Komatsu PC27MR-2 Hydraulic Excavator Index:

• 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
  • 1.3.5 DIRECTIONS OF 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
• 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 ON MACHINES WITH CAB
  • 2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY
  • 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 CARRY ING OUT ANY MAINTENANCE OPER ATION 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 TEMPERA TURES AND HIGH PRESSURE
  • 2.8.18 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE TRACK TENSION
  • 2.8.19 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT
  • 2.8.20 HYDRAULIC ACCUMULATOR
  • 2.8.21 COOLING FAN AND BELT
  • 2.8.22 WASTE MATERIALS
  • 2.8.23 COMPRESSED AIR
  • 2.8.24 PRECAUTIONS FOR THE USE OF THE synthetic biodegrada ble oil type HEES
• 3.1 MACHINE VIEW ILLUSTRATIONS
  • 3.1.1 OVERALL MACHINE VIEW
  • 3.1.2 CONTROLS AND GAUGES
• 3.2 DETAILED CONTROLS AND GAUGES
  • 3.2.1 MONITORING SYSTEM
    • 3.2.1.1 EMERGENCY MONITORS
    • 3.2.1.2 METER DISPLAY PORTION
    • 3.2.1.3 PILOT LAMPS
    • 3.2.1.4 MONITOR SWITCHES PORTION
  • 3.2.2 SWITCHES
  • 3.2.3 CONTROL LEVERS AND PEDALS
  • 3.2.4 WINDSHIELD (Machines equipped with cab)
  • 3.2.5 SLIDING DOOR (Machines equipped with cab)
  • 3.2.6 SLIDING WINDOW (Machines equipped with cab)
  • 3.2.7 EMERGENCY ESCAPE HAMMER (Machines equipped with cab)
  • 3.2.8 COVER WITH LOCK
  • 3.2.9 ENGINE REAR COVER
  • 3.2.10 COOLING COVER
  • 3.2.11 MUD COVER
  • 3.2.12 METHOD OF OPENING (TILTING) FLOOR
  • 3.2.13 FUSE
  • 3.2.14 BLOCK FUSE
  • 3.2.15 OPERATION MANUAL STORAGE
  • 3.2.16 TOOL BOX
  • 3.2.17 GREASE GUN HOLDER
  • 3.2.18 ASHTRAY (Machines equipped with cab)
• 3.3 MACHINE OPERATIONS AND CONTROLS
  • 3.3.1 BEFORE STARTING ENGINE
    • 3.3.1.1 WALK-AROUND CHECKS
    • 3.3.1.2 CHECKS BEFORE STARTING
    • 3.3.1.3 ADJUSTMENT
    • 3.3.1.4 OPERATIONS BEFORE STARTING ENGINE
    • 3.3.1.5 STARTING ENGINE
  • 3.3.2 AFTER STARTING ENGINE
    • 3.3.2.1 BREAKING-IN THE NEW MACHINE
    • 3.3.2.2 WARMING-UP OPERATION
  • 3.3.3 STOPPING THE ENGINE
  • 3.3.4 MACHINE OPERATION
    • 3.3.4.1 PREPARATIONS FOR MOVING THE MACHINE OFF
    • 3.3.4.2 MOVING MACHINE FORWARD
    • 3.3.4.3 MOVING MACHINE BACKWARD
    • 3.3.4.4 STOPPING MACHINE
  • 3.3.5 STEERING THE MACHINE
    • 3.3.5.1 STEERING
  • 3.3.6 SWINGING
  • 3.3.7 WORK EQUIPMENT CONTROLS AND OPERATIONS
  • 3.3.8 PROHIBITED OPERATIONS
  • 3.3.9 GENERAL OPERATION INFORMATION
  • 3.3.10 TRAVELING ON SLOPES
  • 3.3.11 ESCAPE FROM MUD
  • 3.3.12 WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR
  • 3.3.13 CHANGING THE BUCKET
  • 3.3.14 PARKING MACHINE
  • 3.3.15 CHECK AFTER SHUT OFF ENGINE
  • 3.3.16 MACHINE INSPECTION AFTER DAILY WORK
  • 3.3.17 LOCKING
  • 3.3.18 RUBBER SHOES AND ROAD LINERS (Machine equipped with rubber shoe or road liner)
    • 3.3.18.1 RUBBER SHOES AND ROAD LINERS INFORMATION
    • 3.3.18.2 WARRANTY FOR RUBBER SHOES AND ROAD LINERS
    • 3.3.18.3 USING RUBBER SHOES AND ROAD LINERS
• 3.4 TRANSPORTATION
  • 3.4.1 TRANSPORTATION PROCEDURE
  • 3.4.2 LOADING AND UNLOADING WITH TRAILER
  • 3.4.3 LIFTING MACHINE
• 3.5 COLD WEATHER OPERATION
  • 3.5.1 COLD WEATHER OPERATION INFORMATION
    • 3.5.1.1 FUEL AND LUBRICANTS
    • 3.5.1.2 COOLING SYSTEM COOLANT
    • 3.5.1.3 BATTERY
  • 3.5.2 CAB HEATER IN COLD WEATHER (Machines equipped with cab)
  • 3.5.3 AFTER DAILY WORK COMPLETION
  • 3.5.4 AFTER COLD WEATHER SEASON
• 3.6 LONG TERM STORAGE
  • 3.6.1 BEFORE STORAGE
  • 3.6.2 DURING STORAGE
  • 3.6.3 AFTER STORAGE
• 3.7 TROUBLES AND ACTIONS
  • 3.7.1 RUNNING OUT OF FUEL
  • 3.7.2 PHENOMENA THAT ARE NOT FAILURES
  • 3.7.3 TOWING THE MACHINE
  • 3.7.4 SEVERE JOB CONDITION
  • 3.7.5 DISCHARGED BATTERY
    • 3.7.5.1 BATTERY REMOVAL AND INSTALLATION
    • 3.7.5.2 BATTERY CHARGES
    • 3.7.5.3 STARTING ENGINE WITH BOOSTER CABLES
  • 3.7.6 OTHER TROUBLE
    • 3.7.6.1 ELECTRICAL SYSTEM
    • 3.7.6.2 CHASSIS
    • 3.7.6.3 ENGINE
• 4.1 MAINTENANCE INFORMATION
• 4.2 LUBRICANTS, COOLANT AND FILTERS
  • 4.2.1 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
    • 4.2.1.1 OIL
    • 4.2.1.2 FUEL
    • 4.2.1.3 COOLING SYSTEM COOLANT
    • 4.2.1.4 GREASE
    • 4.2.1.5 CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)
    • 4.2.1.6 OIL AND FUEL STORAGE
    • 4.2.1.7 FILTERS
  • 4.2.2 ELECTRIC SYSTEM MAINTENANCE
  • 4.2.3 HANDLING HYDRAULIC SYSTEM
• 4.3 WEAR PARTS
  • 4.3.1 WEAR PARTS LIST
• 4.4 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS
  • 4.4.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS
• 4.5 TIGHTENING TORQUE SPECIFICATIONS
  • 4.5.1 TIGHTENING TORQUE LIST
• 4.6 LUBRICATION
  • 4.6.1 LUBRICATION DIAGRAM
• 4.7 SAFETY CRITICAL PARTS
  • 4.7.1 SAFETY CRITICAL PARTS LIST
• 4.8 MAINTENANCE SCHEDULE
  • 4.8.1 MAINTENANCE SCHEDULE CHART
  • 4.8.2 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER
    • 4.8.2.a CHANGING THE HYDRAULIC OIL FIL TER
    • 4.8.2.b CHANGING THE HYDRAULIC OIL
• 4.9 MAINTENANCE PROCEDURE
  • 4.9.1 WHEN REQUIRED
    • 4.9.1.a CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
    • 4.9.1.b CLEAN INSIDE OF COOLING SYSTEM
    • 4.9.1.c CHECK LEVEL OF BATTERY ELECTROLYTE
    • 4.9.1.d CLEAN WATER SEPARATOR ELEMENT
    • 4.9.1.e DRAIN WATER AND SEDIMENT FROM FUEL TANK
    • 4.9.1.f CHECK AND TIGHTEN TRACK SHOE BOLTS (Machine equipped with road liner, steel shoe)
    • 4.9.1.g CHECK AND ADJUST TRACK TENSION (Machine equipped with road liner, steel shoe)
    • 4.9.1.h CHECK, RUBBER SHOES OR ROAD LINERS (Machine equipped with rubber shoes, road liner)
    • 4.9.1.i CHECK AND ADJUST RUBBER SHOE TENSION (Machine equipped with rubber shoes)
    • 4.9.1.j REPLACE RUBBER SHOES (Machine equipped with rubber shoes)
    • 4.9.1.k REPLACE ROAD LINERS (Machine equipped with road liner)
    • 4.9.1.l CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (Machine equipped with cab)
    • 4.9.1.m CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER (Machine equipped with cab)
    • 4.9.1.n LUBRICATING
    • 4.9.1.o BLEEDING AIR FROM HYDRAULIC SYSTEM
  • 4.9.2 CHECK BEFORE STARTING
  • 4.9.3 EVERY 500 HOURS MAINTENANCE
    • 4.9.3.a LUBRICATING
    • 4.9.3.b CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
    • 4.9.3.c REPLACE FUEL FILTER CARTRIDGE
    • 4.9.3.d CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
    • 4.9.3.e CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS
    • 4.9.3.f CHECK AND ADJUST COOLING FAN BELT TENSION
  • 4.9.4 EVERY 1000 HOURS MAINTENANCE
    • 4.9.4.a REPLACE HYDRAULIC OIL FILTER ELEMENT
    • 4.9.4.b CHANGE OIL IN FINAL DRIVE CASE
    • 4.9.4.c CHECK ENGINE VALVE CLEARANCE, ADJUST
  • 4.9.5 EVERY 2000 HOURS MAINTENANCE
    • 4.9.5.a CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER
    • 4.9.5.b CHECK ALTERNATOR, STARTING MOTOR
• 5.1 SPECIFICATIONS
• 5.2 LIFTING CAPACITIES
  • 5.2.1 LIFTING CAPACITIES (WITH CANOPY)
  • 5.2.2 LIFTING CAPACITIES (WITH CABIN)
• 6.1 ATTACHMENTS AND OPTIONS – GENERAL INFORMATION
  • 6.1.1 SAFETY FIRST
  • 6.1.2 ATTACHMENT INSTALLATION
  • 6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT
    • 6.1.3.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT
• 6.2 MACHINE READY FOR ATTACHMENT
  • 6.2.1 LOCATIONS
  • 6.2.2 HYDRAULIC CIRCUIT
    • 6.2.2.1 ASSEMBLYING AND CONNECTING THE EQUIPMENT
    • 6.2.2.2 MAINTENANCE
    • 6.2.2.3 BLEEDING AIR
• 6.3 ATTACHMENT OPERATIONS
  • 6.3.1 LONG TERM STORAGE
  • 6.3.2 SPECIFICATIONS
• 6.4 ATTACHMENT GUIDE
  • 6.4.1 ATTACHMENT COMBINATIONS
• 6.5 RECOMMENDED ATTACHMENT OPERATIONS
  • 6.5.1 HYDRAULIC BREAKER