Komatsu PC09-1 Hydraulic Excavator Operation and Maintenance Manual WEAM011801

Description

• Model List:
  • PC09-1 Hydraulic Excavator

• 1. FOREWORD
• 1.1. FOREWORD
• 1.2. SAFETY INFORMATION
• 1.2.1. NOISE LEVELS
• 1.2.2. VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
• 1.3. INTRODUCTION
• 1.3.1. DEMOLITION WORK
• 1.3.2. IMPROPER OR UNAUTHORIZED USES
• 1.3.3. DIRECTIONS OF MACHINE
• 1.4. PRODUCT IDENTIFICATION
• 1.4.1. MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
• 1.4.2. MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)
• 1.4.3. ENGINE SERIAL NUMBER PLATE AND ITS LOCATION
• 1.4.4. EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION
• 1.4.5. HOUR COUNTER POSITION
• 1.4.6. TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR
• 1.4.7. DECLARATION OF CONFORMITY (for machines placed on the market as from 29 December 2009)
• 1.4.8. EQUIPMENT, OPTIONAL
• 2. SAFETY
• 2.1. SAFETY LABELS
• 2.1.1. LOCATION OF SAFETY LABELS
• 2.1.2. SAFETY LABELS
• 2.2. GENERAL PRECAUTIONS
• 2.2.1. SAFETY RULES
• 2.2.2. IF PROBLEMS ARE FOUND
• 2.2.3. WORKING WEAR AND PERSONAL PROTECTIVE ITEMS
• 2.2.4. FIRE EXTINGUISHER AND FIRST AID KIT
• 2.2.5. SAFETY EQUIPMENT
• 2.2.6. KEEP MACHINE CLEAN
• 2.2.7. KEEP OPERATORS COMPARTMENT CLEAN
• 2.2.8. LEAVING THE OPERATORS SEAT
• 2.2.9. HANDRAILS AND STEPS
• 2.2.10. MOUNTING AND DISMOUNTING
• 2.2.11. NO PERSONS ON ATTACHMENTS
• 2.2.12. DO NOT GET CAUGHT IN ARTICULATED PORTION
• 2.2.13. BURN PREVENTION
• 2.2.14. FIRE PREVENTION AND EXPLOSION PREVENTION
• 2.2.15. ACTION IF FIRE OCCURS
• 2.2.16. FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION
• 2.2.17. ATTACHMENT INSTALLATION
• 2.2.18. ATTACHMENT COMBINATIONS
• 2.2.19. PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
• 2.2.20. UNAUTHORIZED MODIFICATIONS
• 2.2.21. SAFETY AT JOBSITE
• 2.2.22. WORKING ON LOOSE GROUND
• 2.2.23. DISTANCE TO HIGH VOLTAGE CABLES
• 2.2.24. ENSURE GOOD VISIBILITY
• 2.2.25. VENTILATION FOR ENCLOSED AREA
• 2.2.26. SIGNALMANS SIGNAL AND SIGNS
• 2.2.27. ASBESTOS DUST HAZARD PREVENTION
• 2.3. SAFETY MACHINE OPERATION
• 2.3.1. STARTING ENGINE
• 2.3.2. FUNCTIONING
• 2.3.3. TRANSPORTING THE MACHINE
• 2.3.4. BATTERY
• 2.3.5. TOWING
• 2.3.6. LIFTING OBJECTS WITH BUCKET
• 2.4. SAFETY MAINTENANCE INFORMATION
• 2.4.1. WARNING TAG
• 2.4.2. KEEP WORK PLACE CLEAN AND TIDY
• 2.4.3. APPOINT LEADER WHEN WORKING WITH OTHERS
• 2.4.4. STOP ENGINE BEFORE CARRYING OUT MAINTENANCE
• 2.4.5. MAINTENANCE WITH ENGINE RUNNING
• 2.4.6. PROPER TOOLS
• 2.4.7. ACCUMULATOR, GAS SPRING
• 2.4.8. PERSONNEL
• 2.4.9. ATTACHMENTS
• 2.4.10. WORK UNDER THE MACHINE
• 2.4.11. NOISE
• 2.4.12. WHEN USING HAMMER
• 2.4.13. WELDING WORKS
• 2.4.14. USING LAMPS
• 2.4.15. SAFETY FIRST WHEN USING HIGHPRESSURE GREASE TO ADJUST TRACK TENSION
• 2.4.16. DO NOT DISASSEMBLE RECOIL SPRINGS
• 2.4.17. SAFETY RULES FOR HIGHPRESSURE OIL
• 2.4.18. SAFETY HANDLING HIGHPRESSURE HOSES
• 2.4.19. PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE
• 2.4.20. WASTE MATERIALS
• 2.4.21. COMPRESSED AIR
• 2.4.22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
• 2.4.23. BATTERY MAIN SWITCH PRECAUTIONS
• 2.4.24. PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR
• 2.4.25. PRECAUTIONS CONCERNING THE STARTER
• 2.4.26. CHEMICAL HAZARD
• 2.4.27. PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS
• 2.4.28. PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES
• 2.4.29. FINAL DISPOSAL OF THE MACHINE
• 3. FUNCTIONING
• 3.1. MACHINE ILLUSTRATIONS
• 3.1.1. OVERALL VIEW OF THE MACHINE
• 3.1.2. CONTROLS AND GAUGES
• 3.2. INSTRUMENTS AND CONTROLS
• 3.2.1. WARNING LIGHTS AND GAUGES
• 3.2.2. SWITCHES AND PUSH BUTTONS
• 3.2.3. CONTROL LEVERS AND PEDALS
• 3.2.4. VARIABLE BLADE
• 3.2.5. ENGINE HOOD
• 3.3. SUPPLEMENTARY POWER SUPPLY
• 3.3.1. POWER OUTLET
• 3.4. FUSES
• 3.4.1. BLOCK FUSE
• 3.5. STORAGE COMPARTMENTS
• 3.5.1. OPERATION MANUAL STORAGE
• 3.5.2. FIRE EXTINGUISHER
• 3.5.3. FIRST AID KIT
• 3.6. USE OF THE MACHINE AND RELATED CONTROLS
• 3.6.1. BEFORE STARTING THE ENGINE
• 3.6.2. AFTER STARTING THE ENGINE
• 3.6.3. STOPPING THE ENGINE
• 3.6.4. CHECK AFTER SHUT OFF ENGINE
• 3.6.5. MACHINE OPERATION
• 3.6.6. STEERING THE MACHINE
• 3.6.7. SWINGING
• 3.6.8. WORK EQUIPMENT CONTROLS AND OPERATIONS
• 3.6.9. UNAUTHORIZED OPERATIONS
• 3.6.10. GENERAL OPERATION INFORMATION
• 3.6.11. TRAVELING ON SLOPES
• 3.6.12. ESCAPE FROM MUD
• 3.6.13. WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR
• 3.6.14. BUCKET REPLACEMENT
• 3.6.15. PARKING THE MACHINE
• 3.6.16. MACHINE INSPECTION AFTER DAILY WORK
• 3.6.17. RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)
• 3.7. TRANSPORTATION
• 3.7.1. TRANSPORT PROCEDURE
• 3.7.2. LOADING AND UNLOADING THE MACHINE
• 3.7.3. LIFTING THE MACHINE
• 3.7.4. SHIPPING MACHINE INFORMATION
• 3.8. COLD WEATHER OPERATION
• 3.8.1. COLD WEATHER OPERATION INFORMATION
• 3.8.2. AFTER DAILY WORK COMPLETION
• 3.8.3. AFTER COLD WEATHER SEASON
• 3.9. LONGTERM STORAGE
• 3.9.1. BEFORE STORAGE
• 3.9.2. DURING STORAGE
• 3.9.3. AFTER STORAGE
• 3.9.4. STARTING MACHINE AFTER LONGTERM STORAGE
• 3.9.5. AMBIENT TEMPERATURE RANGE FOR OPERATION AND LONG TERM STORAGE
• 3.10. TROUBLES AND ACTIONS
• 3.10.1. RUNNING OUT OF FUEL
• 3.10.2. PHENOMENA THAT ARE NOT FAILURES
• 3.10.3. TOWING THE MACHINE
• 3.10.4. SEVERE JOB CONDITION
• 3.10.5. IF THE BATTERY IS DOWN
• 3.10.6. OTHER TROUBLES
• 4. MAINTENANCE
• 4.1. GUIDE TO MAINTENANCE
• 4.1.1. MAINTENANCE NOTES
• 4.1.2. OIL, FUEL, COOLANT AND GREASE
• 4.1.3. KOWA (KOMATSU OIL WEAR ANALYSIS)
• 4.1.4. STORING OIL AND FUEL
• 4.1.5. FILTERS
• 4.1.6. NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM
• 4.1.7. NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM
• 4.1.8. MAINTENANCE NOTES REGARDING LUBRICATION
• 4.2. PARTS SUBJECT TO WEAR
• 4.2.1. LIST OF THE PARTS SUBJECT TO WEAR
• 4.3. FUEL, COOLANT AND LUBRICANTS
• 4.3.1. RECOMMENDED BRANDS, QUALITY RECOMMENDED FOR PRODUCTS DIFFERENT THAN ORIGINAL KOMATSU OIL
• 4.4. TIGHTENING TORQUES
• 4.4.1. STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS
• 4.4.2. STANDARD TIGHTENING TORQUES FOR FLEXIBLE HOSES (ORFS)
• 4.5. LUBRICATION
• 4.5.1. LUBRICATION DIAGRAM
• 4.6. PERIODICAL CHANGE OF SAFETYRELATED COMPONENTS
• 4.6.1. SAFETYRELATED PARTS
• 4.7. MAINTENANCE PLAN
• 4.7.1. MAINTENANCE PLAN
• 4.7.2. MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER
• 4.8. MAINTENANCE PROCEDURES
• 4.8.1. INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)
• 4.8.2. WHEN REQUIRED
• 4.8.3. CHECK BEFORE STARTING
• 4.8.4. EVERY 100 HOURS MAINTENANCE
• 4.8.5. EVERY 250 HOURS MAINTENANCE
• 4.8.6. EVERY 500 HOURS MAINTENANCE
• 4.8.7. EVERY 1000 HOURS MAINTENANCE
• 4.8.8. EVERY 2000 HOURS MAINTENANCE
• 4.9. FINAL DISPOSAL OF THE MACHINE
• 5. SPECIFICATIONS
• 5.1. SPECIFICATIONS
• 5.2. OPERATING CHARACTERISTICS
• 5.3. LIFTING CAPACITIES
• 5.3.1. STANDARD LIFTING CAPACITIES
• 5.3.2. LIFTING CAPACITIES WITH HYDRAULIC BREAKER
• 6. EQUIPMENT, OPTIONAL
• 6.1. ATTACHMENTS AND OPTIONS GENERAL INFORMATION
• 6.1.1. SAFETY FIRST
• 6.1.2. ATTACHMENT INSTALLATION
• 6.2. BUCKET WITH HOOK
• 6.2.1. HOOK CONDITION
• 6.2.2. PROHIBITED OPERATIONS
• 6.3. SPECIFICATIONS
• 6.3.1. ARMPIN INFORMATION
• 6.4. EQUIPMENT USE GUIDE
• 6.4.1. COMBINATIONS OF WORK EQUIPMENT
• 6.4.2. EQUIPMENT CONFIGURATION
• 6.5. HANDLING ARM WITH BREAKER
• 6.5.1. BUCKET POSTURE
• 6.5.2. REMOVING AND INSTALLING CHISEL
• 6.5.3. PROCEDURE FOR BREAKER OPERATIONS
• 6.5.4. PRECAUTIONS WHEN CARRYING OUT BREAKER OPERATIONS
• 6.5.5. STOWING CHISEL, DUMMY CHISEL
• 6.5.6. PRECAUTIONS WHEN CARRYING OUT BUCKET OPERATIONS
• 6.5.7. HANDLING DUMMY LINK
• 6.5.8. CHECK BEFORE STARTING
• 6.6. HANDLING BUCKET COUPLER
• 6.6.1. PROCEDURE FOR REMOVING BUCKET
• 6.6.2. PROCEDURE FOR INSTALLING BUCKET
• 6.7. RECOMMENDED ATTACHMENT OPERATIONS
• 6.7.1. HYDRAULIC BREAKER