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KOMATSU GALEO CD110R-2 CRAWLER CARRIER OPERATION & MAINTENANCE MANUAL (SN:1501 & UP) – PDF DOWNLOAD
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- KOMATSU GALEO CD110R-2 CRAWLER CARRIER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:1501 & UP
- PUBLICATION NUMBER:TEN00106-01
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Description
KOMATSU GALEO CD110R-2 CRAWLER CARRIER OPERATION & MAINTENANCE MANUAL (SN:1501 & UP)
KOMATSU GALEO CD110R-2 CRAWLER CARRIER OPERATION & MAINTENANCE MANUAL (SN:1501 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO CD110R-2 CRAWLER CARRIER OPERATION & MAINTENANCE MANUAL (SN:1501 & UP)
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 a hazard when performing operation and maintenance.
TABLE OF CONTENTS:
KOMATSU GALEO CD110R-2 CRAWLER CARRIER OPERATION & MAINTENANCE MANUAL (SN:1501 & UP)
COVER.............................................................................................. 1 FOREWORD........................................................................................... 2 FOREWORD....................................................................................... 3 SAFETY INFORMATION............................................................................. 6 INTRODUCTION................................................................................... 8 FRONT/REAR,LEFT/RIGHT DIRECTIONS OF MACHINE................................................ 8 BREAKING IN TEH NEW MACHINE................................................................ 8 NECESSARY INFORMATION.......................................................................... 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE............................... 9 ENGINE SERIAL NO. PLATE.................................................................... 9 EPA NAMEPLATE.............................................................................. 10 POSITION OF SERVICE METER.................................................................. 10 TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR.................................................. 11 CONTENTS........................................................................................... 12 SAFETY............................................................................................. 16 SAFETY......................................................................................... 17 SAFETY LABELS.................................................................................. 19 POSITIONS OF SAFETY PICTOGRAMS............................................................. 20 SAFETY LABELS.............................................................................. 21 GENERAL PRECAUTIONS............................................................................ 28 SAFETY RULES............................................................................... 28 IF ABNORMALITIES ARE FOUND................................................................. 28 CLOTHING AND PERSONAL PROTECTIVE ITEMS..................................................... 28 FIRE EXTINGUISHER AND FIRST AID KIT........................................................ 28 SAFETY FEATURES............................................................................ 28 KEEP MACHINE CLEAN......................................................................... 29 INSIDE OPERATOR'S COMPARTMENT.............................................................. 29 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT............................................. 29 HANDRAILS AND STEPS........................................................................ 30 MOUNTING AND DISMOUNTING................................................................... 30 CRUSHING OR CUTTING PREVENTION............................................................. 30 PREVENTION OF BURNS........................................................................ 31 FIRE PREVENTION............................................................................ 31 ACTION IF FIRE OCCURS...................................................................... 32 WINDOW WASHER LIQUID....................................................................... 32 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)............................... 32 PRECAUTIONS FOR ATTACHMENTS................................................................ 33 UNAUTHORIZED MODIFICATION.................................................................. 33 SAFETY AT WORKSITE......................................................................... 33 WORKING ON LOOSE GROUND.................................................................... 33 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES..................................................... 34 ENSURE GOOD VISIBILITY..................................................................... 34 VENTILATION FOR ENCLOSED AREAS............................................................. 34 CHECKING SIGNALMAN'S SIGNALS AND SIGNS..................................................... 34 EMERGENCY EXIT FROM OPERATOR'S CAB......................................................... 35 BE CAREFUR ABOUT ASBESTOS DUST............................................................. 35 PRECAUTIONS FOR OPERATION...................................................................... 36 STARTING ENGINE............................................................................ 36 CHECKS BEFORE STARTING ENGINE.......................................................... 36 PRECAUTIONS WHEN STARTING.............................................................. 36 PRECAUTIONS IN COLD AREAS.............................................................. 37 OPERATION.................................................................................. 38 CHECK BEFORE OPERATION................................................................. 38 PRECAUTIONS WHEN CHANGING DIRECTION.................................................... 38 PRECAUTIONS WHEN TRAVELING............................................................. 39 TRAVELING ON SLOPES.................................................................... 40 PRECAUTIONS WHEN OPERATING DUMP BODY................................................... 40 OPERATIONS ON SLOPES................................................................... 40 RPOHIBITED OPERATIONS.................................................................. 41 OPERATE CAREFULLY ON SNOW.............................................................. 41 PARKING MACHINE........................................................................ 41 TRANSPORTATION............................................................................. 42 LOADING AND UNLOADING.................................................................. 42 SHIPPING............................................................................... 42 BATTERY.................................................................................... 43 BATTERY HAZARD PREVENTION.............................................................. 43 STARTING WITH BOOSTER CABLE............................................................ 44 TOWING..................................................................................... 45 WHEN TOWING............................................................................ 45 PRECAUTIONS FOR MAINTENANCE.................................................................... 46 WARNING TAG................................................................................ 46 KEEP WORK PLACE CLEAN AND TIDY............................................................. 46 APPOING LEADER WHEN WORKING WITH OTHERS.................................................... 46 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE................................. 47 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING......................................... 47 PROPER TOOLS............................................................................... 48 ACCUMULATOR................................................................................ 48 PERSONNAL.................................................................................. 48 PRECAUTIONS FOR WORK UNDER MACHINE......................................................... 49 NOISE...................................................................................... 49 PRECAUTIONS WHEN USING HAMMER.............................................................. 49 REPAIR WELDING............................................................................. 49 REMOVING BATTERY TERMINAL.................................................................. 49 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION........................ 50 DO NOT DISASSEMBLE RECOIL SPRING........................................................... 50 PRECAUTIONS WITH HIGH-PRESSURE OIL......................................................... 50 HANDLING HIGH-PRESSURE HOSES............................................................... 51 WASTE MATERIAL............................................................................. 51 MAINTENANCE FOR AIR CONDITIONER............................................................ 51 COMPRESSED AIR............................................................................. 51 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.............................................. 51 OPERATION.......................................................................................... 52 GENERAL VIEW................................................................................... 53 GENERAL VIEW OF MACHINE.................................................................... 53 GENERAL VIEW OF CONTROLS AND GAUGES........................................................ 54 EXPLANATION OF COMPONENTS...................................................................... 55 MACHINE MONITOR............................................................................ 55 CLINOMETER................................................................................. 66 SWITCHES................................................................................... 67 CONTROL LEVERS AND PEDALS.................................................................. 72 SLIDING DOOR............................................................................... 75 EMERGENCY ESCAPE HAMMER.................................................................... 75 CAP, COVER WITH LOCK....................................................................... 77 FALLING BODY PROTECTIVE PROP............................................................... 79 FUSE....................................................................................... 80 SLOW BLOW FUSE............................................................................. 81 FUSIBLELINK................................................................................ 81 POWER SUPPLY TAKE-OFF PORT................................................................. 82 CONTROLLER................................................................................. 83 AIR CONDITIONER CONTROLS................................................................... 84 RADIO...................................................................................... 88 OPERATION MANUAL STORAGE................................................................... 92 TOOL BOX................................................................................... 92 GREASE PUMP HOLDER......................................................................... 92 ASHTRAY.................................................................................... 92 FIRE EXTINGUISHER.......................................................................... 93 OPERATION...................................................................................... 94 CHECK BEFORE STARTING ENGINE, ADJUST....................................................... 94 STARTING ENGINE............................................................................108 OPERATIONS AND CHECKS AFTER STARTING ENGINE................................................112 STOPPING ENGINE............................................................................114 MACHINE OPERATION..........................................................................115 STEERING MACHINE...........................................................................119 SWINGING...................................................................................122 OPERATING DUMP BODY........................................................................124 PROHIBITIONS FOR OPERATION.................................................................125 PRECAUTIONS FOR OPERATION..................................................................126 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS................................................128 PARKING MACHINE............................................................................130 CHECK AFTER FINISHING WORK.................................................................131 LOCKING....................................................................................132 RUBBER SHOES...............................................................................133 TRANSPORTATION.................................................................................136 TRANSPORTATION PROCEDURE...................................................................136 LOADING, UNLOADING WORK....................................................................136 LIFTING MACHINE............................................................................140 COLD WEATHER OPERATION.........................................................................141 PRECAUTIONS FOR LOW TEMPERATURE............................................................141 AFTER COMPLETION OF WORK...................................................................142 AFTER COLD WEATHER.........................................................................142 LONG-TERM STORAGE..............................................................................143 BEFORE STORAGE.............................................................................143 DURING STORAGE.............................................................................143 AFTER STORAGE..............................................................................143 STARTING ENGINE AFTER LONG-TERM STORAGE....................................................143 TROUBLESHOOTING................................................................................144 AFTER RUNNING OUT OF FUEL..................................................................144 TOWING THE MACHINE.........................................................................144 IF BATTERY IS DISCHARGED...................................................................145 OTHER TROUBLE..............................................................................148 MAINTENANCE........................................................................................152 GUIDE TO MAINTENANCE...........................................................................153 OUTLINE OF SERVICE.............................................................................155 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....................................155 RELATING TO ELECTRIC SYSTEM................................................................158 WEAR PARTS.....................................................................................159 WEAR PARTS LIST............................................................................159 RECOMMENDED FUEL, COOLANT, AND LUBRICANT.......................................................160 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL........162 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.................................................163 TORQUE LIST................................................................................163 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..................................................164 SAFETY CRITICAL PARTS......................................................................164 MAINTENANCE SCHEDURE CHART.....................................................................165 MAINTENANCE SCHEDURE CHART.................................................................165 SERVICE PROCEDURE..............................................................................167 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS).............................167 WHEN REQUIRED..............................................................................168 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...........................................168 CLEAN INSIDE OF COOLING SYSTEM.........................................................172 CHECK RUBBER SHOES.....................................................................175 CHECK AND ADJUST TRACK TENSION.........................................................177 REPLACE RUBBER SHOE....................................................................178 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.............................................179 CHECK AND MAINTENANCE AIR CONDITIONER..................................................180 CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER..............................181 REPLACE SLOW BLOW FUSE.................................................................182 CHECK BEFORE STARTING......................................................................183 EVERY 50 HOURS SERVICE.....................................................................184 DRAIN WATER, SEDIMENT FROM FUEL TANK...................................................184 EVERY 100 HOURS SERVICE....................................................................185 LUBRICATING............................................................................185 EVERY 250 HOURS SERVICE....................................................................186 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...........................................186 CHECK LEVEL OF BATTERY ELECTROLYTE.....................................................187 CHECK AIR COMPRESSOR BELT TENSION, ADJUST..............................................189 EVERY 500 HOURS SERVICE....................................................................191 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE......................191 REPLACE FUEL FILTER CARTRIDGE..........................................................192 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.......................................193 CHECK SWING PINION GREASE LEVEL, ADD GREASE............................................194 GREASE SWING CIRCLE....................................................................194 REPLACE HYDRAULIC TANK BREATHER ELEMENT................................................195 CLEAN WATER SEPARATOR STRAINER.........................................................196 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS.............................................197 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, CONDENSER FINS....198 EVERY 1000 HOURS SERVICE...................................................................199 REPLACE HYDRAULIC LINE FILTER ELEMENT..................................................199 REPLACE CORROSION RESISTOR CARTRIDGE...................................................199 REPLACE HYDRAULIC FILTER ELEMENT.......................................................200 CHANGE OIL IN SWING MACHINERY CASE.....................................................201 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL................................................202 CHECK ALL TIGHTENING PARTS OF TURBOCHAGER..............................................202 CHECK PLAY OF TURBOCHAGER ROTOR........................................................202 CHECK FAN BELT, ALTERNATOR BELT TENSION, REPLACE.......................................202 EVERY 2000 HOURS SERVICE...................................................................203 CHANGE OIL IN FINAL DRIVE CASE.........................................................203 CLEAN HYDRAULIC TANK STRAINER..........................................................203 CLEAN ENGINE BREATHER..................................................................204 CHECK ALTERNATOR, STARTING MOTOR.......................................................204 CHECK ENGINE VALVE CLEARANCE, ADJUST...................................................204 CLEAN, CHECK TURBOCHAGER...............................................................204 CHECK VIBRATION DAMPER.................................................................204 EVERY 4000 HOURS SERVICE...................................................................205 CHECK WATER PUMP.......................................................................205 EVERY 5000 HOURS MAINTENANCE...............................................................206 CHANGE OIL IN HYDRAULIC TANK...........................................................206 SPECIFICATIONS.....................................................................................210 SPECIFICATIONS.................................................................................211 INDEX..............................................................................................212
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]
