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KOMATSU GALEO PC1800-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:10011,11002 & UP) KOMATSU GALEO PC1800-6 – PDF DOWNLOAD
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- KOMATSU GALEO PC1800-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:10011,11002 & UP
- PUBLICATION NUMBER:SEAM022908T
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KOMATSU GALEO PC1800-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:10011,11002 & UP) KOMATSU GALEO PC1800-6
KOMATSU GALEO PC1800-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:10011,11002 & UP) KOMATSU GALEO PC1800-6 – PDF DOWNLOAD:
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KOMATSU GALEO PC1800-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:10011,11002 & UP) KOMATSU GALEO PC1800-6
- 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.
- If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor. If you sell the machine, be sure to give this manual to the new owners together with the machine. Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
- If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and speciffications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
TABLE OF CONTENTS:
KOMATSU GALEO PC1800-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:10011,11002 & UP) KOMATSU GALEO PC1800-6
COVER............................................................................................... 1 FOREWORD............................................................................................ 2 FOREWORD........................................................................................ 3 SAFETY INFORMATION.............................................................................. 6 INTRODUCTION.................................................................................... 8 DIRECTIONS OF MACHINE....................................................................... 8 PRODUCT INFORMATION............................................................................. 9 MACHINE SERIAL NUMBER PLATE AND ITS LOCATION................................................ 9 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION................................................. 9 EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION......................................... 10 SERVICE METER LOCATION...................................................................... 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR................................................. 11 CONTENTS........................................................................................ 12 SAFETY.............................................................................................. 16 SAFETY INFORMATION.............................................................................. 17 POSITION FOR ATTACHING SAFETY LABELS............................................................ 19 POSITION FOR ATTACHING SAFETY LABELS........................................................ 20 SAFETY LABELS............................................................................... 21 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........................................................................................... 56 GENERAL VIEW.................................................................................... 57 GENERAL VIEW OF MACHINE..................................................................... 57 GENERAL VIEW OF CONTROLS AND GAUGES......................................................... 58 EXPLANATION OF COMPONENTS....................................................................... 60 MACHINE MONITOR............................................................................. 60 BASIC CHECK ITEMS....................................................................... 62 CAUTION ITEMS........................................................................... 64 EMERGENCY STOP ITEMS.................................................................... 66 METER DISPLAY PORTION................................................................... 68 PILOT DISPLAY........................................................................... 68 GAUGES AND METER........................................................................ 69 MONITOR SWITCHES........................................................................ 72 CGC MONITOR................................................................................. 74 CGC MONITOR............................................................................. 74 CHANGES OF SCREEN AND CONTENT OF DISPLAY ON CGC MONITOR................................. 75 EXPLANATION OF SCREENS.................................................................. 77 SWITCHES....................................................................................112 STARTER SELECTOR SWITCH.................................................................113 STARTING SWITCH.........................................................................113 PREHEATING SWITCH.......................................................................113 FUEL CONTROL DIAL (FRONT ENGINE)........................................................114 FUEL CONTROL DIAL (REAR ENGINE).........................................................114 CIGARETTE LIGHTER.......................................................................114 LAMP SWITCH.............................................................................114 STEP LIGHT SWITCH.......................................................................115 SWING LOCK SWITCH.......................................................................115 ROOM LAMP SWITCH........................................................................116 MACHINE PUSH-UP SWITCH..................................................................116 FOG LAMP SWITCH.........................................................................116 BOOM SHOCKLESS CONTROL SWITCH...........................................................117 ROTATING LAMP SWITCH....................................................................117 ALARM BUZZER STOP SWITCH................................................................117 WINDSHIELD WIPER SWITCH.................................................................118 GREASING SWITCH.........................................................................118 HORN SWITCH.............................................................................118 TRUCK COUNTER SWITCH....................................................................119 ROOM LAMP SWITCH........................................................................120 ROOM LAMP SWITCH........................................................................120 ROOM LAMP SWITCH........................................................................121 PUMP DRIVE EMERGENCY SWITCH.............................................................121 SWING HOLDING BRAKE REPLEASE SWITCH.....................................................121 SPARE SOCKET............................................................................122 ENGINE EMERGENCY STOP SWITCH............................................................122 LAMP........................................................................................123 ENGINE EMERGENCY STOP LAMP..............................................................124 AUTO GREASING CAUTION LAMP..............................................................125 LADDER WARNING LAMP.....................................................................125 TRUCK COUNTER LAMP......................................................................126 CONTROL LEVERS, PEDALS......................................................................127 SAFETY LOCK LEVER.......................................................................128 TRAVEL LEVERS...........................................................................129 WORK EQUIPMENT CONTROL LEVER............................................................130 DOOR LOCK...................................................................................131 POCKET......................................................................................131 EMERGENCY ESCAPE HAMMER.....................................................................131 EMERGENCY ESCAPE LADDER.....................................................................132 FIRE EXTINGUISHER...........................................................................132 CAP, COVER WITH LOCK........................................................................133 METHOD OF OPENING AND CLOSING CAP WITH LOCK.............................................133 METHOD OF OPENING AND CLOSING COVER WITH LOCK...........................................133 ASHTRAY.....................................................................................133 HANDLING AIR CONDITIONER....................................................................134 GENERAL LOCATIONS OF CONTROL PANEL......................................................134 USE AIR CONDITIONER WITH CARE...........................................................141 CAR RADIO...................................................................................142 EXPLANATION OF COMPONENTS...............................................................142 CONTROLS OF RADIO.......................................................................145 AUXILIARY ELECTRIC POWER................................................................147 FUSE........................................................................................147 CIRCUIT BREAKER.............................................................................148 CIRCUIT BREAKER (20A)...................................................................148 CIRCUIT-BREAKER (40A)...................................................................148 FUSE, CIRCUIT BREAKER CAPACITY AND NAME OF CIRCUIT......................................149 FUSE....................................................................................150 CONTROLLER (COMPUTER).......................................................................151 TOOLBOX.....................................................................................152 HANDLING GREASE PUMP AND GREASE GUN.........................................................152 HANDLING ACCUMULATOR........................................................................156 METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR....156 ORBCOMM CONTROLLER..........................................................................157 MACHINE OPERATIONS AND CONTROLS.................................................................158 BEFORE STARTING ENGINE......................................................................158 WALK-AROUND CHECKS......................................................................158 CHECKS BEFORE STARTING..................................................................159 ADJUST BEFORE OPERATION.................................................................171 SEAT BELT...............................................................................174 OPERATIONS BEFORE STARTING ENGINE.......................................................176 STARTING ENGINE.............................................................................179 NORMAL STARTING.........................................................................179 STARTING ENGINE IN COLD WEATHER.........................................................181 AFTER STARTING ENGINE.......................................................................184 BREAKING-IN THE NEW MACHINE.............................................................184 WARMING-UP OPERATION....................................................................185 IN COLD AREAS...............................................................................188 STOPPING THE ENGINE.........................................................................191 NORMAL STOPPING.........................................................................191 STOPPING IN EMERGENCIES.................................................................191 CHECK AFTER SHUT OFF ENGINE.................................................................194 MACHINE OPERATION...........................................................................195 PREPARATIONS FOR MOVING THE MACHINE OFF.................................................195 MOVING MACHINE FORWARD..................................................................196 MOVING MACHINE BACKWARD.................................................................197 STOPPING MACHINE........................................................................198 STEERING THE MACHINE........................................................................199 STEERING................................................................................199 SWINGING....................................................................................201 WORK EQUIPMENT CONTROLS AND OPERATIONS......................................................202 HANDLING WORKING MODE.......................................................................203 WORKING MODE............................................................................203 PROHIBITED OPERATIONS.......................................................................204 OPERATIONS USING SWING FORCE............................................................204 OPERATIONS USING TRAVEL FORCE...........................................................204 OPERATIONS USING HYDRAULIC CYLINDER STROKE ENDS.........................................204 OPERATIONS USING BUCKET DROPPING FORCE..................................................205 OPERATIONS USING MACHINE DROPPING FORCE.................................................205 DIGGING HARD ROCKY GROUND...............................................................205 GENERAL OPERATION INFORMATION...............................................................206 TRAVELING...............................................................................206 PERMISSIBLE WATER DEPTH.................................................................206 TRAVELING ON SLOPES.........................................................................207 TRAVELING DOWNHILL......................................................................208 ENGINE STOPPED ON SLOPE.................................................................208 PRECAUTIONS ON SLOPES...................................................................208 ESCAPE FROM MUD.............................................................................209 STUCK ONE SIDE OF TRACK.................................................................209 STUCK BOTH SIDES OF TRACKS..............................................................209 RECOMMENDED APPLICATIONS....................................................................210 BACKHOE WORK............................................................................210 LOADING WORK............................................................................210 REPLACEMENT AND INVERSION OF BUCKET.........................................................211 REPLACEMENT.............................................................................211 PARKING MACHINE.............................................................................213 CHECK AFTER FINISHING WORK..................................................................214 LOCKING.....................................................................................215 TRANSPORTATION..................................................................................216 PRECAUTIONS FOR TRANSPORTATION..............................................................216 REMOVAL AND INSTALLATION OF MIRRORS.....................................................216 LIFTING MACHINE.............................................................................217 PARTS FOR TRANSPORT.........................................................................217 COLD WEATHER OPERATION..........................................................................218 COLD WEATHER OPERATION INFORMATION..........................................................218 FUEL AND LUBRICANTS.....................................................................218 COOLING SYSTEM COOLANT..................................................................218 BATTERY.................................................................................219 AFTER DAILY WORK COMPLETION.................................................................220 AFTER COLD WEATHER SEASON...................................................................220 LONG TERM STORAGE...............................................................................221 BEFORE STORAGE..............................................................................221 DURING STORAGE..............................................................................221 AFTER STORAGE...............................................................................222 STARTING MACHINE AFTER LONG-TERM STORAGE................................................222 TROUBLESHOOTING.................................................................................223 AFTER RUNNING OUT OF FUEL...................................................................223 PHENOMENA THAT ARE NOT FAILURES.............................................................224 TOWING THE MACHINE..........................................................................225 PRECAUTIONS ON PARTICULAR JOBSITES..........................................................225 DISCHARGED BATTERY..........................................................................226 REMOVAL AND INSTALLATION OF BATTERY.....................................................227 BATTERY CHARGES.........................................................................227 STARTING ENGINE WITH BOOSTER CABLES.....................................................228 OTHER TROUBLE...............................................................................230 ELECTRICAL SYSTEM.......................................................................230 CHASSIS.................................................................................231 ENGINE..................................................................................232 ELECTRONIC CONTROL SYSTEM...............................................................234 MAINTENANCE.........................................................................................236 MAINTENANCE INFORMATION.........................................................................237 SERVICE METER READING.......................................................................237 KOMATSU GENUINE REPLACEMENT PARTS...........................................................237 KOMATSU GENUINE LUBRICANTS..................................................................237 WINDSHIELD WASHER FLUID.....................................................................237 FRESH AND CLEAN LUBRICANTS..................................................................237 CHECK DRAINED OIL AND USED FILTER...........................................................237 FUEL STRAINER...............................................................................237 WELDING INSTRUCTIONS........................................................................237 DO NOT DROP THINGS INSIDE MACHINE...........................................................238 DUSTY JOBSITE...............................................................................238 AVOID MIXING LUBRICANTS.....................................................................238 LOCKING THE INSPECTION COVERS...............................................................238 HYDRAULIC SYSTEM – AIR BLEEDING.............................................................238 HYDRAULIC HOSE INSTALLATION.................................................................238 CHECKS AFTER INSPECTION AND MAINTENANCE WORKS...............................................239 LUBRICANTS, COOLANT AND FILTERS.................................................................240 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................240 OIL.....................................................................................240 FUEL....................................................................................240 COOLING SYSTEM COOLANT..................................................................241 GREASE..................................................................................241 CARRYING OUT KOWA (Komatsu Oil Wear Analysis)...........................................241 OIL AND FUEL STORAGE....................................................................242 FILTERS.................................................................................243 ELECTRIC SYSTEM MAINTENANCE.................................................................243 WEAR PARTS LIST.................................................................................244 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE............................245 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS............................................245 TIGHTENING TORQUE SPECIFICATIONS................................................................249 TIGHTENING TORQUE LIST......................................................................249 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................250 SAFETY CRITICAL PARTS.......................................................................251 MAINTENANCE SCHEDULE............................................................................253 MAINTENANCE SCHEDULE CHART..................................................................253 Initial 100 Hours Maintenance (Only after the first 250 hours)..........................253 Initial 250 Hours Maintenance (Only after the first 250 hours)..........................253 When Required...........................................................................253 Checks Before Starting..................................................................253 Every 10 Hours Maintenance..............................................................253 Every 100 Hours Maintenance.............................................................254 Every 250 Hours Maintenance.............................................................254 Every 500 Hours Maintenance.............................................................254 Every 1000 Hours Maintenance............................................................254 Every 2000 Hours Maintenance............................................................255 Every 4000 Hours Maintenance............................................................255 Every 5000 Hours Maintenance............................................................255 Every 8000 Hours Maintenance............................................................255 MAINTENANCE PROCEDURE...........................................................................256 INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)..............................256 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)..............................256 WHEN REQUIRED...............................................................................257 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................................257 CLEAN INSIDE OF COOLING SYSTEM..........................................................260 CHECK AND TIGHTEN TRACK SHOE BOLTS......................................................264 CHECK AND ADJUST TRACK TENSION..........................................................265 CHECK ELECTRICAL INTAKE AIR HEATER......................................................268 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)................................................269 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)..............................................272 ADJUST BUCKET CLEARANCE.................................................................273 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..............................................274 CHECK AND ADJUST AIR CONDITIONER........................................................275 CLEANING, REMOVING DIRT FROM LINE FILTER................................................276 REPLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER................................277 GREASE LADDER...........................................................................278 INSPECT SEALANT AROUND ENGINE COOLING SYSTEM............................................279 CHECK FOR LOOSE AFTERCOOLER HOSE CLAMPS.................................................280 PROCEDURE FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT.......................................280 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT.............................288 CHECK BEFORE STARTING.......................................................................290 EVERY 10 HOURS MAINTENANCE..................................................................291 LUBRICATING.............................................................................291 EVERY 100 HOURS MAINTENANCE.................................................................295 CHECK OIL LEVEL IN SWING MACHINERY CASE.................................................295 EVERY 250 HOURS MAINTENANCE.................................................................296 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL............................................296 CHECK LEVEL OF BATTERY ELECTROLYTE......................................................297 REPLACE FILTER ELEMENT OF HYDRAULIC TANK BREATHER.......................................299 CHECK, WASH FUEL STRAINER...............................................................300 CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS.................................301 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST.............................................302 CHECK ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT.................................304 EVERY 500 HOURS MAINTENANCE.................................................................306 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.......................306 REPLACE FUEL FILTER CARTRIDGE...........................................................309 CLEAN PILOT FILTER STRAINER.............................................................311 CLEAN HYDRAULIC FILTER STRAINER FOR AUTO GREASING DRIVE.................................311 CHANGE HYDRAULIC FILTER ELEMENT.........................................................312 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, FUEL COOLER AND AFTER COOLER FINS.....313 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM.......................315 CLEAN STRAINER OF PTO LUBRICATING OIL FILTER............................................317 CHECK, REPLACE, ADJUST FAN BELT.........................................................318 CHECK, REPLACE HYDRAULIC PUMP DRAIN FILTER CARTRIDGE....................................319 REPLACING SWING MOTOR DRAIN FILTER CARTRIDGE............................................320 REPLACING TRAVEL MOTOR DRAIN FILTER CARTRIDGE...........................................321 EVERY 1000 HOURS MAINTENANCE................................................................322 CHANGE OIL IN SWING MACHINERY CASE......................................................322 CHANGE OIL IN PTO CASE..................................................................324 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER..............................................324 REPLACE CORROSION RESISTOR CARTRIDGE....................................................325 INSPECTION OF WELDED STRUCTURE AFTER INITIAL 4000 HOURS SERVICE.........................325 GREASING FAN PULLEY ASSEMBLY, TENSION PULLEY ASSEMBLY...................................325 EVERY 2000 HOURS MAINTENANCE................................................................326 CHANGE OIL IN FINAL DRIVE CASE..........................................................326 CHANGE OIL IN HYDRAULIC TANK, WASH STRAINER.............................................327 CHECK SWING PINION GREASE LEVEL, ADD GREASE.............................................330 CLEAN ENGINE BREATHER...................................................................330 CLEAN, CHECK TURBOCHARGER...............................................................330 CHECK ALTERNATOR AND STARTING MOTOR.....................................................330 CHECK ENGINE VALVE CLEARANCES, ADJUST...................................................331 CHECK INJECTOR..........................................................................331 EVERY 4000 HOURS MAINTENENCE................................................................332 CHECK WATER PUMP........................................................................332 CHECK VIBRATION DAMPER..................................................................332 CHECK FAN PULLEY AND TENSION PULLEY.....................................................332 REPLACE INJECTOR NOZZLE ASSEMBLY........................................................332 CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.........................333 CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER........................334 CHECK, ADJUST AIR COMPRESSOR............................................................334 CHECK WELDED STRUCTURE..................................................................335 EVERY 5000 HOURS MAINTENANCE................................................................338 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER............................................338 EVERY 8000 HOURS MAINTENANCE................................................................341 REPLACE HIGH-PRESSURE PIPING CLAMP......................................................341 REPLACE FUEL SPRAY PREVENTION CAP.......................................................341 SPECIFICATIONS......................................................................................342 SPECIFICATIONS..................................................................................343 ATTACHMENTS AND OPTIONS.............................................................................346 GENERAL PRECAUTIONS.............................................................................347 PRECAUTIONS RELATED TO SAFETY...............................................................347 PRECAUTIONS WHEN INSTALLING ATTACHMENTS.....................................................349 ATTACHMENT GUIDE................................................................................350 COMBINATIONS OF WORK EQUIPMENT..............................................................350 PROTECTIVE GUARD............................................................................351 AUTO GREASING SYSTEM........................................................................352 CONTROL DEVICES.........................................................................353 LOADING SHOVEL......................................................................................356 GENERAL VIEW....................................................................................357 GENERAL VIEW OF MACHINE.....................................................................357 GENERAL VIEW OF CONTROLS AND GAUGES.........................................................358 EXPLANATION OF COMPONENTS.......................................................................359 SWITCHES....................................................................................359 AUTOMATIC LEVEL CROWDING/BUCKET ANGLE COMPENSATION SWITCH...............................359 AUTOMATIC LEVEL CROWDING SWITCH.........................................................359 BUCKET ANGLE COMPENSATION SWITCH........................................................359 BOTTOM DUMP SWITCH......................................................................360 HORN SWITCH.............................................................................360 CONTROL BOX.................................................................................360 OPERATIONS......................................................................................361 OPERATION OF WORK EQUIPMENT.................................................................361 PRECAUTIONS DURING OPERATION................................................................363 EXCAVATOR WORK..............................................................................367 PRECAUTIONS WHEN DISASSEMBLING MACHINE..........................................................368 RELEASING PRESSURE..........................................................................368 RELEASING PRESSURE FROM WORK EQUIPMENT CIRCUIT, SWING CIRCUIT, TRAVEL CIRCUIT...........368 RELEASING PRESSURE IN ACCUMULATOR CIRCUIT...............................................368 TROUBLESHOOTING.................................................................................369 WORK EQUIPMENT AUTOMATIC CONTROL CONTROLLER.................................................369 TRANSPORTATION..................................................................................370 MACHINE CONFIGURATION FOR TRANSPORT.........................................................370 MAINTENANCE SCHEDULE............................................................................371 EVERY 10 HOURS MAINTENANCE..................................................................371 PREPARATIONS BEFORE LUBRICATION.........................................................371 LUBRICATION.............................................................................374 SPECIFICATION...................................................................................380 COMBINATION OF WORK EQUIPMENT...................................................................382 COMBINATION OF WORK EQUIPMENT...............................................................382 INDEX...............................................................................................384
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