Komatsu PC1800-6 Hydraulic Excavator Operation & Maintenance Manual EEAM022200 – PDF DOWNLOAD

Komatsu PC1800-6 Hydraulic Excavator Operation & Maintenance Manual EEAM022200 – PDF DOWNLOAD

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Komatsu PC1800-6 Hydraulic Excavator Operation & Maintenance Manual EEAM022200 – PDF DOWNLOAD

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Pages : 386
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Komatsu PC1800-6 Hydraulic Excavator Operation & Maintenance Manual EEAM022200 – PDF DOWNLOAD

• The Komatsu PC1800-6 Hydraulic Excavator Operation & Maintenance Manual (EEAM022200) is a comprehensive resource for anyone who operates or maintains the Komatsu PC1800-6 hydraulic excavator. This manual provides important information on how to safely and effectively operate and maintain the excavator to ensure that it performs at its best and has a long, reliable service life.
• The manual includes detailed information on the various systems and components of the Komatsu PC1800-6 hydraulic excavator, including the hydraulic, electrical, and mechanical systems. This information is critical for understanding how the excavator functions and how to perform routine maintenance and repairs. The manual also provides step-by-step instructions for performing regular maintenance procedures, such as checking and replacing fluids, filters, and other components.
• The Komatsu PC1800-6 Hydraulic Excavator Operation & Maintenance Manual also includes important safety information, including guidelines for safe operation and guidelines for working around the excavator. This information is crucial for ensuring that the excavator is operated safely and that workers are protected from potential hazards.
• In addition to providing important information on the operation and maintenance of the Komatsu PC1800-6 hydraulic excavator, the manual also includes detailed information on troubleshooting common problems that may arise with the excavator. This information can be invaluable for diagnosing and resolving issues quickly and efficiently, helping to minimize downtime and keep the excavator working.
• Overall, the Komatsu PC1800-6 Hydraulic Excavator Operation & Maintenance Manual is an essential resource for anyone who operates or maintains the Komatsu PC1800-6 hydraulic excavator. Whether you are an experienced operator or just starting out, this manual provides a wealth of information that can help you get the most out of your excavator and keep it in top working condition.

TABLE OF CONTENTS:

Komatsu PC1800-6 Hydraulic Excavator Operation & Maintenance Manual EEAM022200 – PDF DOWNLOAD

FOREWORD……………………………………………………………………………….. 3
FOREWORD……………………………………………………………………………. 4
SAFETY INFORMATION…………………………………………………………………… 5
INTRODUCTION………………………………………………………………………… 7
DIRECTIONS OF MACHINE…………………………………………………………….. 7
PRODUCT INFORMATION………………………………………………………………….. 8
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION………………………………………… 8
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…………………………………………. 8
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION………………………………….. 9
SERVICE METER LOCATION……………………………………………………………. 9
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…………………………………………. 10
CONTENTS……………………………………………………………………………. 11
SAFETY…………………………………………………………………………………. 15
SAFETY INFORMATION…………………………………………………………………… 16
POSITION FOR ATTACHING SAFETY LABELS…………………………………………………… 18
POSITION FOR ATTACHING SAFETY LABELS……………………………………………….. 19
SAFETY LABELS……………………………………………………………………. 20
SAFETY INFORMATION…………………………………………………………………… 25
SAFETY RULES…………………………………………………………………….. 25
IF ABNORMALITIES ARE FOUND………………………………………………………… 25
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS………………………………………….. 25
FIRE EXTINGUISHER AND FIRST AID KIT………………………………………………… 25
SAFETY EQUIPMENT…………………………………………………………………. 26
KEEP MACHINE CLEAN……………………………………………………………….. 26
KEEP OPERATOR’S COMPARTMENT CLEAN………………………………………………….. 26
LEAVING OPERATOR’S SEAT WITH LOCK………………………………………………….. 26
HANDRAILS AND STEPS………………………………………………………………. 27
MOUNTING AND DISMOUNTING………………………………………………………….. 28
NO PERSONS ON ATTACHMENTS…………………………………………………………. 28
BURN PREVENTION………………………………………………………………….. 28
FIRE PREVENTION AND EXPLOSION PREVENTION……………………………………………. 29
ACTION IF FIRE OCCURS…………………………………………………………….. 30
WINDSHIELD WASHER FLUID…………………………………………………………… 30
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION………………………. 30
ATTACHMENT INSTALLATION…………………………………………………………… 30
ATTACHMENT COMBINATIONS…………………………………………………………… 31
CAB WIDOW GLASSES………………………………………………………………… 31
UNAUTHORIZED MODIFICATIONS………………………………………………………… 31
SAFETY AT JOBSITE………………………………………………………………… 31
WORKING ON LOOSE GROUND…………………………………………………………… 32
DISTANCE TO HIGH VOLTAGE CABLES……………………………………………………. 32
ENSURE GOOD VISIBILITY……………………………………………………………. 32
VENTILATION FOR ENCLOSED AREA……………………………………………………… 33
SIGNALMAN’S SIGNAL AND SIGNS………………………………………………………. 33
EMERGENCY EXIT FROM OPERATOR’S CAB…………………………………………………. 33
ASBESTOS DUST HAZARD PREVENTION……………………………………………………. 33
SAFETY MACHINE OPERATION……………………………………………………………… 34
STARTING ENGINE………………………………………………………………….. 34
CHECKS BEFORE STARTING ENGINE………………………………………………….. 34
SAFETY RULES FOR STARTING ENGINE……………………………………………….. 35
STARTING ENGINE IN COLD WEATHER………………………………………………… 35
OPERATION……………………………………………………………………….. 36
CHECKS AFTER STARTING ENGINE…………………………………………………… 36
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…………………………………….. 36
SAFETY RULES FOR TRAVELING…………………………………………………….. 37
TRAVELING ON SLOPES…………………………………………………………… 38
OPERATIONS ON SLOPES………………………………………………………….. 39
PROHIBITED OPERATIONS…………………………………………………………. 39
OPERATIONS ON SNOW……………………………………………………………. 41
PARKING MACHINE………………………………………………………………. 41
TRANSPORTATION…………………………………………………………………… 42
SHIPPING THE MACHINE………………………………………………………….. 42
BATTERY…………………………………………………………………………. 43
BATTERY HAZARD PREVENTION……………………………………………………… 43
STARTING ENGINE WITH BOOSTER CABLES…………………………………………….. 44
TOWING………………………………………………………………………….. 45
SAFETY RULES FOR TOWING……………………………………………………….. 45
LIFTING OBJECTS WITH BUCKET……………………………………………………….. 46
SAFETY RULES FOR LIFTING OBJECTS……………………………………………….. 46
SAFETY MAINTENANCE INFORMATION………………………………………………………… 47
WARNING TAG……………………………………………………………………… 47
KEEP WORK PLACE CLEAN AND TIDY…………………………………………………….. 47
APPOINT LEADER WHEN WORKING WITH OTHERS…………………………………………….. 47
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…………………………………………. 48
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…………………………………… 49
PROPER TOOLS…………………………………………………………………….. 49
ACCUMULATOR……………………………………………………………………… 50
PERSONNEL……………………………………………………………………….. 50
ATTACHMENTS……………………………………………………………………… 50
WORK UNDER THE MACHINE……………………………………………………………. 50
NOISE…………………………………………………………………………… 51
WHEN USING HAMMER………………………………………………………………… 51
WELDING WORKS……………………………………………………………………. 51
REMOVING BATTERY TERMINALS………………………………………………………… 51
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…………………… 52
DO NOT DISASSEMBLE RECOIL SPRINGS………………………………………………….. 52
SAFETY RULES FOR HIGH-PRESSURE OIL…………………………………………………. 52
PRECAUTION FOR HIGH FUEL PRESSURE………………………………………………….. 53
SAFETY HANDLING HIGH-PRESSURE HOSES………………………………………………… 53
PRECAUTION FOR HIGH VOLTAGE……………………………………………………….. 53
WASTE MATERIALS………………………………………………………………….. 53
AIR CONDITIONER MAINTENANCE……………………………………………………….. 54
COMPRESSED AIR…………………………………………………………………… 54
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS……………………………………….. 54
OPERATION………………………………………………………………………………. 55
GENERAL VIEW………………………………………………………………………… 56
GENERAL VIEW OF MACHINE…………………………………………………………… 56
GENERAL VIEW OF CONTROLS AND GAUGES………………………………………………… 57
EXPLANATION OF COMPONENTS…………………………………………………………….. 59
MACHINE MONITOR………………………………………………………………….. 59
BASIC CHECK ITEMS…………………………………………………………….. 61
CAUTION ITEMS………………………………………………………………… 63
EMERGENCY STOP ITEMS………………………………………………………….. 65
METER DISPLAY PORTION…………………………………………………………. 67
PILOT DISPLAY………………………………………………………………… 67
GAUGES AND METER……………………………………………………………… 68
MONITOR SWITCHES……………………………………………………………… 71
CGC MONITOR……………………………………………………………………… 73
CGC MONITOR………………………………………………………………….. 73
CHANGES OF SCREEN AND CONTENT OF DISPLAY ON CGC MONITOR…………………………… 74
EXPLANATION OF SCREENS………………………………………………………… 76
SWITCHES…………………………………………………………………………111
STARTER SELECTOR SWITCH………………………………………………………..112
STARTING SWITCH……………………………………………………………….112
PREHEATING SWITCH……………………………………………………………..112
FUEL CONTROL DIAL (FRONT ENGINE)………………………………………………..113
FUEL CONTROL DIAL (REAR ENGINE)…………………………………………………113
CIGARETTE LIGHTER……………………………………………………………..113
LAMP SWITCH…………………………………………………………………..113
STEP LIGHT SWITCH……………………………………………………………..114
SWING LOCK SWITCH……………………………………………………………..114
ROOM LAMP SWITCH………………………………………………………………115
MACHINE PUSH-UP SWITCH…………………………………………………………115
FOG LAMP SWITCH……………………………………………………………….115
BOOM SHOCKLESS CONTROL SWITCH…………………………………………………..116
ROTATING LAMP SWITCH…………………………………………………………..116
ALARM BUZZER STOP SWITCH……………………………………………………….116
WINDSHIELD WIPER SWITCH………………………………………………………..117
GREASING SWITCH……………………………………………………………….117
HORN SWITCH…………………………………………………………………..117
TRUCK COUNTER SWITCH…………………………………………………………..118
ROOM LAMP SWITCH………………………………………………………………119
ROOM LAMP SWITCH………………………………………………………………120
ROOM LAMP SWITCH………………………………………………………………120
PUMP DRIVE EMERGENCY SWITCH…………………………………………………….120
SWING HOLDING BRAKE REPLEASE SWITCH……………………………………………..121
SPARE SOCKET………………………………………………………………….121
ENGINE EMERGENCY STOP SWITCH……………………………………………………121
LAMP…………………………………………………………………………….122
ENGINE EMERGENCY STOP LAMP……………………………………………………..123
AUTO GREASING CAUTION LAMP……………………………………………………..124
LADDER WARNING LAMP……………………………………………………………124
TRUCK COUNTER LAMP…………………………………………………………….125
CONTROL LEVERS, PEDALS…………………………………………………………….126
SAFETY LOCK LEVER……………………………………………………………..127
TRAVEL LEVERS…………………………………………………………………128
WORK EQUIPMENT CONTROL LEVER……………………………………………………129
DOOR LOCK………………………………………………………………………..130
POCKET…………………………………………………………………………..130
EMERGENCY ESCAPE HAMMER……………………………………………………………130
EMERGENCY ESCAPE LADDER……………………………………………………………131
FIRE EXTINGUISHER…………………………………………………………………131
CAP, COVER WITH LOCK………………………………………………………………132
METHOD OF OPENING AND CLOSING CAP WITH LOCK………………………………………132
METHOD OF OPENING AND CLOSING COVER WITH LOCK…………………………………….132
ASHTRAY………………………………………………………………………….132
HANDLING AIR CONDITIONER…………………………………………………………..133
GENERAL LOCATIONS OF CONTROL PANEL………………………………………………133
USE AIR CONDITIONER WITH CARE…………………………………………………..140
CAR RADIO………………………………………………………………………..141
EXPLANATION OF COMPONENTS………………………………………………………141
CONTROLS OF RADIO……………………………………………………………..144
AUXILIARY ELECTRIC POWER……………………………………………………….146
FUSE…………………………………………………………………………….146
CIRCUIT BREAKER…………………………………………………………………..147
CIRCUIT BREAKER (20A)………………………………………………………….147
CIRCUIT-BREAKER (40A)………………………………………………………….147
FUSE, CIRCUIT BREAKER CAPACITY AND NAME OF CIRCUIT………………………………..148
FUSE…………………………………………………………………………149
CONTROLLER (COMPUTER)……………………………………………………………..150
TOOLBOX………………………………………………………………………….151
HANDLING GREASE PUMP AND GREASE GUN…………………………………………………151
HANDLING ACCUMULATOR………………………………………………………………155
METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR….155
ORBCOMM CONTROLLER………………………………………………………………..156
MACHINE OPERATIONS AND CONTROLS………………………………………………………..157
BEFORE STARTING ENGINE…………………………………………………………….157
WALK-AROUND CHECKS…………………………………………………………….157
CHECKS BEFORE STARTING…………………………………………………………158
ADJUST BEFORE OPERATION………………………………………………………..170
SEAT BELT…………………………………………………………………….173
OPERATIONS BEFORE STARTING ENGINE……………………………………………….175
STARTING ENGINE…………………………………………………………………..178
NORMAL STARTING……………………………………………………………….178
STARTING ENGINE IN COLD WEATHER…………………………………………………180
AFTER STARTING ENGINE……………………………………………………………..183
BREAKING-IN THE NEW MACHINE…………………………………………………….183
WARMING-UP OPERATION…………………………………………………………..184
IN COLD AREAS…………………………………………………………………….187
STOPPING THE ENGINE……………………………………………………………….190
NORMAL STOPPING……………………………………………………………….190
STOPPING IN EMERGENCIES………………………………………………………..190
CHECK AFTER SHUT OFF ENGINE………………………………………………………..193
MACHINE OPERATION…………………………………………………………………194
PREPARATIONS FOR MOVING THE MACHINE OFF………………………………………….194
MOVING MACHINE FORWARD…………………………………………………………195
MOVING MACHINE BACKWARD………………………………………………………..196
STOPPING MACHINE………………………………………………………………197
STEERING THE MACHINE………………………………………………………………198
STEERING……………………………………………………………………..198
SWINGING…………………………………………………………………………200
WORK EQUIPMENT CONTROLS AND OPERATIONS………………………………………………201
HANDLING WORKING MODE……………………………………………………………..202
WORKING MODE………………………………………………………………….202
PROHIBITED OPERATIONS……………………………………………………………..203
OPERATIONS USING SWING FORCE……………………………………………………203
OPERATIONS USING TRAVEL FORCE…………………………………………………..203
OPERATIONS USING HYDRAULIC CYLINDER STROKE ENDS…………………………………..203
OPERATIONS USING BUCKET DROPPING FORCE…………………………………………..204
OPERATIONS USING MACHINE DROPPING FORCE………………………………………….204
DIGGING HARD ROCKY GROUND………………………………………………………204
GENERAL OPERATION INFORMATION………………………………………………………205
TRAVELING…………………………………………………………………….205
PERMISSIBLE WATER DEPTH………………………………………………………..205
TRAVELING ON SLOPES……………………………………………………………….206
TRAVELING DOWNHILL…………………………………………………………….207
ENGINE STOPPED ON SLOPE………………………………………………………..207
PRECAUTIONS ON SLOPES………………………………………………………….207
ESCAPE FROM MUD…………………………………………………………………..208
STUCK ONE SIDE OF TRACK………………………………………………………..208
STUCK BOTH SIDES OF TRACKS……………………………………………………..208
RECOMMENDED APPLICATIONS…………………………………………………………..209
BACKHOE WORK………………………………………………………………….209
LOADING WORK………………………………………………………………….209
REPLACEMENT AND INVERSION OF BUCKET…………………………………………………210
REPLACEMENT…………………………………………………………………..210
PARKING MACHINE…………………………………………………………………..212
CHECK AFTER FINISHING WORK…………………………………………………………213
LOCKING………………………………………………………………………….214
TRANSPORTATION……………………………………………………………………….215
PRECAUTIONS FOR TRANSPORTATION……………………………………………………..215
REMOVAL AND INSTALLATION OF MIRRORS……………………………………………..215
LIFTING MACHINE…………………………………………………………………..216
PARTS FOR TRANSPORT……………………………………………………………….216
COLD WEATHER OPERATION………………………………………………………………..217
COLD WEATHER OPERATION INFORMATION………………………………………………….217
FUEL AND LUBRICANTS……………………………………………………………217
COOLING SYSTEM COOLANT…………………………………………………………217
BATTERY………………………………………………………………………218
AFTER DAILY WORK COMPLETION………………………………………………………..219
AFTER COLD WEATHER SEASON………………………………………………………….219
LONG TERM STORAGE…………………………………………………………………….220
BEFORE STORAGE……………………………………………………………………220
DURING STORAGE……………………………………………………………………220
AFTER STORAGE…………………………………………………………………….221
STARTING MACHINE AFTER LONG-TERM STORAGE…………………………………………221
TROUBLESHOOTING………………………………………………………………………222
AFTER RUNNING OUT OF FUEL………………………………………………………….222
PHENOMENA THAT ARE NOT FAILURES…………………………………………………….223
TOWING THE MACHINE………………………………………………………………..224
PRECAUTIONS ON PARTICULAR JOBSITES………………………………………………….224
DISCHARGED BATTERY………………………………………………………………..225
REMOVAL AND INSTALLATION OF BATTERY……………………………………………..226
BATTERY CHARGES……………………………………………………………….226
STARTING ENGINE WITH BOOSTER CABLES……………………………………………..227
OTHER TROUBLE…………………………………………………………………….229
ELECTRICAL SYSTEM……………………………………………………………..229
CHASSIS………………………………………………………………………230
ENGINE……………………………………………………………………….231
ELECTRONIC CONTROL SYSTEM………………………………………………………233
MAINTENANCE……………………………………………………………………………..235
MAINTENANCE INFORMATION……………………………………………………………….236
SERVICE METER READING……………………………………………………………..236
KOMATSU GENUINE REPLACEMENT PARTS…………………………………………………..236
KOMATSU GENUINE LUBRICANTS…………………………………………………………236
WINDSHIELD WASHER FLUID……………………………………………………………236
FRESH AND CLEAN LUBRICANTS…………………………………………………………236
CHECK DRAINED OIL AND USED FILTER…………………………………………………..236
FUEL STRAINER…………………………………………………………………….236
WELDING INSTRUCTIONS………………………………………………………………236
DO NOT DROP THINGS INSIDE MACHINE…………………………………………………..237
DUSTY JOBSITE…………………………………………………………………….237
AVOID MIXING LUBRICANTS……………………………………………………………237
LOCKING THE INSPECTION COVERS………………………………………………………237
HYDRAULIC SYSTEM – AIR BLEEDING…………………………………………………….237
HYDRAULIC HOSE INSTALLATION………………………………………………………..237
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS………………………………………..238
LUBRICANTS, COOLANT AND FILTERS………………………………………………………..239
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC………………………………..239
OIL………………………………………………………………………….239
FUEL…………………………………………………………………………239
COOLING SYSTEM COOLANT…………………………………………………………240
GREASE……………………………………………………………………….240
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)…………………………………….240
OIL AND FUEL STORAGE…………………………………………………………..241
FILTERS………………………………………………………………………242
ELECTRIC SYSTEM MAINTENANCE………………………………………………………..242
WEAR PARTS LIST………………………………………………………………………243
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE……………………….244
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS……………………………………..244
TIGHTENING TORQUE SPECIFICATIONS……………………………………………………….248
TIGHTENING TORQUE LIST…………………………………………………………….248
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS……………………………………………249
SAFETY CRITICAL PARTS……………………………………………………………..250
MAINTENANCE SCHEDULE………………………………………………………………….252
MAINTENANCE SCHEDULE CHART…………………………………………………………252
Initial 100 Hours Maintenance (Only after the first 250 hours)……………………..252
Initial 250 Hours Maintenance (Only after the first 250 hours)……………………..252
When Required…………………………………………………………………252
Checks Before Starting…………………………………………………………252
Every 10 Hours Maintenance……………………………………………………..252
Every 100 Hours Maintenance…………………………………………………….253
Every 250 Hours Maintenance…………………………………………………….253
Every 500 Hours Maintenance…………………………………………………….253
Every 1000 Hours Maintenance……………………………………………………253
Every 2000 Hours Maintenance……………………………………………………254
Every 4000 Hours Maintenance……………………………………………………254
Every 5000 Hours Maintenance……………………………………………………254
Every 8000 Hours Maintenance……………………………………………………254
MAINTENANCE PROCEDURE…………………………………………………………………255
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…………………………255
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…………………………255
WHEN REQUIRED…………………………………………………………………….256
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT……………………………………..256
CLEAN INSIDE OF COOLING SYSTEM………………………………………………….259
CHECK AND TIGHTEN TRACK SHOE BOLTS………………………………………………263
CHECK AND ADJUST TRACK TENSION………………………………………………….264
CHECK ELECTRICAL INTAKE AIR HEATER………………………………………………267
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…………………………………………268
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)……………………………………….271
ADJUST BUCKET CLEARANCE………………………………………………………..272
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID……………………………………….273
CHECK AND ADJUST AIR CONDITIONER………………………………………………..274
CLEANING, REMOVING DIRT FROM LINE FILTER…………………………………………275
REPLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER…………………………..276
GREASE LADDER…………………………………………………………………277
INSPECT SEALANT AROUND ENGINE COOLING SYSTEM……………………………………..278
CHECK FOR LOOSE AFTERCOOLER HOSE CLAMPS………………………………………….279
PROCEDURE FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT…………………………………279
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT………………………..287
CHECK BEFORE STARTING……………………………………………………………..289
EVERY 10 HOURS MAINTENANCE…………………………………………………………290
LUBRICATING…………………………………………………………………..290
EVERY 100 HOURS MAINTENANCE………………………………………………………..294
CHECK OIL LEVEL IN SWING MACHINERY CASE………………………………………….294
EVERY 250 HOURS MAINTENANCE………………………………………………………..295
GREASING FAN PULLEY ASSEMBLY, TENSION PULLEY ASSEMBLY……………………………..295
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL……………………………………..295
CHECK LEVEL OF BATTERY ELECTROLYTE………………………………………………296
REPLACE FILTER ELEMENT OF HYDRAULIC TANK BREATHER…………………………………298
CHECK, WASH FUEL STRAINER………………………………………………………299
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS……………………………300
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST………………………………………301
CHECK ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT……………………………303
EVERY 500 HOURS MAINTENANCE………………………………………………………..305
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…………………..305
REPLACE FUEL FILTER CARTRIDGE…………………………………………………..308
CLEAN PILOT FILTER STRAINER…………………………………………………….310
CLEAN HYDRAULIC FILTER STRAINER FOR AUTO GREASING DRIVE……………………………310
CHANGE HYDRAULIC FILTER ELEMENT…………………………………………………311
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, FUEL COOLER AND AFTER COOLER FINS…..312
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM…………………..314
CLEAN STRAINER OF PTO LUBRICATING OIL FILTER……………………………………..316
CHECK, REPLACE, ADJUST FAN BELT…………………………………………………317
CHECK, REPLACE HYDRAULIC PUMP DRAIN FILTER CARTRIDGE………………………………318
REPLACING SWING MOTOR DRAIN FILTER CARTRIDGE……………………………………..319
REPLACING TRAVEL MOTOR DRAIN FILTER CARTRIDGE…………………………………….320
EVERY 1000 HOURS MAINTENANCE……………………………………………………….321
CHANGE OIL IN SWING MACHINERY CASE………………………………………………321
CHANGE OIL IN PTO CASE…………………………………………………………323
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER……………………………………….323
REPLACE CORROSION RESISTOR CARTRIDGE…………………………………………….324
INSPECTION OF WELDED STRUCTURE AFTER INITIAL 4000 HOURS SERVICE…………………….324
EVERY 2000 HOURS MAINTENANCE……………………………………………………….325
CHANGE OIL IN FINAL DRIVE CASE………………………………………………….325
CHANGE OIL IN HYDRAULIC TANK, WASH STRAINER………………………………………326
CHECK SWING PINION GREASE LEVEL, ADD GREASE………………………………………329
CLEAN ENGINE BREATHER………………………………………………………….329
CLEAN, CHECK TURBOCHARGER………………………………………………………329
CHECK ALTERNATOR AND STARTING MOTOR……………………………………………..329
CHECK ENGINE VALVE CLEARANCES, ADJUST……………………………………………330
CHECK INJECTOR………………………………………………………………..330
EVERY 4000 HOURS MAINTENENCE……………………………………………………….331
CHECK WATER PUMP………………………………………………………………331
CHECK VIBRATION DAMPER…………………………………………………………331
CHECK FAN PULLEY AND TENSION PULLEY……………………………………………..331
REPLACE INJECTOR NOZZLE ASSEMBLY………………………………………………..331
CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…………………….332
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER……………………333
CHECK, ADJUST AIR COMPRESSOR……………………………………………………333
CHECK WELDED STRUCTURE…………………………………………………………334
EVERY 5000 HOURS MAINTENANCE……………………………………………………….337
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER……………………………………..337
EVERY 8000 HOURS MAINTENANCE……………………………………………………….340
REPLACE HIGH-PRESSURE PIPING CLAMP………………………………………………340
REPLACE FUEL SPRAY PREVENTION CAP……………………………………………….340
SPECIFICATIONS…………………………………………………………………………..341
SPECIFICATIONS……………………………………………………………………….342
ATTACHMENTS AND OPTIONS…………………………………………………………………..345
GENERAL PRECAUTIONS…………………………………………………………………..346
PRECAUTIONS RELATED TO SAFETY………………………………………………………346
PRECAUTIONS WHEN INSTALLING ATTACHMENTS……………………………………………..348
ATTACHMENT GUIDE……………………………………………………………………..349
COMBINATIONS OF WORK EQUIPMENT……………………………………………………..349
PROTECTIVE GUARD………………………………………………………………….350
AUTO GREASING SYSTEM………………………………………………………………351
CONTROL DEVICES……………………………………………………………….352
LOADING SHOVEL…………………………………………………………………………..355
GENERAL VIEW…………………………………………………………………………356
GENERAL VIEW OF MACHINE……………………………………………………………356
GENERAL VIEW OF CONTROLS AND GAUGES…………………………………………………357
EXPLANATION OF COMPONENTS……………………………………………………………..358
SWITCHES…………………………………………………………………………358
AUTOMATIC LEVEL CROWDING/BUCKET ANGLE COMPENSATION SWITCH………………………….358
AUTOMATIC LEVEL CROWDING SWITCH…………………………………………………358
BUCKET ANGLE COMPENSATION SWITCH………………………………………………..358
BOTTOM DUMP SWITCH…………………………………………………………….359
HORN SWITCH…………………………………………………………………..359
CONTROL BOX………………………………………………………………………359
OPERATIONS…………………………………………………………………………..360
OPERATION OF WORK EQUIPMENT………………………………………………………..360
PRECAUTIONS DURING OPERATION……………………………………………………….362
EXCAVATOR WORK……………………………………………………………………366
PRECAUTIONS WHEN DISASSEMBLING MACHINE………………………………………………….367
RELEASING PRESSURE………………………………………………………………..367
RELEASING PRESSURE FROM WORK EQUIPMENT CIRCUIT, SWING CIRCUIT, TRAVEL CIRCUIT………..367
RELEASING PRESSURE IN ACCUMULATOR CIRCUIT………………………………………..367
TROUBLESHOOTING………………………………………………………………………368
WORK EQUIPMENT AUTOMATIC CONTROL CONTROLLER………………………………………….368
TRANSPORTATION……………………………………………………………………….369
MACHINE CONFIGURATION FOR TRANSPORT…………………………………………………369
MAINTENANCE SCHEDULE………………………………………………………………….370
EVERY 10 HOURS MAINTENANCE…………………………………………………………370
PREPARATIONS BEFORE LUBRICATION…………………………………………………370
LUBRICATION…………………………………………………………………..373
SPECIFICATION………………………………………………………………………..379
COMBINATION OF WORK EQUIPMENT………………………………………………………….381
COMBINATION OF WORK EQUIPMENT………………………………………………………381
INDEX……………………………………………………………………………….383