Komatsu PC16R-2 Galeo Hydraulic Excavator Operation & Maintenance Manual (F00003 and up) - WEAM007800
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This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the Komatsu PC16R-2 Galeo Hydraulic Excavator (S/N: F00003 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.
APPLICABLE MODELS :
Komatsu PC16R-2
S/N: F00003 and up
TABLE OF CONTENTS :
- SAFETY
- OPERATION
- MAINTENANCE
- SPECIFICATIONS
- OPTIONS, ATTACHMENTS
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : WEAM007800
Total Pages : 226
This page sometime can be found use following keyword : service manual, repair manual, workshop manual, technical manual, owner manual, operating manual, maintenance manual, parts manual. Please make sure you read and understand the title of this manual before decided to buy.
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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 MAIN CHARACTERISTICS
1.3.4 RUNNING-IN
1.3.5 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 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
2.1.4 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 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 ROPS STRUCTURE
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE
2.3.1 SAFETY AT THE WORK SITE
2.3.2 FIRE PREVENTION
2.3.3 PRECAUTIONS CONCERNING THE OPERATOR SEAT
2.3.4 ROOM VENTILATION
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS
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 HAND SIGNALS
2.4.4 CHECKS FOR TRAVELLING IN REVERSE
2.4.5 MOVING THE MACHINE
2.4.6 MOVING ON SLOPES
2.4.7 WORKING ON SLOPES
2.4.8 UNAUTHORIZED OPERATIONS
2.4.9 PREVENTING ELECTROCUTION
2.4.10 VISIBILITY
2.4.11 WORKING ON ICY OR SNOW-COVERED SURFACES
2.4.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
2.4.13 WORKING ON LOOSE GROUND
2.4.14 PARKING THE MACHINE
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES
2.5.1 LOADING AND UNLOADING THE MACHINE
2.5.2 TRANSPORTING THE MACHINE
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 OF THE MACHINE
2.8 PRECAUTIONS FOR MAINTENANCE
2.8.1 WARNING PLATES
2.8.2 TOOLS
2.8.3 MAINTENANCE STAFF
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
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 WHEN REFUELLING OR ADDING OIL
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR
2.8.12 USING LAMPS
2.8.13 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR
2.8.14 PRECAUTIONS CONCERNING THE STARTER
2.8.15 HANDLING HIGH-PRESSURE HOSES
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 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 TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS
2.8.25 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE HEES
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
3.2.1.1 EMERGENCY WARNING LIGHTS
3.2.1.2 GAUGES
3.2.1.3 WARNING LIGHTS
3.2.2 SWITCHES AND PUSH BUTTONS
3.2.3 CONTROL LEVERS AND PEDALS
3.2.4 COVERSWITH LOCK
3.2.5 ENGINE HOOD
3.2.6 RADIATOR COVER
3.2.7 BATTERY COVER
3.2.8 TILTING THE CAB FLOOR
3.2.9 FUSES
3.2.10 MAIN FUSE
3.2.11 TECHNICAL DOCUMENTATION COMPARTMENT
3.2.12 TOOL BOX
3.3 USE OF THE MACHINE AND RELATED CONTROLS
3.3.1 BEFORE STARTING THE ENGINE
3.3.1.1 VISUAL CHECKS
3.3.1.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE
3.3.1.3 ADJUSTMENTS
3.3.1.4 OPERATIONS TO BE CARRIED OUT BEFORE STARTING THE ENGINE
3.3.2 STARTING THE ENGINE
3.3.2.1 STARTING WITH WARM ENGINE OR IN WARM CLIMATES
3.3.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES
3.3.3 AFTER STARTING THE ENGINE
3.3.3.1 RUNNING IN A NEW MACHINE
3.3.3.2 WARMING-UP OPERATIONS
3.3.4 STOPPING THE ENGINE
3.3.5 HOW TO MOVE THE MACHINE
3.3.5.1 PRELIMINARY OPERATIONS TO BE CARRIED OUT BEFORE MOVING THE MACHINE
3.3.5.2 MOVING THE MACHINE FORWARD
3.3.5.3 MOVING THE MACHINE IN REVERSE
3.3.5.4 STOPPING THE MACHINE
3.3.6 STEERING THE MACHINE
3.3.6.1 STEERING (CHANGING DIRECTION)
3.3.7 SWINGING THE TURRET
3.3.8 WORK EQUIPMENT CONTROLS AND FUNCTIONS
3.3.9 UNAUTHORIZED OPERATIONS
3.3.10 PRECAUTIONS FOR USE
3.3.11 PRECAUTIONS TO BE TAKEN WHEN TRAVELLING ON SLOPES
3.3.12 GETTING THE MACHINE OUT OF MUD
3.3.13 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR
3.3.14 CHANGING THE BUCKET
3.3.15 PARKING THE MACHINE
3.3.16 CHECKING THE MACHINE EVERY DAY AFTER WORK
3.3.16.1 BEFORE STOPPING THE ENGINE
3.3.16.2 AFTER STOPPING THE ENGINE
3.3.17 LOCKING THE MACHINE
3.3.18 RUBBER TRACKS (Machines equipped with rubber tracks only)
3.3.18.1 OPTIMAL USE OF THE RUBBER TRACKS
3.3.18.2 WARRANTY ON RUBBER TRACKS
3.3.18.3 USE OF THE RUBBER TRACKS
3.3.18.4 HOW TO PRESERVE THE RUBBER TRACKS OVER TIME
3.4 TRANSPORTING THE MACHINE
3.4.1 TRANSPORT PROCEDURE
3.4.2 LOADING AND UNLOADING THE MACHINE
3.4.3 LIFTING THE MACHINE
3.5 USING THE MACHINE IN THE COLD SEASON
3.5.1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON
3.5.1.1 FUEL AND LUBRICANTS
3.5.1.2 COOLANT
3.5.1.3 BATTERY
3.5.2 PRECAUTIONS TO BE TAKEN EVERY DAY AT THE END OF WORK
3.5.3 HOW TO PROCEED 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 PRECAUTIONS TO BE TAKEN WHEN WORKING IN PARTICULAR CONDITIONS
3.7.5 IF THE BATTERY IS DOWN
3.7.5.1 REMOVING AND INSTALLING THE BATTERY
3.7.5.2 CHARGING THE BATTERY
3.7.5.3 STARTING WITH BOOSTER CABLES
3.7.6 OTHER TROUBLES
3.7.6.1 ELECTRICAL CIRCUIT
3.7.6.2 FRAME
3.7.6.3 ENGINE
4.1 GUIDE TO MAINTENANCE
4.2 MAINTENANCE NOTES
4.2.1 OIL, FUEL AND COOLANT
4.2.1.1 OIL
4.2.1.2 FUEL
4.2.1.3 COOLANT
4.2.1.4 KOWA (KOMATSU OIL WEAR ANALYSIS)
4.2.1.5 STORING OIL AND FUEL
4.2.1.6 FILTERS
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 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
4.8.2.a CHANGING THE HYDRAULIC OIL FILTER
4.8.2.b CHANGING THE HYDRAULIC OIL
4.9 MAINTENANCE PROCEDURES
4.9.1 WHEN REQUIRED
4.9.1.a CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE
4.9.1.b CHECKING THE BATTERY CHARGE LEVEL
4.9.1.c CLEANING THE WATER SEPARATOR FILTER
4.9.1.d DRAINING THE FUEL TANK
4.9.1.e CHECKING AND ADJUSTING THE STEEL TRACK TENSION
4.9.1.f CHECKING THE RUBBER TRACKS
4.9.1.g CHECKING AND ADJUSTING THE RUBBER TRACK TENSION
4.9.1.h CHANGING THE RUBBER TRACKS
4.9.1.i BLEEDING THE HYDRAULIC SYSTEM
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 AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)
4.9.5 MAINTENANCE EVERY 500 HOURS OF OPERATION
4.9.5.a LUBRICATION
4.9.5.b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE
4.9.5.c CHANGING THE FUEL FILTER CARTRIDGE
4.9.5.d CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS
4.9.5.e CHECKING AND CLEANING THE FINS OF THE RADIATOR AND OF THE EXCHANGER
4.9.5.f CHECKING AND ADJUSTING THE FAN BELT TENSION
4.9.5.g DRAINING THE HYDRAULIC OIL TANK (Only for machines in which synthetic biodegradable oil type HEES is used)
4.9.6 MAINTENANCE EVERY 1000 HOURS OF OPERATION
4.9.6.a CHANGING THE HYDRAULIC OIL FILTER
4.9.6.b CHANGING THE OIL IN THE FINAL REDUCTION GEARS
4.9.6.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE
4.9.7 MAINTENANCE EVERY 2000 HOURS OF OPERATION
4.9.7.a CHANGING THE OIL IN THE HYDRAULIC TANK AND CLEANING THE FILTER
4.9.7.b CHANGING THE COOLANT
4.9.7.c CHECKING THE ALTERNATOR AND THE STARTER
5.1 TECHNICAL DATA
5.2 LIFTING CAPACITIES
5.2.1 LIFTING CAPACITIES
6.1 AUTHORIZED OPTIONAL EQUIPMENT
6.1.1 PRECAUTIONS REGARDING SAFETY
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT
6.1.3.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT
6.2 MACHINE CONFIGURATION FOR THE INSTALLATION OF ATTACHMENTS
6.2.1 POSITION OF THE DEVICES
6.2.2 HYDRAULIC CIRCUIT
6.2.2.1 INSTALLING AND CONNECTING THE EQUIPMENT
6.2.2.2 MAINTENANCE
6.2.2.3 BLEEDING
6.3 OPERATING THE EQUIPMENT
6.3.1 LONG PERIODS OF INACTIVITY
6.4 PRECAUTIONS TO BE TAKEN WHEN USING OPTIONAL EQUIPMENT
6.4.1 HYDRAULIC BREAKER
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Komatsu PC16R-2 Galeo Excavator Operation & Maintenance Manual (F00003 and up) - WEAM007800.pdf