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KOMATSU GALEO PC1250 -8 PC1250SP-8 PC1250LC -8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:30001 and up) – PDF DOWNLOAD
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- KOMATSU GALEO PC1250 -8 PC1250SP-8 PC1250LC -8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:30001 and up
- PUBLICATION NUMBER:TEN00146-02
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Description
KOMATSU GALEO PC1250 -8 PC1250SP-8 PC1250LC -8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:30001 and up)
KOMATSU GALEO PC1250 -8 PC1250SP-8 PC1250LC -8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:30001 AND UP) – PDF DOWNLOAD:
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TABLE OF CONTENTS:
KOMATSU GALEO PC1250 -8 PC1250SP-8 PC1250LC -8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:30001 and up)
COVER................................................................................................................................................................... 1 FOREWORD................................................................................................................................................................ 2 FOREWORD............................................................................................................................................................ 3 SAFETY INFORMATION.................................................................................................................................................. 6 INTRODUCTION........................................................................................................................................................ 8 DIRECTIONS OF MACHINE........................................................................................................................................... 8 VISIBILITY FROM OPERATOR'S SEAT................................................................................................................................. 9 BREAKING-IN THE NEW MACHINE..................................................................................................................................... 10 PRODUCT INFORMATION................................................................................................................................................. 11 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.................................................................................................... 11 EPA REGULATIONS, ENGINE NUMBER PLATE............................................................................................................................ 11 SERVICE METER LOCATION.......................................................................................................................................... 12 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR..................................................................................................................... 12 CONTENTS................................................................................................................................................................ 13 SAFETY.................................................................................................................................................................. 18 SAFETY.............................................................................................................................................................. 19 SAFETY LABELS....................................................................................................................................................... 21 LOCATION OF SAFETY LABELS....................................................................................................................................... 22 SAFETY LABELS................................................................................................................................................... 23 GENERAL PRECAUTIONS................................................................................................................................................. 29 SAFETY RULES.................................................................................................................................................... 29 IF PROBLEMS ARE FOUND........................................................................................................................................... 29 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...................................................................................................................... 29 FIRE EXTINGUISHER AND FIRST AID KIT............................................................................................................................. 29 SAFETY EQUIPMENT................................................................................................................................................ 29 KEEP MACHINE CLEAN.............................................................................................................................................. 30 KEEP OPERATOR'S COMPARTMENT CLEAN............................................................................................................................... 30 LEAVING OPERATOR'S SEAT WITH LOCK............................................................................................................................... 30 HANDRAILS AND STEPS............................................................................................................................................. 31 PRECAUTIONS WHEN WORKING IN HIGH PLACES......................................................................................................................... 31 MOUNTING AND DISMOUNTING........................................................................................................................................ 31 NO PERSONS ON ATTACHMENTS....................................................................................................................................... 31 DO NOT GET CAUGHT IN ARTICULATED PORTION........................................................................................................................ 32 BURN PREVENTION................................................................................................................................................. 32 FIRE PREVENTION AND EXPLOSION PREVENTION........................................................................................................................ 33 ACTION IF FIRE OCCURS........................................................................................................................................... 34 WINDSHIELD WASHER FLUID......................................................................................................................................... 34 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION................................................................................................ 34 ATTACHMENT INSTALLATION......................................................................................................................................... 34 ATTACHMENT COMBINATIONS......................................................................................................................................... 34 CAB WINDOW GLASSES.............................................................................................................................................. 34 UNAUTHORIZED MODIFICATIONS...................................................................................................................................... 35 SAFETY AT JOBSITE............................................................................................................................................... 35 WORKING ON LOOSE GROUND......................................................................................................................................... 35 DISTANCE TO HIGH VOLTAGE CABLES................................................................................................................................. 36 ENSURE GOOD VISIBILITY.......................................................................................................................................... 36 VENTILATION FOR ENCLOSED AREA................................................................................................................................... 37 SIGNALMAN'S SIGNAL AND SIGNS.................................................................................................................................... 37 EMERGENCY EXIT FROM OPERATOR'S CAB.............................................................................................................................. 37 ASBESTOS DUST HAZARD PREVENTION................................................................................................................................. 37 SAFETY MACHINE OPERATION............................................................................................................................................ 38 STARTING ENGINE................................................................................................................................................. 38 CHECKS BEFORE STARTING ENGINE............................................................................................................................... 38 SAFETY RULES FOR STARTING ENGINE............................................................................................................................ 38 STARTING ENGINE IN COLD WEATHER............................................................................................................................. 39 OPERATION....................................................................................................................................................... 40 CHECKS BEFORE OPERATION..................................................................................................................................... 40 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS................................................................................................................ 40 SAFETY RULES FOR TRAVELING.................................................................................................................................. 41 TRAVELING ON SLOPES......................................................................................................................................... 41 OPERATIONS ON SLOPES ....................................................................................................................................... 42 PROHIBITED OPERATIONS....................................................................................................................................... 43 OPERATIONS ON SNOW.......................................................................................................................................... 44 PARKING MACHINE............................................................................................................................................. 45 TRANSPORTATION.................................................................................................................................................. 46 LOADING AND UNLOADING....................................................................................................................................... 46 SHIPPING THE MACHINE........................................................................................................................................ 46 BATTERY......................................................................................................................................................... 47 BATTERY HAZARD PREVENTION................................................................................................................................... 47 STARTING ENGINE WITH BOOSTER CABLES......................................................................................................................... 48 TOWING.......................................................................................................................................................... 49 SAFETY RULES FOR TOWING..................................................................................................................................... 49 LIFTING OBJECTS WITH BUCKET..................................................................................................................................... 50 SAFETY RULES FOR LIFTING OBJECTS............................................................................................................................ 50 SAFETY MAINTENANCE INFORMATION...................................................................................................................................... 51 WARNING TAG..................................................................................................................................................... 51 KEEP WORK PLACE CLEAN AND TIDY.................................................................................................................................. 51 APPOINT LEADER WHEN WORKING WITH OTHERS......................................................................................................................... 51 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE..................................................................................................................... 52 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.............................................................................................................. 53 PROPER TOOLS.................................................................................................................................................... 53 ACCUMULATOR, GAS SPRING......................................................................................................................................... 54 PERSONNEL....................................................................................................................................................... 54 ATTACHMENTS..................................................................................................................................................... 54 WORK UNDER THE MACHINE.......................................................................................................................................... 54 NOISE........................................................................................................................................................... 54 WHEN USING HAMMER............................................................................................................................................... 55 WELDING WORKS................................................................................................................................................... 55 REMOVING BATTERY TERMINALS...................................................................................................................................... 55 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION............................................................................................ 55 DO NOT DISASSEMBLE RECOIL SPRINGS............................................................................................................................... 56 SAFETY RULES FOR HIGH-PRESSURE OIL.............................................................................................................................. 56 PRECAUTION FOR HIGH FUEL PRESSURE............................................................................................................................... 56 SAFETY HANDLING HIGH-PRESSURE HOSES............................................................................................................................. 56 PRECAUTION FOR HIGH VOLTAGE..................................................................................................................................... 57 WASTE MATERIALS................................................................................................................................................. 57 AIR CONDITIONER MAINTENANCE..................................................................................................................................... 57 COMPRESSED AIR.................................................................................................................................................. 57 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................................................... 57 OPERATION............................................................................................................................................................... 58 MACHINE VIEW ILLUSTRATIONS.......................................................................................................................................... 59 OVERALL MACHINE VIEW............................................................................................................................................ 59 CONTROLS AND GAUGES............................................................................................................................................. 60 DETAILED CONTROLS AND GAUGES........................................................................................................................................ 62 MONITORING SYSTEM............................................................................................................................................... 62 SWITCHES........................................................................................................................................................ 91 CONTROL LEVERS AND PEDALS....................................................................................................................................... 97 EMERGENCY EXIT FROM OPERATOR'S CAB..............................................................................................................................100 DOOR LOCK.......................................................................................................................................................100 CAP WITH LOCK...................................................................................................................................................101 HOT AND COOL BOX................................................................................................................................................103 MAGAZINE BOX....................................................................................................................................................103 ASHTRAY.........................................................................................................................................................103 FIRE EXTINGUISHER...............................................................................................................................................103 AIR CONDITIONER CONTROLS........................................................................................................................................104 RADIO...........................................................................................................................................................118 AUXILIARY ELECTRIC POWER........................................................................................................................................123 FUSE............................................................................................................................................................124 CIRCUIT BREAKER.................................................................................................................................................125 CONTROLLER......................................................................................................................................................127 TOOL BOX........................................................................................................................................................127 GREASE PUMP.....................................................................................................................................................128 MACHINE OPERATIONS AND CONTROLS.....................................................................................................................................132 BEFORE STARTING ENGINE..........................................................................................................................................132 STARTING ENGINE.................................................................................................................................................155 AFTER STARTING ENGINE...........................................................................................................................................158 STOPPING THE ENGINE.............................................................................................................................................168 MACHINE OPERATION...............................................................................................................................................169 STEERING THE MACHINE............................................................................................................................................173 SWINGING........................................................................................................................................................175 WORK EQUIPMENT CONTROLS AND OPERATIONS..........................................................................................................................176 WORKING MODE....................................................................................................................................................178 PROHIBITED OPERATIONS...........................................................................................................................................179 GENERAL OPERATION INFORMATION...................................................................................................................................184 TRAVELING ON SLOPES.............................................................................................................................................186 ESCAPE FROM MUD.................................................................................................................................................188 RECOMMENDED APPLICATIONS........................................................................................................................................189 BUCKET REPLACEMENT..............................................................................................................................................190 PARKING MACHINE.................................................................................................................................................192 MACHINE INSPECTION AFTER DAILY WORK.............................................................................................................................193 LOCKING.........................................................................................................................................................194 TRANSPORTATION......................................................................................................................................................195 TRANSPORTATION PROCEDURE........................................................................................................................................195 PRECAUTIONS FOR TRANSPORTATION..................................................................................................................................195 LIFTING MACHINE.................................................................................................................................................195 SHIPPING MACHINE INFORMATION....................................................................................................................................197 TRANSPORTATION POSTURE..........................................................................................................................................198 COLD WEATHER OPERATION..............................................................................................................................................206 COLD WEATHER OPERATION INFORMATION..............................................................................................................................206 AFTER DAILY WORK COMPLETION.....................................................................................................................................209 AFTER COLD WEATHER SEASON.......................................................................................................................................209 LONG TERM STORAGE...................................................................................................................................................210 BEFORE STORAGE..................................................................................................................................................210 DURING STORAGE..................................................................................................................................................210 AFTER STORAGE...................................................................................................................................................210 STARTING MACHINE AFTER LONG-TERM STORAGE........................................................................................................................211 TROUBLES AND ACTIONS................................................................................................................................................212 RUNNING OUT OF FUEL.............................................................................................................................................212 PHENOMENA THAT ARE NOT FAILURES.................................................................................................................................212 TOWING THE MACHINE..............................................................................................................................................213 SEVERE JOB CONDITION............................................................................................................................................213 DISCHARGED BATTERY..............................................................................................................................................214 OTHER TROUBLE...................................................................................................................................................218 MAINTENANCE.............................................................................................................................................................224 MAINTENANCE INFORMATION.............................................................................................................................................225 OUTLINE OF SERVICE..................................................................................................................................................227 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC..........................................................................................................227 ELECTRIC SYSTEM MAINTENANCE.....................................................................................................................................230 WEAR PARTS..........................................................................................................................................................231 WEAR PARTS LIST.................................................................................................................................................231 RECOMMENDED FUEL, COOLANT, AND LUBRICANT............................................................................................................................232 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.............................................................................234 TIGHTENING TORQUE SPECIFICATIONS....................................................................................................................................235 TIGHTENING TORQUE LIST..........................................................................................................................................235 SAFETY CRITICAL PARTS...............................................................................................................................................236 SAFETY CRITICAL PARTS LIST......................................................................................................................................236 MAINTENANCE SCHEDULE................................................................................................................................................237 MAINTENANCE SCHEDULE CHART......................................................................................................................................237 MAINTENANCE PROCEDURE...............................................................................................................................................239 INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)..................................................................................................239 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)..................................................................................................239 WHEN REQUIRED...................................................................................................................................................240 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT................................................................................................................240 CLEAN INSIDE OF COOLING SYSTEM..............................................................................................................................243 CHECK AND TIGHTEN TRACK SHOE BOLTS..........................................................................................................................247 CHECK AND ADJUST TRACK TENSION..............................................................................................................................248 REPLACE BUCKET TEETH (XS)...................................................................................................................................251 ADJUST BUCKET CLEARANCE.....................................................................................................................................255 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..................................................................................................................256 CHECK AND MAINTENANCE AIR CONDITIONER.......................................................................................................................257 CLEAN LINE FILTER, REMOVE DIRT..............................................................................................................................258 CHECK GAS SPRING............................................................................................................................................259 BLEEDING AIR FROM HYDRAULIC SYSTEM..........................................................................................................................260 BLEEDING AIR FROM FUEL CIRCUIT..............................................................................................................................263 CHECK BEFORE STARTING...........................................................................................................................................266 EVERY 10 HOURS MAINTENANCE......................................................................................................................................267 LUBRICATING.................................................................................................................................................267 EVERY 100 HOURS MAINTENANCE.....................................................................................................................................269 LUBRICATING SWING CIRCLE....................................................................................................................................269 EVERY 250 HOURS MAINTENANCE.....................................................................................................................................270 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL................................................................................................................270 CHECK LEVEL OF BATTERY ELECTROLYTE..........................................................................................................................271 CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS.....................................................................................................273 EVERY 500 HOURS MAINTENANCE.....................................................................................................................................274 REPLACE FUEL PRE-FILTER CARTRIDGE...........................................................................................................................274 REPLACE FUEL MAIN FILTER CARTRIDGE..........................................................................................................................276 CHECK SWING PINION GREASE LEVEL, ADD GREASE.................................................................................................................278 CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS, FUEL COOLER FINS, AFTERCOOLER FINS, CONDENSER FINS (MACHINES EQUIPPED WITH AIR CONDITIONER), PTO OIL COOLER....279 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS..................................................................................................................280 REPLACE PILOT FILTER ELEMENT................................................................................................................................281 CLEAN STRAINER OF PTO LUBRICATING OIL FILTER................................................................................................................282 CHECK, REPLACE ALTERNATOR, AIR CONDITIONER COMPRESSOR DRIVE BELTS...........................................................................................282 REPLACE DRAIN FILTER CARTRIDGE..............................................................................................................................283 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...........................................................................................284 EVERY 1000 HOURS MAINTENANCE....................................................................................................................................286 REPLACE HYDRAULIC OIL FILTER ELEMENT........................................................................................................................286 REPLACE BREATHER ELEMENT IN HYDRAULIC TANK..................................................................................................................287 CLEAN HYDRAULIC TANK RETURN STRAINER........................................................................................................................288 CHANGE OIL IN SWING MACHINERY CASE..........................................................................................................................289 CHANGE OIL IN PTO CASE......................................................................................................................................291 REPLACE CORROSION RESISTOR CARTRIDGE........................................................................................................................292 GREASE, CHECK TENSION PULLEY ASSEMBLY OF ALTERNATOR, AIR CONDITIONER COMPRESSOR DRIVE BELT..................................................................293 CHECK WELDED STRUCTURE......................................................................................................................................294 EVERY 2000 HOURS MAINTENANCE....................................................................................................................................297 CHANGE OIL IN FINAL DRIVE CASE..............................................................................................................................297 CHECK BOOST PIPING HOSE CLAMPS..............................................................................................................................297 CHECK ALTERNATOR............................................................................................................................................297 CHECK ENGINE VALVE CLEARANCE, ADJUST........................................................................................................................297 CLEAN HYDRAULIC TANK STRAINER...............................................................................................................................298 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)...............................................................................299 EVERY 4000 HOURS MAINTENANCE....................................................................................................................................303 CHECK WATER PUMP............................................................................................................................................303 CHECK STARTING MOTOR........................................................................................................................................303 CHECK AIR COMPRESSOR, ADJUST................................................................................................................................303 REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)...................................................................................................................303 CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER......................................................................................304 CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER............................................................................................305 EVERY 5000 HOURS MAINTENANCE....................................................................................................................................306 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER................................................................................................................306 EVERY 8000 HOURS MAINTENANCE....................................................................................................................................308 REPLACE HIGH-PRESSURE PIPING CLAMP..........................................................................................................................308 REPLACE FUEL SPRAY PREVENTION CAP...........................................................................................................................308 OVERHAUL STARTING MOTOR AND ALTERNATOR......................................................................................................................308 SPECIFICATIONS..........................................................................................................................................................310 SPECIFICATIONS......................................................................................................................................................311 ATTACHMENTS, OPTIONS....................................................................................................................................................314 GENERAL PRECAUTIONS FOR SAFETY......................................................................................................................................315 PRECAUTIONS WHEN SELECTING......................................................................................................................................315 READ THE INSTRUCTION MANUAL THOROUGHLY..........................................................................................................................315 PRECAUTIONS WHEN REMOVING OR INSTALLING.........................................................................................................................315 PRECAUTIONS WHEN USING..........................................................................................................................................315 ATTACHMENT GUIDE....................................................................................................................................................316 COMBINATIONS OF WORK EQUIPMENT..................................................................................................................................316 SELECTION OF TRACK SHOES............................................................................................................................................320 AUTO-GREASING SYSTEM................................................................................................................................................321 EXPLANATION OF COMPONENTS.......................................................................................................................................321 OPERATION.......................................................................................................................................................326 TROUBLESHOOTING.................................................................................................................................................330 MAINTENANCE.....................................................................................................................................................331 HANDLING MACHINES EQUIPPED WITH VHMS................................................................................................................................337 VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED...........................................................................................................337 VHMS AND COMMUNICATIONS TERMINAL INSTALLED......................................................................................................................338 LOADING SHOVEL..........................................................................................................................................................340 EXPLANATION OF COMPONENTS...........................................................................................................................................341 SWITCHES........................................................................................................................................................341 FUSE............................................................................................................................................................344 OPERATIONS..........................................................................................................................................................345 OPERATION OF WORK EQUIPMENT.....................................................................................................................................345 PRECAUTIONS DURING OPERATION....................................................................................................................................347 EXCAVATOR WORK..................................................................................................................................................351 PRECAUTIONS WHEN DISASSEMBLING MACHINE..............................................................................................................................352 RELEASING PRESSURE..............................................................................................................................................352 TRANSPORTATION......................................................................................................................................................353 MACHINE CONFIGURATION FOR TRANSPORT.............................................................................................................................353 WEAR PARTS..........................................................................................................................................................360 WEAR PARTS LIST.................................................................................................................................................360 MAINTENANCE.........................................................................................................................................................361 CHECK BEFORE STARTING...........................................................................................................................................361 EVERY 10 HOURS MAINTENANCE......................................................................................................................................363 EVERY 5000 HOURS MAINTENANCE....................................................................................................................................364 SPECIFICATION.......................................................................................................................................................366 COMBINATION OF WORK EQUIPMENT.......................................................................................................................................367 COMBINATION OF WORK EQUIPMENT...................................................................................................................................367 INDEX...................................................................................................................................................................370
DESCRIPTION:
KOMATSU GALEO PC1250 -8 PC1250SP-8 PC1250LC -8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:30001 and 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
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