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KOMATSU GALEO PC200-8 PC200LC-8 PC220-8 PC220LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00116-05) – PDF DOWNLOAD
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- KOMATSU GALEO PC200-8 PC200LC-8 PC220-8 PC220LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL
- PUBLICATION NUMBER:TEN00116-05
- SERIAL NUMBER:PC200-300001 and up
PC220- 70001 and up
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Description
KOMATSU GALEO PC200-8 PC200LC-8 PC220-8 PC220LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00116-05)
KOMATSU GALEO PC200-8 PC200LC-8 PC220-8 PC220LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00116-05) – PDF DOWNLOAD:
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KOMATSU GALEO PC200-8 PC200LC-8 PC220-8 PC220LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00116-05)
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance
TABLE OF CONTENTS:
KOMATSU GALEO PC200-8 PC200LC-8 PC220-8 PC220LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00116-05)
COVER................................................................................................................................... 1 FOREWORD................................................................................................................................ 2 FOREWORD............................................................................................................................ 3 SAFETY INFORMATION.................................................................................................................. 6 INTRODUCTION........................................................................................................................ 8 DIRECTIONS OF MACHINE........................................................................................................... 8 BREAKING-IN THE NEW MACHINE..................................................................................................... 8 PRODUCT INFORMATION................................................................................................................. 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.................................................................... 9 EPA REGULATIONS, ENGINE NUMBER PLATE............................................................................................ 9 SERVICE METER LOCATION.......................................................................................................... 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR..................................................................................... 10 CONTENTS................................................................................................................................ 11 SAFETY.................................................................................................................................. 16 SAFETY.............................................................................................................................. 17 SAFETY LABELS....................................................................................................................... 19 LOCATION OF SAFETY LABELS....................................................................................................... 20 SAFETY LABELS................................................................................................................... 21 GENERAL PRECAUTIONS................................................................................................................. 27 SAFETY RULES.................................................................................................................... 27 IF PROBLEMS ARE FOUND........................................................................................................... 27 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...................................................................................... 27 FIRE EXTINGUISHER AND FIRST AID KIT............................................................................................. 27 SAFETY EQUIPMENT................................................................................................................ 27 KEEP MACHINE CLEAN.............................................................................................................. 28 KEEP OPERATOR'S COMPARTMENT CLEAN............................................................................................... 28 LEAVING OPERATOR'S SEAT WITH LOCK............................................................................................... 28 HANDRAILS AND STEPS............................................................................................................. 29 PRECAUTIONS WHEN WORKING IN HIGH PLACES......................................................................................... 29 MOUNTING AND DISMOUNTING........................................................................................................ 29 NO PERSONS ON ATTACHMENTS....................................................................................................... 29 DO NOT GET CAUGHT IN ARTICULATED PORTION........................................................................................ 30 BURN PREVENTION................................................................................................................. 30 FIRE PREVENTION AND EXPLOSION PREVENTION........................................................................................ 31 ACTION IF FIRE OCCURS........................................................................................................... 32 WINDSHIELD WASHER FLUID......................................................................................................... 32 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION................................................................ 32 ATTACHMENT INSTALLATION......................................................................................................... 32 ATTACHMENT COMBINATIONS......................................................................................................... 32 CAB WINDOW GLASSES.............................................................................................................. 32 UNAUTHORIZED MODIFICATIONS...................................................................................................... 33 SAFETY AT JOBSITE............................................................................................................... 33 WORKING ON LOOSE GROUND......................................................................................................... 33 DISTANCE TO HIGH VOLTAGE CABLES................................................................................................. 34 ENSURE GOOD VISIBILITY.......................................................................................................... 34 VENTILATION FOR ENCLOSED AREA................................................................................................... 35 SIGNALMAN'S SIGNAL AND SIGNS.................................................................................................... 35 EMERGENCY EXIT FROM OPERATOR'S CAB.............................................................................................. 35 ASBESTOS DUST HAZARD PREVENTION................................................................................................. 35 SAFETY MACHINE OPERATION............................................................................................................ 36 STARTING ENGINE................................................................................................................. 36 CHECKS BEFORE STARTING ENGINE............................................................................................... 36 SAFETY RULES FOR STARTING ENGINE............................................................................................ 37 STARTING ENGINE IN COLD WEATHER............................................................................................. 37 OPERATION....................................................................................................................... 38 CHECKS BEFORE OPERATION..................................................................................................... 38 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS................................................................................ 38 SAFETY RULES FOR TRAVELING.................................................................................................. 39 TRAVELING ON SLOPES......................................................................................................... 39 OPERATIONS ON SLOPES........................................................................................................ 40 PROHIBITED OPERATIONS....................................................................................................... 41 OPERATIONS ON SNOW.......................................................................................................... 42 PARKING MACHINE............................................................................................................. 43 TRANSPORTATION.................................................................................................................. 44 LOADING AND UNLOADING....................................................................................................... 44 SHIPPING THE MACHINE........................................................................................................ 44 BATTERY......................................................................................................................... 45 BATTERY HAZARD PREVENTION................................................................................................... 45 STARTING ENGINE WITH BOOSTER CABLES......................................................................................... 46 TOWING.......................................................................................................................... 47 SAFETY RULES FOR TOWING..................................................................................................... 47 LIFTING OBJECTS WITH BUCKET..................................................................................................... 48 SAFETY RULES FOR LIFTING OBJECTS............................................................................................ 48 SAFETY MAINTENANCE INFORMATION...................................................................................................... 49 WARNING TAG..................................................................................................................... 49 KEEP WORK PLACE CLEAN AND TIDY.................................................................................................. 49 APPOINT LEADER WHEN WORKING WITH OTHERS......................................................................................... 49 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE..................................................................................... 50 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.............................................................................. 51 PROPER TOOLS.................................................................................................................... 51 ACCUMULATOR, GAS SPRING......................................................................................................... 52 PERSONNEL....................................................................................................................... 52 ATTACHMENTS..................................................................................................................... 52 WORK UNDER THE MACHINE.......................................................................................................... 52 NOISE........................................................................................................................... 52 WHEN USING HAMMER............................................................................................................... 53 WELDING WORKS................................................................................................................... 53 REMOVING BATTERY TERMINALS...................................................................................................... 53 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION............................................................ 53 DO NOT DISASSEMBLE RECOIL SPRINGS............................................................................................... 54 SAFETY RULES FOR HIGH-PRESSURE OIL.............................................................................................. 54 PRECAUTION FOR HIGH FUEL PRESSURE............................................................................................... 54 SAFETY HANDLING HIGH-PRESSURE HOSES............................................................................................. 54 PRECAUTION FOR HIGH VOLTAGE..................................................................................................... 55 WASTE MATERIALS................................................................................................................. 55 AIR CONDITIONER MAINTENANCE..................................................................................................... 55 COMPRESSED AIR.................................................................................................................. 55 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................... 55 OPERATION............................................................................................................................... 56 MACHINE VIEW ILLUSTRATIONS.......................................................................................................... 57 OVERALL MACHINE VIEW............................................................................................................ 57 CONTROLS AND GAUGES............................................................................................................. 58 DETAILED CONTROLS AND GAUGES........................................................................................................ 60 MONITORING SYSTEM............................................................................................................... 60 SWITCHES........................................................................................................................126 CONTROL LEVERS AND PEDALS.......................................................................................................131 SUN ROOF........................................................................................................................134 WINDSHIELD......................................................................................................................134 EMERGENCY ESCAPE HAMMER.........................................................................................................140 DOOR LOCK.......................................................................................................................140 CAP WITH LOCK...................................................................................................................141 DRINK BOX.......................................................................................................................143 MAGAZINE BOX....................................................................................................................143 ASHTRAY.........................................................................................................................143 AIR CONDITIONER CONTROLS........................................................................................................144 RADIO...........................................................................................................................157 AUXILIARY ELECTRIC POWER........................................................................................................162 FUSE............................................................................................................................163 FUSIBLE LINK....................................................................................................................164 CONTROLLER......................................................................................................................164 TOOL BOX........................................................................................................................164 GREASE PUMP HOLDER..............................................................................................................164 FIRE EXTINGUISHER...............................................................................................................165 MACHINE OPERATIONS AND CONTROLS.....................................................................................................166 BEFORE STARTING ENGINE..........................................................................................................166 STARTING ENGINE.................................................................................................................183 AFTER STARTING ENGINE...........................................................................................................186 STOPPING THE ENGINE.............................................................................................................197 MACHINE OPERATION...............................................................................................................198 STEERING THE MACHINE............................................................................................................202 SWINGING........................................................................................................................204 WORK EQUIPMENT CONTROLS AND OPERATIONS..........................................................................................205 WORKING MODE....................................................................................................................207 PROHIBITED OPERATIONS...........................................................................................................209 GENERAL OPERATION INFORMATION...................................................................................................211 TRAVELING ON SLOPES.............................................................................................................213 ESCAPE FROM MUD.................................................................................................................215 RECOMMENDED APPLICATIONS........................................................................................................216 BUCKET REPLACEMENT AND INVERSION................................................................................................218 PARKING MACHINE.................................................................................................................222 MACHINE INSPECTION AFTER DAILY WORK.............................................................................................223 LOCKING.........................................................................................................................224 TRANSPORTATION......................................................................................................................225 TRANSPORTATION PROCEDURE........................................................................................................225 LOADING AND UNLOADING WITH TRAILER..............................................................................................226 LIFTING MACHINE.................................................................................................................235 COLD WEATHER OPERATION..............................................................................................................238 COLD WEATHER OPERATION INFORMATION..............................................................................................238 AFTER DAILY WORK COMPLETION.....................................................................................................240 AFTER COLD WEATHER SEASON.......................................................................................................240 LONG TERM STORAGE...................................................................................................................241 BEFORE STORAGE..................................................................................................................241 DURING STORAGE..................................................................................................................241 AFTER STORAGE...................................................................................................................242 STARTING MACHINE AFTER LONG-TERM STORAGE........................................................................................242 TROUBLES AND ACTIONS................................................................................................................243 RUNNING OUT OF FUEL.............................................................................................................243 PHENOMENA THAT ARE NOT FAILURES.................................................................................................243 TOWING THE MACHINE..............................................................................................................244 LIGHTWEIGHT TOWING HOLE.........................................................................................................245 SEVERE JOB CONDITION............................................................................................................245 DISCHARGED BATTERY..............................................................................................................246 OTHER TROUBLE...................................................................................................................250 MAINTENANCE.............................................................................................................................256 MAINTENANCE INFORMATION.............................................................................................................257 OUTLINE OF SERVICE..................................................................................................................259 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC..........................................................................259 ELECTRIC SYSTEM MAINTENANCE.....................................................................................................262 WEAR PARTS..........................................................................................................................263 WEAR PARTS LIST.................................................................................................................263 RECOMMENDED FUEL, COOLANT, AND LUBRICANT............................................................................................264 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.............................................266 TIGHTENING TORQUE SPECIFICATIONS....................................................................................................267 TIGHTENING TORQUE LIST..........................................................................................................267 SAFETY CRITICAL PARTS...............................................................................................................268 SAFETY CRITICAL PARTS LIST......................................................................................................269 MAINTENANCE SCHEDULE................................................................................................................270 MAINTENANCE SCHEDULE CHART......................................................................................................270 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER......................................................................................272 MAINTENANCE PROCEDURE...............................................................................................................273 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)..................................................................273 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)..................................................................273 WHEN REQUIRED...................................................................................................................274 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT................................................................................274 CLEAN INSIDE OF COOLING SYSTEM..............................................................................................280 CHECK AND TIGHTEN TRACK SHOE BOLTS..........................................................................................284 CHECK AND ADJUST TRACK TENSION..............................................................................................285 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)....................................................................................287 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)..................................................................................290 ADJUST BUCKET CLEARANCE.....................................................................................................292 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..................................................................................293 CHECK AND MAINTENANCE AIR CONDITIONER.......................................................................................294 WASH WASHABLE FLOOR.........................................................................................................295 CHECK GAS SPRING............................................................................................................298 BLEEDING AIR FROM HYDRAULIC SYSTEM..........................................................................................299 CHECK BEFORE STARTING...........................................................................................................301 EVERY 100 HOURS MAINTENANCE.....................................................................................................302 LUBRICATING.................................................................................................................302 EVERY 250 HOURS MAINTENANCE.....................................................................................................303 CHECK LEVEL OF BATTERY ELECTROLYTE..........................................................................................303 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.......................................................................305 EVERY 500 HOURS MAINTENANCE.....................................................................................................306 LUBRICATING.................................................................................................................306 LUBRICATE SWING CIRCLE......................................................................................................307 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...........................................................308 REPLACE FUEL PRE-FILTER CARTRIDGE...........................................................................................310 CHECK SWING PINION GREASE LEVEL, ADD GREASE.................................................................................312 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS....313 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS..................................................................................315 REPLACE BREATHER ELEMENT IN HYDRAULIC TANK..................................................................................317 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL............................................................................318 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL................................................................................319 EVERY 1000 HOURS MAINTENANCE....................................................................................................320 REPLACE HYDRAULIC OIL FILTER ELEMENT........................................................................................320 CHANGE OIL IN SWING MACHINERY CASE..........................................................................................321 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.....................................................................................322 REPLACE FUEL MAIN FILTER CARTRIDGE..........................................................................................323 CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS...................................................................325 REPLACE CORROSION RESISTOR CARTRIDGE........................................................................................325 CHECK FAN BELT TENSION AND REPLACE FAN BELT.................................................................................325 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER).............................................................325 EVERY 2000 HOURS MAINTENANCE....................................................................................................326 CHANGE OIL IN FINAL DRIVE CASE..............................................................................................326 CLEAN HYDRAULIC TANK STRAINER...............................................................................................327 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)...............................................328 CHECK ALTERNATOR............................................................................................................332 CHECK ENGINE VALVE CLEARANCE, ADJUST........................................................................................332 EVERY 4000 HOURS MAINTENANCE....................................................................................................333 CHECK WATER PUMP............................................................................................................333 CHECK VIBRATION DAMPER......................................................................................................333 CHECK STARTING MOTOR........................................................................................................333 REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)...................................................................................334 CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER......................................................335 CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER............................................................335 CHECK OPERATING CONDITION OF COMPRESSOR.....................................................................................336 EVERY 5000 HOURS MAINTENANCE....................................................................................................337 CHANGE OIL IN HYDRAULIC TANK................................................................................................337 EVERY 8000 HOURS MAINTENANCE....................................................................................................338 REPLACE HIGH-PRESSURE PIPING CLAMP..........................................................................................338 REPLACE FUEL SPRAY PREVENTION CAP...........................................................................................338 SPECIFICATIONS..........................................................................................................................340 SPECIFICATIONS......................................................................................................................341 ATTACHMENTS, OPTIONS....................................................................................................................344 GENERAL PRECAUTIONS FOR SAFETY......................................................................................................345 PRECAUTIONS WHEN SELECTING......................................................................................................345 READ THE INSTRUCTION MANUAL THOROUGHLY..........................................................................................345 PRECAUTIONS WHEN REMOVING OR INSTALLING.........................................................................................345 PRECAUTIONS WHEN USING..........................................................................................................345 BUCKET WITH HOOK....................................................................................................................346 HOOK CONDITION..................................................................................................................346 PROHIBITED OPERATIONS...........................................................................................................346 MACHINE READY FOR ATTACHMENT........................................................................................................347 LOCATIONS.......................................................................................................................347 HYDRAULIC CIRCUIT...............................................................................................................351 ATTACHMENT REMOVAL AND INSTALLATION.............................................................................................358 ATTACHMENT OPERATIONS...........................................................................................................362 LONG TERM STORAGE...............................................................................................................365 SPECIFICATIONS..................................................................................................................365 ATTACHMENT GUIDE....................................................................................................................366 ATTACHMENT COMBINATIONS.........................................................................................................366 TRACK SHOES SELECTION...........................................................................................................369 BUCKET TEETH SELECTION..........................................................................................................370 HANDLING OF RUBBER PAD SHOE AND ROAD LINER......................................................................................371 TRAPEZOIDAL BUCKET..............................................................................................................373 HANDLING EXTENSION ARM..........................................................................................................375 HANDLING CLAMSHELL BUCKET.......................................................................................................376 RECOMMENDED ATTACHMENT OPERATIONS...................................................................................................377 HYDRAULIC BREAKER...............................................................................................................377 HANDLING MACHINES EQUIPPED WITH KOMTRAX.............................................................................................381 BASIC PRECAUTIONS...............................................................................................................381 INDEX...................................................................................................................................382
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