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Komatsu Hydraulic Excavator Galeo PC228US-3 PC228USLC-3 Operation & Maintenance Manual – PDF DOWNLOAD
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Komatsu Hydraulic Excavator Galeo PC228US-3 PC228USLC-3 Operation & Maintenance Manual
Book Code : TEN00030-01
SERIAL NUMBERS :
PC228US-3 30001 and up
PC228USLC-3 30001 and up
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Description
Komatsu Hydraulic Excavator Galeo PC228US-3 PC228USLC-3 Operation & Maintenance Manual
DESCRIPTION:
Komatsu Hydraulic Excavator Galeo PC228US-3 PC228USLC-3 Operation & Maintenance Manual
FOREWORD:
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 forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
KOMATSU HYDRAULIC EXCAVATOR GALEO PC228US-3 PC228USLC-3 OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:
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TABLE OF CONTENTS:
Komatsu Hydraulic Excavator Galeo PC228US-3 PC228USLC-3 Operation & Maintenance Manual
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 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION................................................... 9 SERVICE METER LOCATION........................................................................ 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR................................................... 10 CONTENTS.............................................................................................. 11 SAFETY................................................................................................ 16 SAFETY INFORMATION................................................................................ 17 SAFETY LABELS..................................................................................... 19 LOCATION OF SAFETY LABELS..................................................................... 19 SAFETY LABELS................................................................................. 20 SAFETY INFORMATION................................................................................ 26 SAFETY RULES.................................................................................. 26 IF PROBLEMS ARE FOUND......................................................................... 26 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS.................................................... 26 FIRE EXTINGUISHER AND FIRST AID KIT........................................................... 26 SAFETY EQUIPMENT.............................................................................. 26 KEEP MACHINE CLEAN............................................................................ 27 KEEP OPERATOR'S COMPARTMENT CLEAN............................................................. 27 LEAVING OPERATOR'S SEAT WITH LOCK............................................................. 27 HANDRAILS AND STEPS........................................................................... 28 MOUNTING AND DISMOUNTING...................................................................... 28 NO PERSONS ON ATTACHMENTS..................................................................... 28 BURN PREVENTION............................................................................... 29 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....................................................................... 31 ATTACHMENT COMBINATIONS....................................................................... 31 CAB WINDOW GLASSES............................................................................ 31 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.......................................................... 34 STARTING ENGINE IN COLD WEATHER........................................................... 34 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..................................................................... 38 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........................................................................................ 44 SAFETY RULES FOR TOWING................................................................... 44 LIFTING OBJECTS WITH BUCKET................................................................... 45 SAFETY RULES FOR LIFTING OBJECTS.......................................................... 45 SAFETY MAINTENANCE INFORMATION.................................................................... 46 WARNING TAG................................................................................... 46 KEEP WORK PLACE CLEAN AND TIDY................................................................ 46 APPOINT LEADER WHEN WORKING WITH OTHERS....................................................... 46 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE................................................... 47 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING............................................ 48 PROPER TOOLS.................................................................................. 48 ACCUMULATOR................................................................................... 49 PERSONNEL..................................................................................... 49 ATTACHMENTS................................................................................... 49 WORK UNDER THE MACHINE........................................................................ 49 NOISE......................................................................................... 49 WHEN USING HAMMER............................................................................. 50 WELDING WORKS................................................................................. 50 REMOVING BATTERY TERMINALS.................................................................... 50 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION.......................... 50 DO NOT DISASSEMBLE RECOIL SPRINGS............................................................. 50 SAFETY RULES FOR HIGH-PRESSURE OIL............................................................ 51 SAFETY HANDLING HIGH-PRESSURE HOSES........................................................... 51 WASTE MATERIALS............................................................................... 51 AIR CONDITIONER MAINTENANCE................................................................... 51 COMPRESSED AIR................................................................................ 52 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................. 52 OPERATION............................................................................................. 54 MACHINE VIEW ILLUSTRATIONS........................................................................ 55 OVERALL MACHINE VIEW.......................................................................... 55 CONTROLS AND GAUGES........................................................................... 56 DETAILED CONTROLS AND GAUGES...................................................................... 58 MONITORING SYSTEM............................................................................. 58 SWITCHES...................................................................................... 81 CONTROL LEVERS AND PEDALS..................................................................... 87 SUN ROOF...................................................................................... 91 WINDSHIELD.................................................................................... 92 SLIDING DOOR.................................................................................. 97 ASHTRAY....................................................................................... 97 CONTROLLERS................................................................................... 97 REAR UNDERVIEW MIRROR......................................................................... 98 EMERGENCY ESCAPE HAMMER....................................................................... 98 CAP WITH LOCK................................................................................. 99 HOT AND COOL BOX..............................................................................100 AIR CONDITIONER CONTROLS......................................................................101 RADIO.........................................................................................107 AUXILIARY ELECTRIC POWER......................................................................112 FUSE..........................................................................................113 FUSIBLE LINK..................................................................................114 TOOL BOX......................................................................................114 GREASE GUN HOLDER.............................................................................114 ACCUMULATOR...................................................................................115 MACHINE OPERATIONS AND CONTROLS...................................................................116 BEFORE STARTING ENGINE........................................................................116 STARTING ENGINE...............................................................................132 AFTER STARTING ENGINE.........................................................................136 STOPPING THE ENGINE...........................................................................145 MACHINE OPERATION.............................................................................146 STEERING THE MACHINE..........................................................................150 SWINGING......................................................................................152 WORK EQUIPMENT CONTROLS AND OPERATIONS........................................................153 WORKING MODE..................................................................................155 PROHIBITED OPERATIONS.........................................................................156 GENERAL OPERATION INFORMATION.................................................................158 TRAVELING ON SLOPES...........................................................................159 ESCAPE FROM MUD...............................................................................161 RECOMMENDED APPLICATIONS......................................................................162 BUCKET REPLACEMENT AND INVERSION..............................................................164 PARKING MACHINE...............................................................................167 CHECK AFTER SHUT OFF ENGINE...................................................................168 MACHINE INSPECTION AFTER DAILY WORK...........................................................168 LOCKING.......................................................................................169 TRANSPORTATION....................................................................................170 TRANSPORTATION PROCEDURE......................................................................170 LOADING AND UNLOADING WITH TRAILER............................................................170 LIFTING MACHINE...............................................................................178 COLD WEATHER OPERATION............................................................................180 COLD WEATHER OPERATION INFORMATION............................................................180 AFTER DAILY WORK COMPLETION...................................................................183 AFTER COLD WEATHER SEASON.....................................................................183 LONG TERM STORAGE.................................................................................184 BEFORE STORAGE................................................................................184 DURING STORAGE................................................................................184 AFTER STORAGE.................................................................................184 STARTING MACHINE AFTER LONG-TERM STORAGE......................................................185 TROUBLES AND ACTIONS..............................................................................186 RUNNING OUT OF FUEL...........................................................................186 PHENOMENA THAT ARE NOT FAILURES...............................................................186 TOWING THE MACHINE............................................................................187 LIGHTWEIGHT TOWING HOLE.......................................................................188 SEVERE JOB CONDITION..........................................................................188 DISCHARGED BATTERY............................................................................188 OTHER TROUBLE.................................................................................192 MAINTENANCE...........................................................................................198 MAINTENANCE INFORMATION...........................................................................199 OUTLINE OF SERVICE................................................................................201 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC........................................201 ELECTRIC SYSTEM MAINTENANCE...................................................................203 WEAR PARTS........................................................................................204 WEAR PARTS LIST...............................................................................204 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS.......................................................205 PROPER SELECTION..............................................................................205 TIGHTENING TORQUE SPECIFICATIONS..................................................................209 TIGHTENING TORQUE LIST........................................................................209 SAFETY CRITICAL PARTS.............................................................................210 SAFETY CRITICAL PARTS LIST....................................................................210 MAINTENANCE SCHEDULE..............................................................................211 MAINTENANCE SCHEDULE CHART....................................................................211 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....................................................213 MAINTENANCE PROCEDURE.............................................................................214 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)................................214 REPLACE FUEL FILTER CARTRIDGE.............................................................252 CHECK ENGINE VALVE CLEARANCE, ADJUST......................................................266 INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)..............................214 CHECK ENGINE VALVE CLEARANCE, ADJUST......................................................266 WHEN REQUIRED.................................................................................215 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..............................................215 CLEAN INSIDE OF COOLING SYSTEM............................................................221 CHECK AND TIGHTEN TRACK SHOE BOLTS........................................................223 CHECK AND ADJUST TRACK TENSION............................................................224 CHECK ELECTRICAL INTAKE AIR HEATER........................................................226 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)..................................................227 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)................................................230 ADJUST BUCKET CLEARANCE...................................................................231 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID................................................232 CHECK AND MAINTENANCE AIR CONDITIONER.....................................................233 WASH WASHABLE FLOOR.......................................................................235 BLEEDING AIR FROM HYDRAULIC SYSTEM........................................................238 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...............................240 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (control circuit).......................241 CHECK BEFORE STARTING.........................................................................242 EVERY 100 HOURS MAINTENANCE...................................................................243 LUBRICATING...............................................................................243 EVERY 250 HOURS MAINTENANCE...................................................................245 LUBRICATING...............................................................................245 LUBRICATE SWING CIRCLE....................................................................246 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL..........................................247 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL..............................................248 CHECK LEVEL OF BATTERY ELECTROLYTE........................................................249 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.....................................251 EVERY 500 HOURS MAINTENANCE...................................................................252 REPLACE FUEL FILTER CARTRIDGE.............................................................252 CHECK SWING PINION GREASE LEVEL, ADD GREASE...............................................253 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, CONDENSER FINS AND AFTER COOLER FINS....254 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS................................................255 REPLACE BREATHER ELEMENT IN HYDRAULIC TANK................................................257 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.........................258 EVERY 1000 HOURS MAINTENANCE..................................................................260 REPLACE HYDRAULIC OIL FILTER ELEMENT......................................................260 CHANGE OIL IN SWING MACHINERY CASE........................................................262 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...................................................263 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER................................................263 CHECK PLAY TURBOCHARGER ROTOR.............................................................263 REPLACE CORROSION RESISTOR CARTRIDGE......................................................264 CHECK FAN BELT TENSION AND REPLACE FAN BELT...............................................264 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)...........................264 EVERY 2000 HOURS MAINTENANCE..................................................................265 CHANGE OIL IN FINAL DRIVE CASE............................................................265 CLEAN HYDRAULIC TANK STRAINER.............................................................266 CLEAN, CHECK TURBOCHARGER.................................................................266 CHECK ALTERNATOR, STARTING MOTOR..........................................................266 CHECK ENGINE VALVE CLEARANCE, ADJUST......................................................266 CHECK VIBRATION DAMPER....................................................................267 EVERY 4000 HOURS MAINTENANCE..................................................................268 CHECK WATER PUMP..........................................................................268 EVERY 5000 HOURS MAINTENANCE..................................................................269 CHANGE OIL IN HYDRAULIC TANK..............................................................269 SPECIFICATIONS........................................................................................272 SPECIFICATIONS....................................................................................273 ATTACHMENTS, OPTIONS..................................................................................276 GENERAL PRECAUTIONS FOR SAFETY....................................................................277 PRECAUTIONS WHEN SELECTING....................................................................277 READ THE INSTRUCTION MANUAL THOROUGHLY........................................................277 PRECAUTIONS WHEN REMOVING OR INSTALLING.......................................................277 PRECAUTIONS WHEN USING........................................................................277 BUCKET WITH HOOK..................................................................................278 HOOK CONDITION................................................................................278 OPERATIONS WITH CARE..........................................................................278 PROHIBITED OPERATIONS.........................................................................278 AIR CONDITIONER...................................................................................279 AIR CONDITIONER CONTROL PANEL.................................................................279 AIR CONDITIONER CONTROLS......................................................................284 AIR CONDITIONER MAINTENANCE...................................................................284 MACHINE READY FOR ATTACHMENT......................................................................285 LOCATIONS.....................................................................................285 HYDRAULIC CIRCUIT.............................................................................289 ATTACHMENT REMOVAL AND INSTALLATION...........................................................293 ATTACHMENT OPERATIONS.........................................................................295 LONG TERM STORAGE.............................................................................297 SPECIFICATIONS................................................................................297 ATTACHMENT GUIDE..................................................................................298 ATTACHMENT COMBINATIONS.......................................................................298 TRACK SHOES SELECTION.........................................................................299 BUCKET TEETH SELECTION........................................................................300 HANDLING OF RUBBER PAD SHOE AND ROAD LINER....................................................301 RECOMMENDED ATTACHMENT OPERATIONS.................................................................303 HYDRAULIC BREAKER.............................................................................303 INDEX.................................................................................................308
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
