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KOMATSU GALEO PC270-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:20001 & up) KOMATSU PC270 8 – PDF DOWNLOAD
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- KOMATSU GALEO PC270-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual
- SERIAL NUMBER:20001 & up
- PUBLICATION NUMBER:TEN00148-03
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Description
KOMATSU GALEO PC270-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:20001 & up) KOMATSU PC270 8
KOMATSU GALEO PC270-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:20001 & UP) KOMATSU PC270 8 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO PC270-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:20001 & up) KOMATSU PC270 8
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 PC270-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:20001 & up) KOMATSU PC270 8
MAIN MENU............................................................................................................................... 0 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.................................................................................................................................. 14 SAFETY INFORMATION.................................................................................................................. 15 SAFETY LABELS....................................................................................................................... 17 LOCATION OF SAFETY LABELS....................................................................................................... 18 SAFETY LABELS................................................................................................................... 19 SAFETY INFORMATION.................................................................................................................. 25 SAFETY RULES.................................................................................................................... 25 IF PROBLEMS ARE FOUND........................................................................................................... 25 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...................................................................................... 25 FIRE EXTINGUISHER AND FIRST AID KIT............................................................................................. 25 SAFETY EQUIPMENT................................................................................................................ 25 KEEP MACHINE CLEAN.............................................................................................................. 26 KEEP OPERATOR'S COMPARTMENT CLEAN............................................................................................... 26 LEAVING OPERATOR'S SEAT WITH LOCK............................................................................................... 26 HANDRAILS AND STEPS............................................................................................................. 27 PRECAUTIONS WHEN WORKING IN HIGH PLACES......................................................................................... 27 MOUNTING AND DISMOUNTING........................................................................................................ 27 NO PERSONS ON ATTACHMENTS....................................................................................................... 27 DO NOT GET CAUGHT IN ARTICULATED PORTION........................................................................................ 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......................................................................................................... 30 CAB WINDOW GLASSES.............................................................................................................. 30 UNAUTHORIZED MODIFICATIONS...................................................................................................... 31 SAFETY AT JOBSITE............................................................................................................... 31 WORKING ON LOOSE GROUND......................................................................................................... 31 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 BEFORE OPERATION..................................................................................................... 36 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS................................................................................ 36 SAFETY RULES FOR TRAVELING.................................................................................................. 37 TRAVELING ON SLOPES......................................................................................................... 37 OPERATIONS ON SLOPES........................................................................................................ 38 PROHIBITED OPERATIONS....................................................................................................... 39 OPERATIONS ON SNOW.......................................................................................................... 40 PARKING MACHINE............................................................................................................. 41 TRANSPORTATION.................................................................................................................. 42 LOADING AND UNLOADING....................................................................................................... 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, GAS SPRING......................................................................................................... 50 PERSONNEL....................................................................................................................... 50 ATTACHMENTS..................................................................................................................... 50 WORK UNDER THE MACHINE.......................................................................................................... 50 NOISE........................................................................................................................... 50 WHEN USING HAMMER............................................................................................................... 51 WELDING WORKS................................................................................................................... 51 REMOVING BATTERY TERMINALS...................................................................................................... 51 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION............................................................ 51 DO NOT DISASSEMBLE RECOIL SPRINGS............................................................................................... 52 SAFETY RULES FOR HIGH-PRESSURE OIL.............................................................................................. 52 PRECAUTION FOR HIGH FUEL PRESSURE............................................................................................... 52 SAFETY HANDLING HIGH-PRESSURE HOSES............................................................................................. 52 PRECAUTION FOR HIGH VOLTAGE..................................................................................................... 53 WASTE MATERIALS................................................................................................................. 53 AIR CONDITIONER MAINTENANCE..................................................................................................... 53 COMPRESSED AIR.................................................................................................................. 53 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................... 53 OPERATION............................................................................................................................... 54 MACHINE VIEW ILLUSTRATIONS.......................................................................................................... 55 OVERALL MACHINE VIEW............................................................................................................ 55 CONTROLS AND GAUGES............................................................................................................. 56 DETAILED CONTROLS AND GAUGES........................................................................................................ 58 MONITORING SYSTEM............................................................................................................... 58 SWITCHES........................................................................................................................124 CONTROL LEVERS AND PEDALS.......................................................................................................129 SUN ROOF........................................................................................................................132 WINDSHIELD......................................................................................................................132 EMERGENCY ESCAPE HAMMER.........................................................................................................138 DOOR LOCK.......................................................................................................................138 CAP WITH LOCK...................................................................................................................139 DRINK BOX.......................................................................................................................141 MAGAZINE BOX....................................................................................................................141 ASHTRAY.........................................................................................................................141 AIR CONDITIONER CONTROLS........................................................................................................142 RADIO...........................................................................................................................155 AUXILIARY ELECTRIC POWER........................................................................................................160 FUSE............................................................................................................................161 FUSIBLE LINK....................................................................................................................162 CONTROLLER......................................................................................................................162 TOOL BOX........................................................................................................................162 GREASE PUMP HOLDER..............................................................................................................162 FIRE EXTINGUISHER...............................................................................................................163 MACHINE OPERATIONS AND CONTROLS.....................................................................................................164 BEFORE STARTING ENGINE..........................................................................................................164 STARTING ENGINE.................................................................................................................181 AFTER STARTING ENGINE...........................................................................................................184 STOPPING THE ENGINE.............................................................................................................195 MACHINE OPERATION...............................................................................................................196 STEERING THE MACHINE............................................................................................................200 SWINGING........................................................................................................................202 WORK EQUIPMENT CONTROLS AND OPERATIONS..........................................................................................203 WORKING MODE....................................................................................................................205 PROHIBITED OPERATIONS...........................................................................................................207 GENERAL OPERATION INFORMATION...................................................................................................209 TRAVELING ON SLOPES.............................................................................................................211 ESCAPE FROM MUD.................................................................................................................213 RECOMMENDED APPLICATIONS........................................................................................................214 BUCKET REPLACEMENT AND INVERSION................................................................................................216 PARKING MACHINE.................................................................................................................220 MACHINE INSPECTION AFTER DAILY WORK.............................................................................................221 LOCKING.........................................................................................................................222 TRANSPORTATION......................................................................................................................223 TRANSPORTATION PROCEDURE........................................................................................................223 LOADING AND UNLOADING WITH TRAILER..............................................................................................224 LIFTING MACHINE.................................................................................................................233 COLD WEATHER OPERATION..............................................................................................................236 COLD WEATHER OPERATION INFORMATION..............................................................................................236 AFTER DAILY WORK COMPLETION.....................................................................................................238 AFTER COLD WEATHER SEASON.......................................................................................................238 LONG TERM STORAGE...................................................................................................................239 BEFORE STORAGE..................................................................................................................239 DURING STORAGE..................................................................................................................239 AFTER STORAGE...................................................................................................................240 STARTING MACHINE AFTER LONG-TERM STORAGE........................................................................................240 TROUBLES AND ACTIONS................................................................................................................241 RUNNING OUT OF FUEL.............................................................................................................241 PHENOMENA THAT ARE NOT FAILURES.................................................................................................241 TOWING THE MACHINE..............................................................................................................242 LIGHTWEIGHT TOWING HOLE.........................................................................................................243 SEVERE JOB CONDITION............................................................................................................243 DISCHARGED BATTERY..............................................................................................................244 OTHER TROUBLE...................................................................................................................248 MAINTENANCE.............................................................................................................................253 MAINTENANCE INFORMATION.............................................................................................................254 OUTLINE OF SERVICE..................................................................................................................256 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC..........................................................................256 ELECTRIC SYSTEM MAINTENANCE.....................................................................................................259 WEAR PARTS..........................................................................................................................260 WEAR PARTS LIST.................................................................................................................260 RECOMMENDED FUEL, COOLANT, AND LUBRICANT............................................................................................261 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.............................................263 TIGHTENING TORQUE SPECIFICATIONS....................................................................................................264 TIGHTENING TORQUE LIST..........................................................................................................264 SAFETY CRITICAL PARTS...............................................................................................................265 SAFETY CRITICAL PARTS LIST......................................................................................................266 MAINTENANCE SCHEDULE................................................................................................................267 MAINTENANCE SCHEDULE CHART......................................................................................................267 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER......................................................................................269 MAINTENANCE PROCEDURE...............................................................................................................270 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)..................................................................270 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)..................................................................270 WHEN REQUIRED...................................................................................................................271 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT................................................................................271 CLEAN INSIDE OF COOLING SYSTEM..............................................................................................277 CHECK AND TIGHTEN TRACK SHOE BOLTS..........................................................................................281 CHECK AND ADJUST TRACK TENSION..............................................................................................282 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)....................................................................................284 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)..................................................................................287 ADJUST BUCKET CLEARANCE.....................................................................................................289 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..................................................................................290 CHECK AND MAINTENANCE AIR CONDITIONER.......................................................................................291 WASH WASHABLE FLOOR.........................................................................................................292 CHECK GAS SPRING............................................................................................................295 BLEEDING AIR FROM HYDRAULIC SYSTEM..........................................................................................296 CHECK BEFORE STARTING...........................................................................................................298 EVERY 100 HOURS MAINTENANCE.....................................................................................................299 LUBRICATING.................................................................................................................299 EVERY 250 HOURS MAINTENANCE.....................................................................................................301 CHECK LEVEL OF BATTERY ELECTROLYTE..........................................................................................301 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.......................................................................303 EVERY 500 HOURS MAINTENANCE.....................................................................................................304 LUBRICATE SWING CIRCLE......................................................................................................304 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...........................................................305 REPLACE FUEL PRE-FILTER CARTRIDGE...........................................................................................307 CHECK SWING PINION GREASE LEVEL, ADD GREASE.................................................................................309 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS....310 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS..................................................................................312 REPLACE BREATHER ELEMENT IN HYDRAULIC TANK..................................................................................314 REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT..........................................................................315 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL............................................................................316 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL................................................................................317 EVERY 1000 HOURS MAINTENANCE....................................................................................................318 REPLACE HYDRAULIC OIL FILTER ELEMENT........................................................................................318 CHANGE OIL IN SWING MACHINERY CASE..........................................................................................319 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.....................................................................................320 REPLACE FUEL MAIN FILTER CARTRIDGE..........................................................................................321 CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS...................................................................323 REPLACE CORROSION RESISTOR CARTRIDGE........................................................................................323 CHECK FAN BELT TENSION AND REPLACE FAN BELT.................................................................................323 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER).............................................................323 EVERY 2000 HOURS MAINTENANCE....................................................................................................324 CHANGE OIL IN FINAL DRIVE CASE..............................................................................................324 CLEAN HYDRAULIC TANK STRAINER...............................................................................................325 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)...............................................326 CHECKING FUNCTION OF ACCUMULATOR............................................................................................327 CHECK ALTERNATOR............................................................................................................330 CHECK ENGINE VALVE CLEARANCE, ADJUST........................................................................................330 EVERY 4000 HOURS MAINTENANCE....................................................................................................331 CHECK WATER PUMP............................................................................................................331 CHECK VIBRATION DAMPER......................................................................................................331 CHECK STARTING MOTOR........................................................................................................331 REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)...................................................................................332 CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER......................................................333 CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER............................................................333 CHECK OPERATING CONDITION OF COMPRESSOR.....................................................................................334 EVERY 5000 HOURS MAINTENANCE....................................................................................................335 CHANGE OIL IN HYDRAULIC TANK................................................................................................335 EVERY 8000 HOURS MAINTENANCE....................................................................................................336 REPLACE HIGH-PRESSURE PIPING CLAMP..........................................................................................336 REPLACE FUEL SPRAY PREVENTION CAP...........................................................................................336 SPECIFICATIONS..........................................................................................................................337 SPECIFICATIONS......................................................................................................................338 ATTACHMENTS, OPTIONS....................................................................................................................340 GENERAL PRECAUTIONS FOR SAFETY......................................................................................................341 PRECAUTIONS WHEN SELECTING......................................................................................................341 READ THE INSTRUCTION MANUAL THOROUGHLY..........................................................................................341 PRECAUTIONS WHEN REMOVING OR INSTALLING.........................................................................................341 PRECAUTIONS WHEN USING..........................................................................................................341 BUCKET WITH HOOK....................................................................................................................342 HOOK CONDITION..................................................................................................................342 PROHIBITED OPERATIONS...........................................................................................................342 MACHINE READY FOR ATTACHMENT........................................................................................................343 LOCATIONS.......................................................................................................................343 HYDRAULIC CIRCUIT...............................................................................................................347 ATTACHMENT REMOVAL AND INSTALLATION.............................................................................................354 ATTACHMENT OPERATIONS...........................................................................................................358 LONG TERM STORAGE...............................................................................................................361 SPECIFICATIONS..................................................................................................................361 ATTACHMENT GUIDE....................................................................................................................362 ATTACHMENT COMBINATIONS.........................................................................................................362 TRACK SHOES SELECTION...........................................................................................................363 BUCKET TEETH SELECTION..........................................................................................................364 RECOMMENDED ATTACHMENT OPERATIONS...................................................................................................365 HYDRAULIC BREAKER...............................................................................................................365 HANDLING MACHINES EQUIPPED WITH KOMTRAX.............................................................................................369 BASIC PRECAUTIONS...............................................................................................................369 INDEX...................................................................................................................................370
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