTECTION AGAINST FALLING OBJECTS, FLYING OBJECTS, FOREIGN BODIES
  • 2.2.17 PRECAUTIONS CONCERNING THE EQUIPMENT
  • 2.2.18 COMBINING THE WORK EQUIPMENT
  • 2.2.19 WORK LIGHT AND CAB LIGHTS
  • 2.2.20 CAB WINDOWS
  • 2.2.21 PRECAUTIONS CONCERNING THE CAB STRUCTURE
  • 2.2.22 UNAUTHORIZED MODIFICATIONS
  • 2.2.23 SAFETY AT THE WORKPLACE
  • 2.2.24 WORKING ON LOOSE GROUND
  • 2.2.25 PREVENTING ELECTROCUTION
  • 2.2.26 VISIBILITY
  • 2.2.27 ROOM VENTILATION
  • 2.2.28 CHECKING THE SIGNALS OF THE SIGNALMAN AND THE FIXED SIGNS
  • 2.2.29 HAND SIGNALS
  • 2.2.30 EMERGENCY EXIT
  • 2.2.31 PREVENTING DAMAGE DUE TO ASBESTOS POWDER
• 2.3 PRECAUTIONS FOR USE
  • 2.3.1 BEFORE STARTING THE ENGINE
  • 2.3.2 PRECAUTIONS TO BE TAKEN WHEN WORKING
  • 2.3.3 TRANSPORTING THE MACHINE
  • 2.3.4 BATTERY
  • 2.3.5 REMOVAL
• 2.4 PRECAUTIONS FOR MAINTENANCE
  • 2.4.1 WARNING PLATES
  • 2.4.2 KEEP THE WORK PLACE CLEAN AND ORDERLY
  • 2.4.3 APPOINT A SUPERVISOR WHEN WORKING WITH OTHER PEOPLE
  • 2.4.4 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION
  • 2.4.5 MAINTENANCE OPERATIONS TO BE CARRIED OUT WITH THE ENGINE RUNNING REQUIRE THE PRESENCE OF TWO OPERATORS
  • 2.4.6 TOOLS
  • 2.4.7 HYDRAULIC ACCUMULATOR
  • 2.4.8 MAINTENANCE STAFF
  • 2.4.9 EQUIPMENT
  • 2.4.10 WORKING UNDER THE MACHINE
  • 2.4.11 NOISE
  • 2.4.12 PRECAUTIONS TO BE TAKEN WHEN USING THE HAMMER
  • 2.4.13 REPAIR WELDS
  • 2.4.14 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL
  • 2.4.15 CHECKING THE COOLANT LEVEL IN THE RADIATOR
  • 2.4.16 USING LAMPS
  • 2.4.17 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR
  • 2.4.18 PRECAUTIONS CONCERNING THE STARTER
  • 2.4.19 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE TRACK TENSION
  • 2.4.20 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT
  • 2.4.21 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL
  • 2.4.22 HANDLING HIGH-PRESSURE HOSES
  • 2.4.23 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE
  • 2.4.24 COOLING FAN AND BELT
  • 2.4.25 WASTE MATERIALS
  • 2.4.26 SERVICING THE AIR CONDITIONER
  • 2.4.27 COMPRESSED AIR
  • 2.4.28 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY
  • 2.4.29 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS
  • 2.4.30 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE HEES
• 3.1 DESCRIPTION AND USE OF THE MACHINE
  • 3.1.1 GENERAL VIEW OF THE MACHINE WITH MONOBOOM
  • 3.1.2 GENERAL VIEW OF THE MACHINE WITH TWO-PIECE BOOM
  • 3.1.3 CONTROLS AND INDICATORS
• 3.2 INSTRUMENTS AND CONTROLS
  • 3.2.1 DASHBOARD
  • 3.2.2 SWITCHES AND PUSH BUTTONS
  • 3.2.3 CONTROL LEVERS AND PEDALS
  • 3.2.4 CAB
  • 3.2.5 COVERS WITH LOCK
  • 3.2.6 ENGINE HOOD
  • 3.2.7 TANK COVER
  • 3.2.8 FUSES AND RELAY
  • 3.2.9 CONTROLLER
  • 3.2.10 VENTILATION AND HEATING
  • 3.2.11 AIR CONDITIONER (if installed)
  • 3.2.12 TECHNICAL DOCUMENTATION COMPARTMENT
  • 3.2.13 TOOL BOX
  • 3.2.14 GREASING PUMP SUPPORT
  • 3.2.15 ASHTRAY
  • 3.2.16 FIRE EXTINGUISHERS
  • 3.2.17 FIRST AID KIT
• 3.3 USE OF THE MACHINE
  • 3.3.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE
  • 3.3.2 DAILY CHECKS
  • 3.3.3 ADJUSTMENTS
  • 3.3.4 SEAT BELT
  • 3.3.5 OPERATIONAL CHECKS
  • 3.3.6 STARTING THE ENGINE
  • 3.3.7 AFTER STARTING THE ENGINE
  • 3.3.8 STOPPING THE ENGINE
  • 3.3.9 CHECKS TO BE CARRIED OUT AFTER STOPPING THE ENGINE
  • 3.3.10 OPERATING THE MACHINE
  • 3.3.11 STEERING THE MACHINE
  • 3.3.12 SWINGING THE TURRET
  • 3.3.13 WORK EQUIPMENT CONTROLS AND FUNCTIONS
  • 3.3.14 WORK MODE
  • 3.3.15 UNAUTHORIZED OPERATIONS
  • 3.3.16 IGENERAL INFORMATION ON THE OPERATION OF THE MACHINE
  • 3.3.17 MOVING ON SLOPES
  • 3.3.18 GETTING THE MACHINE OUT OF MUD
  • 3.3.19 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR
  • 3.3.20 CHANGING THE BUCKET
  • 3.3.21 PARKING THE MACHINE
  • 3.3.22 CHECKS TO BE CARRIED OUT ON THE MACHINE AT THE END OF THE WORK DAY
  • 3.3.23 LOCKING THE MACHINE
  • 3.3.24 ROAD LINERS AND RUBBER TRACKS
• 3.4 TRANSPORTING THE MACHINE
  • 3.4.1 TRANSPORT PROCEDURE
  • 3.4.2 LOADING AND UNLOADING THE MACHINE
  • 3.4.3 HOW TO LIFT THE MACHINE
• 3.5 USING THE MACHINE IN COLD CLIMATES
  • 3.5.1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON
  • 3.5.2 AT THE END OF THE WORK DAY
  • 3.5.3 AT THE END OF THE COLD SEASON
• 3.6 LONG PERIODS OF INACTIVITY
  • 3.6.1 BEFORE A PERIOD OF INACTIVITY
  • 3.6.2 DURING A PERIOD OF INACTIVITY
  • 3.6.3 AFTER A PERIOD OF INACTIVITY
• 3.7 TROUBLESHOOTING
  • 3.7.1 IF FUEL RUNS OUT COMPLETELY
  • 3.7.2 OCCURRENCES THAT ARE NOT FAILURES
  • 3.7.3 REMOVING THE MACHINE
  • 3.7.4 DEMANDING OPERATING CONDITIONS
  • 3.7.5 IF THE BATTERY IS DOWN
  • 3.7.6 REMOVING AND INSTALLING THE BATTERY
  • 3.7.7 CHARGING THE BATTERY
  • 3.7.8 STARTING WITH BOOSTER CABLES
  • 3.7.9 LOWERING THE WORK EQUIPMENT WHEN THE ENGINE STOPS BECAUSE OF A FAILURE
  • 3.7.10 OTHER TROUBLES
• 4.1 GUIDE TO MAINTENANCE
• 4.2 MAINTENANCE NOTES
  • 4.2.1 OIL, FUEL AND COOLANT
  • 4.2.2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM
  • 4.2.3 NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM
  • 4.2.4 MAINTENANCE NOTES REGARDING LUBRICATION
• 4.3 PARTS SUBJECT TO WEAR
  • 4.3.1 LIST OF THE PARTS SUBJECT TO WEAR
• 4.4 FUEL, COOLANT AND LUBRICANTS
  • 4.4.1 COOLANT
  • 4.4.2 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES
• 4.5 TIGHTENING TORQUES
  • 4.5.1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS
  • 4.5.2 STANDARD TIGHTENING TORQUES FOR HOSES WITH ORFS
• 4.6 LUBRICATION
  • 4.6.1 LUBRICATION DIAGRAM
• 4.7 PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS
  • 4.7.1 SAFETY-RELATED PARTS
• 4.8 MAINTENANCE PLAN
  • 4.8.1 MAINTENANCE PLAN
  • 4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER
• 4.9 MAINTENANCE PROCEDURES
  • 4.9.1 WHEN REQUIRED
  • 4.9.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE
  • 4.9.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)
  • 4.9.4 MAINTENANCE EVERY 50 HOURS OF OPERATION
  • 4.9.5 MAINTENANCE EVERY 100 HOURS OF OPERATION
  • 4.9.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION
  • 4.9.7 MAINTENANCE EVERY 250 HOURS OF OPERATION
  • 4.9.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)
  • 4.9.9 MAINTENANCE EVERY 500 HOURS OF OPERATION
  • 4.9.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION
  • 4.9.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION
  • 4.9.12 MAINTENANCE EVERY 4000 HOURS OF OPERATION
  • 4.9.13 MAINTENANCE EVERY 5000 HOURS OF OPERATION
• 5.1 TECHNICAL DATA
• 5.2 LIFTING CAPACITIES
  • 5.2.1 LIFTING CAPACITIES WITH MONOBOOM
• 6.1 AUTHORIZED OPTIONAL EQUIPMENT
  • 6.1.1 PRECAUTIONS REGARDING SAFETY
  • 6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT
  • 6.1.3 AUTHORISED TOOLS CHARACTERISTICS
• 6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER
  • 6.2.1 DESCRIPTION AND CONTROL
  • 6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED
  • 6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER
  • 6.2.4 MAINTENANCE
• 6.3 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET SWING SYSTEM (second hydraulic line)
• 6.4 ARRANGEMENT FOR THE INSTALLATION OF THE BUCKET QUICK COUPLING SYSTEM (Third hydraulic line)
• 6.5 INSTALLING AND REMOVING THE ADDITIONAL COUNTERWEIGHT