Description

Komatsu PC20R-8, PC27R-8 Hydraulic Excavator Operation and Maintenance Manual (WEAM000102)

Komatsu PC20R-8, PC27R-8 Hydraulic Excavator Index:

• EAMPC20.pdf
  • 1.1 FOREWORD
  • 1.2 INFORMATION ON SAFETY
  • 1.3 INTRODUCTION
    • 1.3.1 INTENDED USES
    • 1.3.2 IMPROPER OR UNAUTHORIZED USES
    • 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 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 MOTOR SERIAL NUMBER (for PC20R only)
    • 1.4.6 SWING REDUCTION GEAR SERIAL NUMBER (for PC27R only)
    • 1.4.7 CAB SERIAL NUMBER
    • 1.4.8 SERIAL NUMBERS AND DEALER’S ADDRESS
  • THIS PAGE WAS INTENTIONALLY LEFT EMPTY
  • TABLE OF CONTENTS
  • THIS PAGE WAS INTENTIONALLY LEFT EMPTY
  • 2.1 SAFETY, NOISE AND VIBRATION PLATES
    • 2.1.1 POSITION OF THE SAFETY PLATES
    • 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS
    • DANGER IN THE WORK AREA
    • DO NOT OPEN THE HOOD
    • CONSULT THE MANUAL
    • HYDRAULIC OIL TOPPING UP
    • FILLING THE HYDRAULIC SYSTEM WITH OIL
    • REFUELLING
    • ENGINE LUBRICATING OIL FILTER
    • FUEL FILTER
    • ENGINE AIR SUCTION FILTER
    • ENGINE COOLANT
    • ENGINE COOLANT PRESSURE
    • HYDRAULIC OIL LEVEL
    • HYDRAULIC OIL FILTER
    • ELECTRIC OUTLET
    • ANCHORAGE POINT
    • EMERGENCY EXIT
    • LIFTING POINT
    • DO NOT LIFT MORE THAN 1000 kg
    • 2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB
    • NOISE OUTSIDE THE CAB
    • NOISE INSIDE THE CAB
    • 2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY
    • EXTERNAL NOISE
    • NOISE PERCEIVED BY THE OPERATOR
    • 2.1.5 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 – 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 MOTOR VEHICLES
    • 2.5.1 LOADING AND UNLOADING
    • 2.5.2 TRANSPORT
  • 2.6 BATTERY
    • 2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY
    • 2.6.2 STARTING WITH BOOSTER CABLES
  • 2.7 PRECAUTIONS FOR THE REMOVAL
  • 2.8 PRECAUTIONS FOR 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 CLEANING THE MACHINE
    • 2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS
    • 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 TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP
    • 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 HANDLING HIGH-PRESSURE PIPES
    • 2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL
    • 2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE
    • 2.8.18 COOLING FAN AND BELT
    • 2.8.19 WASTE MATERIALS
    • 2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES
  • POSITION
  • COLOUR
  • CAPACITY (A)
  • INVOLVED CIRCUIT
    • 1
    • Green
    • 30
    • 2
    • Violet
    • 3
    • 3
    • Light blue
    • 15
    • 4
    • Red
    • 10
    • 5
    • Brown
    • 7,5
    • 6
    • Red
    • 10
    • 7
    • Brown
    • 7,5
    • 8
    • Brown
    • 7,5
    • 9
    • Brown
    • 7,5
    • 10
    • Brown
    • 7,5
    • 11
    • Brown
    • 7,5
  • POSITION
  • COLOUR
  • CAPACITY (A)
  • INVOLVED CIRCUIT
    • 1
    • –
    • 60
  • POSITION
  • DESCRIPTION
    • 1
    • 2
    • 3
    • 4
    • 5
    • 6
    • 3.6 USE OF THE MACHINE
    • 3.7 PARKING THE MACHINE
    • 3.8 STOPPING THE ENGINE
    • 3.9 TRANSPORTING THE MACHINE ON MOTOR VEHICLES
    • 3.10 LIFTING THE MACHINE
    • 3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON
  • CHARGE PERCENTAGE
  • FLUID TEMPERATURE
  • 20°C
  • 0°C
  • -10°C
  • -20°C
  • 100%
  • 1.28
  • 1.29
  • 1.30
  • 1.31
  • 90%
  • 1.26
  • 1.27
  • 1.28
  • 1.29
  • 80%
  • 1.24
  • 1.25
  • 1.26
  • 1.27
  • 75%
  • 1.23
  • 1.24
  • 1.25
  • 1.26
    • 3.11.4 OTHER PRECAUTIONS
    • 3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK
    • 3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON
    • 3.13 USING THE WORK EQUIPMENT
    • 3.14 LONG PERIODS OF INACTIVITY
    • 3.15 TROUBLESHOOTING
    • 4.1 GUIDE TO MAINTENANCE
    • 4.2 MAINTENANCE NOTES
  • Minimum ambient temperature
  • (°C)
  • -4
  • -6
  • -9
  • -12
  • -16
  • -20
  • -26
  • -32
  • -36
  • (°F)
  • 24.8
  • 21.2
  • 15.8
  • 10.4
  • 3.2
  • -4
  • -14.8
  • -25.6
  • -32.8
  • Quantity of antifreeze
  • (l)
  • 0.4
  • 0.6
  • 0.8
  • 1.0
  • 1.2
  • 1.4
  • 1.6
  • 1.8
  • 2
  • (US gal)
  • 0.10
  • 0.15
  • 0.21
  • 0.26
  • 0.31
  • 0.36
  • 0.42
  • 0.47
  • 0.52
  • Quantity of water
  • (l)
  • 3.6
  • 3.4
  • 3.2
  • 3.0
  • 2.8
  • 2.6
  • 2.4
  • 2.2
  • 2
  • (US gal)
  • 0.95
  • 0.89
  • 0.84
  • 0.79
  • 0.73
  • 0.68
  • 0.63
  • 0.58
  • 0.52
    • 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
  • 848101172
  • 1
  • EVERY 250 HOURS
  • YM129150-35152
  • 1
  • EVERY 500 HOURS
  • YM119802-55800
  • 1
  • EVERY 500 HOURS
  • YM129052-55630
  • 1
  • EVERY 500 HOURS
  • YM119808-12520
  • 1
  • WHEN NEEDED
  • 825011090
  • 801015574
  • 801920106
  • AR
  • AR
  • AR
  • —
  • —
  • —
    • 4.3 FUEL, COOLANT AND LUBRICANTS
  • OIL
  • 3.6
  • (PC20R)
  • 5.2
  • (PC27R)
  • 3.6
  • (PC20R)
  • 5.2
  • (PC27R)
  • OIL
  • 48
  • 29
  • SEE “4.3.1”
  • 48
  • 29
  • OIL
  • 0.7
  • 0.7
  • DIESEL OIL
  • 35
  • —
  • WATER + ANTIFREEZE
  • 4
  • —
  • WATER
  • 4
  • —
  • PERMANENT COOLANT
  • 4
  • —
    • LUBRICATION WITH GREASE
  • NLGI 2
    • 4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS
  • SUPPLIER
  • HEES SYNTHETIC BIODEGRADABLE OIL
  • —
  • —
  • —
  • —
  • —
  • —
  • —
  • —
  • —
  • —
  • —
  • —
  • —
  • —
    • 4.4 DRIVING TORQUES FOR SCREWS AND NUTS
  • 6
  • 8
  • 10
  • 12
  • 14
  • 1
  • 1.25
  • 1.5
  • 1.75
  • 2
  • 10
  • 13
  • 17
  • 19
  • 22
  • 0.96 ± 0.1
  • 2.3 ± 0.2
  • 4.6 ± 0.5
  • 7.8 ± 0.8
  • 12.5 ± 1
  • 9.5 ± 1
  • 23 ± 2
  • 45 ± 4.9
  • 77 ± 8
  • 122 ± 13
  • 1.3 ± 0.15
  • 3.2 ± 0.3
  • 6.5 ± 0.6
  • 11 ± 1
  • 17.5 ± 2
  • 13.5 ± 1.5
  • 32.2 ± 3.5
  • 63 ± 6.5
  • 108 ± 11
  • 172 ± 18
  • 16
  • 18
  • 20
  • 22
  • 24
  • 2
  • 2.5
  • 2.5
  • 2.5
  • 3
  • 24
  • 27
  • 30
  • 32
  • 36
  • 19.5 ± 2
  • 27 ± 3
  • 38 ± 4
  • 52 ± 6
  • 66 ± 7
  • 191 ± 21
  • 262 ± 28
  • 372 ± 40
  • 511 ± 57
  • 644 ± 70
  • 27 ± 3
  • 37 ± 4
  • 53 ± 6
  • 73 ± 8
  • 92 ± 10
  • 268 ± 29
  • 366 ± 36
  • 524 ± 57
  • 719 ± 80
  • 905 ± 98
  • 27
  • 30
  • 3
  • 3.5
  • 41
  • 46
  • 96 ± 10
  • 131 ± 14
  • 945 ± 100
  • 1287 ± 140
  • 135 ± 15
  • 184 ± 20
  • 1329 ± 140
  • 1810 ± 190
    • 4.4.2 SPECIFIC DRIVING TORQUES
  • 6.75 ± 0.75 6.75 ± 0.75
  • 66 ± 7.3 66 ± 7.3
  • 11 ± 1 6.75 ± 0.75
  • 108 ± 11 66 ± 7.3
    • 4.5 LUBRICATION
    • 4.6 PERIODICAL CHANGE OF THE COMPONENTS THAT ARE CONNECTED WITH SAFETY
  • No
  • Qty
  • 1
  • 1
  • Every 2 years or 4000 hours, whichever occurs first
  • 2
  • 1
  • 3
  • 1
  • 4
  • 1
  • 5
  • 1
  • 6
  • 1
  • 7
  • 2
  • 8
  • 1
  • 9
  • 1
  • No
  • Qty
  • 1
  • 1
  • Every 2 years or 4000 hours, whichever occurs first
  • 2
  • 1
  • 3
  • 1
  • 4
  • 4
  • 5
  • 4
  • 6
  • 4
  • 1
  • 1
  • Every 4 years
    • 4.7 MAINTENANCE PLAN
  • a
  • 136
  • b
  • 137
  • c
  • 138
  • d
  • 138
  • e
  • 140
  • f
  • 142
  • g
  • 144
  • h
  • 146
    • 4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER)
  • a
  • 147
  • b
  • 147
    • 4.7.3 CHECKS BEFORE STARTING
  • a
  • —
  • 148
  • b
  • 148
  • c
  • 149
  • d
  • 149
  • e
  • 150
  • f
  • 151
  • g
  • 152
    • 4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic…
  • a
  • 157
    • 4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION
  • a
  • 153
    • 4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION (Operations to be carried out together w…
  • a
  • 164
  • b
  • 169
    • 4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION
  • a
  • 155
  • b
  • 156
  • c
  • 156
  • d
  • 157
  • e
  • 158
    • 4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the syntheti…
  • a
  • 165
    • 4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION
  • a
  • 159
  • b
  • 160
  • c
  • 161
  • d
  • 162
  • e
  • 163
    • 4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION
  • a
  • 164
    • 4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION
  • a
  • 165
  • b
  • 168
  • c
  • 169
  • d
  • 169
    • 4.7.1 WHEN REQUIRED
    • 4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER (BREAKER)
    • 4.7.3 CHECKS BEFORE STARTING
    • 4.7.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic…
    • 4.7.5 MAINTENANCE EVERY 100 HOURS OF OPERATION
  • (1 point)
  • (1 point)
  • (1 point)
  • (1 point)
  • (2 points)
  • (2 points)
  • (1 point)
  • (1 point)
  • (1 point)
  • (1 point)
  • (1 point)
  • (1 point)
  • (1 point)
  • (1 point)
  • (1 point)
  • (1 point)
  • (1 point)
  • (1 point)
  • (2 points)
  • (1 point)
    • 4.7.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION
    • 4.7.7 MAINTENANCE EVERY 250 HOURS OF OPERATION
    • 4.7.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the syntheti…
    • 4.7.9 MAINTENANCE EVERY 500 HOURS OF OPERATION
    • 4.7.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION
    • 4.7.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION
  • 5.1 TECHNICAL DATA
    • 5.1.1 STANDARD OVERALL DIMENSIONS (for model PC20R only)
    • 5.1.2 TECHNICAL CHARACTERISTICS PC20R
    • TOTAL MASS
    • STANDARD BUCKET CAPACITY
    • ENGINE
    • ELECTRICAL SYSTEM
    • UPPER STRUCTURE ROTATION
    • SPEEDS
    • TOTAL MASS
    • STANDARD BUCKET CAPACITY
    • ENGINE
    • ELECTRICAL SYSTEM
    • UPPER STRUCTURE ROTATION
    • SPEEDS
    • 6.1 AUTHORIZED OPTIONAL EQUIPMENT
  • (kg)
  • (m3)
  • (bar)
  • (l/min.)
  • Width (mm)
  • Height (mm)
  • 60
  • 550
  • —
  • 0.085
  • —
  • —
  • 40
  • 1300
  • —
  • 0.050
  • —
  • —
  • 55
  • 950
  • —
  • 0.075
  • —
  • —
  • 70
  • 275
  • 1000
  • 0.025
  • 210
  • 24
  • 150
  • —
  • 950
  • —
  • 140
  • 35
  • 90
  • 250 k
  • 1500 l
  • —
  • 210
  • 35
    • (FOR MODEL PC27R ONLY)
  • (kg)
  • (m3)
  • (bar)
  • (l/min.)
  • Width (mm)
  • Height (mm)
  • 70
  • 550
  • —
  • 0.085
  • —
  • —
  • 40
  • 1300
  • —
  • 0.050
  • —
  • —
  • 55
  • 950
  • —
  • 0.075
  • —
  • —
  • 100
  • 410
  • 1000
  • 0.040
  • 210
  • 24
  • 150
  • —
  • 950
  • —
  • 140
  • 30
  • 125
  • 300 k
  • 2000 l
  • —
  • 210
  • 30
    • 6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER (BREAKER)
    • 6.3 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT

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