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KOMATSU GALEO PC1800-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:PC1800-6 11035 and up) KOMATSU GALEO PC1800-6 – PDF DOWNLOAD
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- KOMATSU GALEO PC1800-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERVICE NUMBER:PC1800-6 11035 and up
- PUBLICATION NUMBER:TEN00051-00
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KOMATSU GALEO PC1800-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:PC1800-6 11035 and up) KOMATSU GALEO PC1800-6
KOMATSU GALEO PC1800-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:PC1800-6 11035 AND UP) KOMATSU GALEO PC1800-6 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO PC1800-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:PC1800-6 11035 and 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 SERVICE REPAIR MANUAL (SN:PC1800-6 11035 and up) KOMATSU GALEO PC1800-6
MAIN MENU.......................................................................................... 0 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 WINDOW 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 CGC MONITOR................................................................................ 74 SWITCHES...................................................................................112 LAMP.......................................................................................123 CONTROL LEVERS, PEDALS.....................................................................127 DOOR LOCK..................................................................................131 POCKET.....................................................................................131 EMERGENCY ESCAPE HAMMER....................................................................131 EMERGENCY ESCAPE LADDER....................................................................132 FIRE EXTINGUISHER..........................................................................132 CAP, COVER WITH LOCK.......................................................................133 ASHTRAY....................................................................................133 HANDLING AIR CONDITIONER...................................................................134 RADIO......................................................................................142 FUSE.......................................................................................146 CIRCUIT BREAKER............................................................................147 CONTROLLER (COMPUTER)......................................................................150 TOOLBOX....................................................................................151 HANDLING GREASE PUMP AND GREASE GUN........................................................151 HANDLING ACCUMULATOR.......................................................................155 ORBCOMM CONTROLLER.........................................................................156 MACHINE OPERATIONS AND CONTROLS................................................................157 BEFORE STARTING ENGINE.....................................................................157 STARTING ENGINE............................................................................178 AFTER STARTING ENGINE......................................................................183 IN COLD AREAS..............................................................................187 STOPPING THE ENGINE........................................................................190 CHECK AFTER SHUT OFF ENGINE................................................................193 MACHINE OPERATION..........................................................................194 STEERING THE MACHINE.......................................................................198 SWINGING...................................................................................200 WORK EQUIPMENT CONTROLS AND OPERATIONS.....................................................201 HANDLING WORKING MODE......................................................................202 PROHIBITED OPERATIONS......................................................................203 GENERAL OPERATION INFORMATION..............................................................205 TRAVELING ON SLOPES........................................................................206 ESCAPE FROM MUD............................................................................208 RECOMMENDED APPLICATIONS...................................................................209 REPLACEMENT AND INVERSION OF BUCKET........................................................210 PARKING MACHINE............................................................................212 CHECK AFTER FINISHING WORK.................................................................213 LOCKING....................................................................................214 TRANSPORTATION.................................................................................215 PRECAUTIONS FOR TRANSPORTATION.............................................................215 LIFTING MACHINE............................................................................216 PARTS FOR TRANSPORT........................................................................216 COLD WEATHER OPERATION.........................................................................217 COLD WEATHER OPERATION INFORMATION.........................................................217 AFTER DAILY WORK COMPLETION................................................................219 AFTER COLD WEATHER SEASON..................................................................219 LONG TERM STORAGE..............................................................................220 BEFORE STORAGE.............................................................................220 DURING STORAGE.............................................................................220 AFTER STORAGE..............................................................................221 TROUBLESHOOTING................................................................................222 RUNNING OUT OF FUEL........................................................................222 PHENOMENA THAT ARE NOT FAILURES............................................................223 TOWING THE MACHINE.........................................................................224 PRECAUTIONS ON PARTICULAR JOBSITES.........................................................224 DISCHARGED BATTERY.........................................................................225 OTHER TROUBLE..............................................................................229 MAINTENANCE........................................................................................234 MAINTENANCE INFORMATION........................................................................235 LUBRICANTS, COOLANT AND FILTERS................................................................238 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....................................238 ELECTRIC SYSTEM MAINTENANCE................................................................241 WEAR PARTS LIST................................................................................242 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...........................243 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...........................................243 TIGHTENING TORQUE SPECIFICATIONS...............................................................247 TIGHTENING TORQUE LIST.....................................................................247 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..................................................248 SAFETY CRITICAL PARTS......................................................................249 MAINTENANCE SCHEDULE...........................................................................251 MAINTENANCE SCHEDULE CHART.................................................................251 MAINTENANCE PROCEDURE..........................................................................254 INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS).............................254 CLEAN STRAINER OF PTO LUBRICATING OIL FILTER...........................................315 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS).............................254 CHANGE OIL IN SWING MACHINERY CASE.....................................................324 CHANGE OIL IN PTO CASE.................................................................326 CHANGE OIL IN FINAL DRIVE CASE.........................................................328 WHEN REQUIRED..............................................................................255 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...........................................255 CLEAN INSIDE OF COOLING SYSTEM.........................................................258 CHECK AND TIGHTEN TRACK SHOE BOLTS.....................................................262 CHECK AND ADJUST TRACK TENSION.........................................................263 CHECK ELECTRICAL INTAKE AIR HEATER.....................................................266 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...............................................267 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE).............................................270 ADJUST BUCKET CLEARANCE................................................................271 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.............................................272 CHECK AND ADJUST AIR CONDITIONER.......................................................273 CLEANING, REMOVING DIRT FROM LINE FILTER...............................................274 REPLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER...............................275 GREASE LADDER..........................................................................276 INSPECT SEALANT AROUND ENGINE COOLING SYSTEM...........................................277 CHECK FOR LOOSE AFTERCOOLER HOSE CLAMPS................................................278 PROCEDURE FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT......................................278 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT............................286 CHECK BEFORE STARTING......................................................................288 EVERY 10 HOURS MAINTENANCE.................................................................289 LUBRICATING............................................................................289 EVERY 100 HOURS MAINTENANCE................................................................293 CHECK OIL LEVEL IN SWING MACHINERY CASE................................................293 EVERY 250 HOURS MAINTENANCE................................................................294 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...........................................294 CHECK LEVEL OF BATTERY ELECTROLYTE.....................................................295 REPLACE FILTER ELEMENT OF HYDRAULIC TANK BREATHER......................................297 CHECK, WASH FUEL STRAINER..............................................................298 CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS................................299 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST............................................300 CHECK ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT................................302 EVERY 500 HOURS MAINTENANCE................................................................304 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE......................304 REPLACE FUEL FILTER CARTRIDGE..........................................................307 CLEAN PILOT FILTER STRAINER............................................................309 CLEAN HYDRAULIC FILTER STRAINER FOR AUTO GREASING DRIVE................................309 CHANGE HYDRAULIC FILTER ELEMENT........................................................310 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, FUEL COOLER AND AFTER COOLER FINS....311 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM......................313 CLEAN STRAINER OF PTO LUBRICATING OIL FILTER...........................................315 CHECK, REPLACE, ADJUST FAN BELT........................................................316 CHECK, REPLACE HYDRAULIC PUMP DRAIN FILTER CARTRIDGE...................................317 REPLACING SWING MOTOR DRAIN FILTER CARTRIDGE...........................................318 REPLACING TRAVEL MOTOR DRAIN FILTER CARTRIDGE..........................................319 REPLACE ADDITIONAL FUEL FILTER CARTRIDGE...............................................320 EVERY 1000 HOURS MAINTENANCE...............................................................322 REPLACE FUEL FILTER CARTRIDGE..........................................................322 CHANGE OIL IN SWING MACHINERY CASE.....................................................324 CHANGE OIL IN PTO CASE.................................................................326 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER.............................................326 REPLACE CORROSION RESISTOR CARTRIDGE...................................................327 INSPECTION OF WELDED STRUCTURE AFTER INITIAL 4000 HOURS SERVICE........................327 GREASING FAN PULLEY ASSEMBLY, TENSION PULLEY ASSEMBLY..................................327 EVERY 2000 HOURS MAINTENANCE...............................................................328 CHANGE OIL IN FINAL DRIVE CASE.........................................................328 CHANGE OIL IN HYDRAULIC TANK, WASH STRAINER............................................329 CHECK SWING PINION GREASE LEVEL, ADD GREASE............................................332 CLEAN ENGINE BREATHER..................................................................332 CLEAN, CHECK TURBOCHARGER..............................................................332 CHECK ALTERNATOR AND STARTING MOTOR....................................................332 CHECK ENGINE VALVE CLEARANCES, ADJUST..................................................333 CHECK INJECTOR.........................................................................333 EVERY 4000 HOURS MAINTENENCE...............................................................334 CHECK WATER PUMP.......................................................................334 CHECK VIBRATION DAMPER.................................................................334 CHECK FAN PULLEY AND TENSION PULLEY....................................................334 REPLACE INJECTOR NOZZLE ASSEMBLY.......................................................334 CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER........................335 CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.......................336 CHECK, ADJUST AIR COMPRESSOR...........................................................336 CHECK WELDED STRUCTURE.................................................................337 EVERY 5000 HOURS MAINTENANCE...............................................................340 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER...........................................340 EVERY 8000 HOURS MAINTENANCE...............................................................343 REPLACE HIGH-PRESSURE PIPING CLAMP.....................................................343 REPLACE FUEL SPRAY PREVENTION CAP......................................................343 SPECIFICATIONS.....................................................................................344 SPECIFICATIONS.................................................................................345 ATTACHMENTS AND OPTIONS............................................................................348 GENERAL PRECAUTIONS............................................................................349 PRECAUTIONS RELATED TO SAFETY..............................................................349 PRECAUTIONS WHEN INSTALLING ATTACHMENTS....................................................351 ATTACHMENT GUIDE...............................................................................352 COMBINATIONS OF WORK EQUIPMENT.............................................................352 PROTECTIVE GUARD...........................................................................353 AUTO GREASING SYSTEM.......................................................................354 LOADING SHOVEL.....................................................................................358 GENERAL VIEW...................................................................................359 GENERAL VIEW OF MACHINE....................................................................359 GENERAL VIEW OF CONTROLS AND GAUGES........................................................360 EXPLANATION OF COMPONENTS......................................................................361 SWITCHES...................................................................................361 CONTROL BOX................................................................................362 OPERATIONS.....................................................................................363 OPERATION OF WORK EQUIPMENT................................................................363 PRECAUTIONS DURING OPERATION...............................................................365 EXCAVATOR WORK.............................................................................369 PRECAUTIONS WHEN DISASSEMBLING MACHINE.........................................................370 RELEASING PRESSURE.........................................................................370 TROUBLESHOOTING................................................................................371 WORK EQUIPMENT AUTOMATIC CONTROL CONTROLLER................................................371 TRANSPORTATION.................................................................................372 MACHINE CONFIGURATION FOR TRANSPORT........................................................372 MAINTENANCE SCHEDULE...........................................................................373 EVERY 10 HOURS MAINTENANCE.................................................................373 SPECIFICATION..................................................................................382 COMBINATION OF WORK EQUIPMENT..................................................................384 COMBINATION OF WORK EQUIPMENT..............................................................384 INDEX..............................................................................................386
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