Komatsu PC1800-6 Hydraulic Excavator Operation & Maintenance Manual EEAM022200 – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC1800-6 Hydraulic Excavator Operation & Maintenance Manual EEAM022200 – PDF DOWNLOAD
SERIAL NUMBER
PC1800-6 – 10011 and up
PC1800-6 – 11002 and up
FOREWORD:
- This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions
in this manual must be followed at all times when performing operation and maintenance. - Most accidents are
caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents
can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
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
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V