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Komatsu Hydraulic Excavator Galeo PC600-7 PC600LC-7 Operation & Maintenance Manual SN 20001 and up – PDF DOWNLOAD
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Komatsu Hydraulic Excavator Galeo PC600-7 PC600LC-7 Operation & Maintenance Manual
Book Code : SEAM053202T
SERIAL NUMBERS:
PC600-7 20001 and up
PC600LC-7 20001 and up
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Description
Komatsu Hydraulic Excavator Galeo PC600-7 PC600LC-7 Operation & Maintenance Manual
FILE DETAILS:
Komatsu Hydraulic Excavator Galeo PC600-7 PC600LC-7 Operation & Maintenance Manual
Size : 8.66 MB
Format : PDF
Language : English
Number of Pages : 299 Pages
KOMATSU HYDRAULIC EXCAVATOR GALEO PC600-7 PC600LC-7 OPERATION & MAINTENANCE MANUAL SN 20001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Hydraulic Excavator Galeo PC600-7 PC600LC-7 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.
TABLE OF CONTENTS:
Komatsu Hydraulic Excavator Galeo PC600-7 PC600LC-7 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............................................................................................... 9 PRODUCT INFORMATION........................................................................................................... 10 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.............................................................. 10 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION............................................................................... 10 SERVICE METER LOCATION.................................................................................................... 11 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR............................................................................... 11 CONTENTS.......................................................................................................................... 12 SAFETY............................................................................................................................ 18 SAFETY INFORMATION............................................................................................................ 19 SAFETY LABELS................................................................................................................. 21 LOCATION OF SAFETY LABELS................................................................................................. 22 SAFETY LABELS............................................................................................................. 23 SAFETY INFORMATION............................................................................................................ 29 SAFETY RULES.............................................................................................................. 29 IF ABNORMALITIES ARE FOUND................................................................................................ 29 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS................................................................................ 29 FIRE EXTINGUISHER AND FIRST AID KIT....................................................................................... 29 SAFETY EQUIPMENT.......................................................................................................... 30 KEEP MACHINE CLEAN........................................................................................................ 30 KEEP OPERATOR'S COMPARTMENT CLEAN......................................................................................... 30 LEAVING OPERATOR'S SEAT WITH LOCK......................................................................................... 30 HANDRAILS AND STEPS....................................................................................................... 31 MOUNTING AND DISMOUNTING.................................................................................................. 32 NO PERSONS ON ATTACHMENTS................................................................................................. 32 BURN PREVENTION........................................................................................................... 32 FIRE PREVENTION AND EXPLOSION PREVENTION.................................................................................. 33 ACTION IF FIRE OCCURS..................................................................................................... 34 WINDSHIELD WASHER FLUID................................................................................................... 34 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION.......................................................... 34 ATTACHMENT INSTALLATION................................................................................................... 34 ATTACHMENT COMBINATIONS................................................................................................... 34 CAB WINDOW GLASSES........................................................................................................ 35 UNAUTHORIZED MODIFICATIONS................................................................................................ 35 SAFETY AT JOBSITE......................................................................................................... 35 WORKING ON LOOSE GROUND................................................................................................... 35 DISTANCE TO HIGH VOLTAGE CABLES........................................................................................... 36 ENSURE GOOD VISIBILITY.................................................................................................... 36 VENTILATION FOR ENCLOSED AREA............................................................................................. 36 SIGNALMAN'S SIGNAL AND SIGNS.............................................................................................. 37 EMERGENCY EXIT FROM OPERATOR'S CAB........................................................................................ 37 ASBESTOS DUST HAZARD PREVENTION........................................................................................... 37 SAFETY MACHINE OPERATION...................................................................................................... 38 STARTING ENGINE........................................................................................................... 38 CHECKS BEFORE STARTING ENGINE......................................................................................... 38 SAFETY RULES FOR STARTING ENGINE...................................................................................... 39 STARTING ENGINE IN COLD WEATHER....................................................................................... 39 OPERATION................................................................................................................. 40 CHECKS BEFORE OPERATION............................................................................................... 40 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS.......................................................................... 40 SAFETY RULES FOR TRAVELING............................................................................................ 42 TRAVELING ON SLOPES................................................................................................... 42 OPERATIONS ON SLOPES.................................................................................................. 43 PROHIBITED OPERATIONS................................................................................................. 43 OPERATIONS ON SNOW.................................................................................................... 45 PARKING MACHINE....................................................................................................... 46 TRANSPORTATION............................................................................................................ 47 LOADING AND UNLOADING................................................................................................. 47 SHIPPING THE MACHINE.................................................................................................. 47 BATTERY................................................................................................................... 48 BATTERY HAZARD PREVENTION............................................................................................. 48 STARTING ENGINE WITH BOOSTER CABLES................................................................................... 49 TOWING.................................................................................................................... 50 SAFETY RULES FOR TOWING............................................................................................... 50 LIFTING OBJECTS WITH BUCKET............................................................................................... 51 SAFETY RULES FOR LIFTING OBJECTS...................................................................................... 51 SAFETY MAINTENANCE INFORMATION................................................................................................ 52 WARNING TAG............................................................................................................... 52 KEEP WORK PLACE CLEAN AND TIDY............................................................................................ 52 APPOINT LEADER WHEN WORKING WITH OTHERS................................................................................... 52 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE............................................................................... 53 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING........................................................................ 53 PROPER TOOLS.............................................................................................................. 54 ACCUMULATOR............................................................................................................... 54 PERSONNEL................................................................................................................. 54 ATTACHMENTS............................................................................................................... 55 WORK UNDER THE MACHINE.................................................................................................... 55 NOISE..................................................................................................................... 55 WHEN USING HAMMER......................................................................................................... 55 WELDING WORKS............................................................................................................. 55 REMOVING BATTERY TERMINALS................................................................................................ 56 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION ..................................................... 56 DO NOT DISASSEMBLE RECOIL SPRINGS......................................................................................... 56 SAFETY RULES FOR HIGH-PRESSURE OIL........................................................................................ 56 PRECAUTION FOR HIGH FUEL PRESSURE ....................................................................................... 57 SAFETY HANDLING HIGH-PRESSURE HOSES....................................................................................... 57 PRECAUTION FOR HIGH VOLTAGE............................................................................................... 57 WASTE MATERIALS........................................................................................................... 57 AIR CONDITIONER MAINTENANCE............................................................................................... 57 COMPRESSED AIR............................................................................................................ 58 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................................................. 58 OPERATION......................................................................................................................... 59 MACHINE VIEW ILLUSTRATIONS.................................................................................................... 60 OVERALL MACHINE VIEW...................................................................................................... 60 CONTROLS AND GAUGES....................................................................................................... 61 DETAILED CONTROLS AND GAUGES.................................................................................................. 63 MONITORING SYSTEM......................................................................................................... 63 BASIC OPERATION OF MACHINE MONITOR.................................................................................... 64 BASIC CHECK MONITORS.................................................................................................. 66 CAUTION MONITORS...................................................................................................... 68 EMERGENCY MONITORS.................................................................................................... 70 METER DISPLAY PORTION................................................................................................. 72 MONITOR SWITCHES PORTION.............................................................................................. 76 SWITCHES.................................................................................................................. 85 CONTROL LEVERS AND PEDALS................................................................................................. 92 SUN ROOF.................................................................................................................. 95 OPENING .............................................................................................................. 95 CLOSING .............................................................................................................. 95 WINDSHIELD................................................................................................................ 96 EMERGENCY EXIT FROM OPERATOR'S CAB........................................................................................101 DOOR LOCK.................................................................................................................101 CAP WITH LOCK.............................................................................................................102 HOT AND COOL BOX..........................................................................................................103 MAGAZINE BOX..............................................................................................................103 ASHTRAY...................................................................................................................104 AIR CONDITIONER CONTROLS..................................................................................................105 AIR CONDITIONER CONTROL PANEL ........................................................................................105 METHOD OF OPERATION ..................................................................................................110 USE AIR CONDITIONER WITH CARE.........................................................................................116 INSPECTION AND MAINTENANCE OF AIR CONDITIONER EQUIPPED MACHINE .......................................................116 OTHER FUNCTIONS ......................................................................................................117 RADIO.....................................................................................................................119 CONTROL PANEL.........................................................................................................119 CONTROLS OF RADIO ....................................................................................................120 USE RADIO WITH CARE ..................................................................................................122 AUXILIARY ELECTRIC POWER..................................................................................................122 24V POWER SOURCE .....................................................................................................122 12V POWER SOURCE......................................................................................................122 FUSE......................................................................................................................123 CIRCUIT BREAKER ..........................................................................................................124 CONTROLLERS...............................................................................................................125 TOOL BOX..................................................................................................................125 GREASE PUMP ..............................................................................................................126 METHOD OF USE ........................................................................................................126 PRECAUTIONS WHEN USING ...............................................................................................127 SUPPLYING GREASE......................................................................................................127 ACCUMULATOR...............................................................................................................129 RELEASING HYDRAULIC PRESSURE WITH ACCUMULATOR.........................................................................130 MACHINE OPERATIONS AND CONTROLS...............................................................................................131 BEFORE STARTING ENGINE....................................................................................................131 WALK-AROUND CHECKS....................................................................................................131 CHECKS BEFORE STARTING ...............................................................................................133 ADJUSTMENT ...........................................................................................................140 SEAT BELT ............................................................................................................143 OPERATIONS BEFORE STARTING ENGINE ....................................................................................144 STARTING ENGINE...........................................................................................................147 NORMAL STARTING ......................................................................................................147 STARTING ENGINE IN COLD WEATHER ......................................................................................149 AFTER STARTING ENGINE.....................................................................................................152 WARMING-UP OPERATION .................................................................................................152 IN COLD WEATHER AREAS.................................................................................................155 STOPPING THE ENGINE.......................................................................................................159 MACHINE OPERATION.........................................................................................................160 PREPARATIONS FOR MOVING THE MACHINE ..................................................................................160 MOVING MACHINE FORWARD ...............................................................................................161 MOVING MACHINE BACKWARD ..............................................................................................162 STOPPING MACHINE .....................................................................................................163 STEERING THE MACHINE......................................................................................................164 STEERING .............................................................................................................164 SWINGING..................................................................................................................166 WORK EQUIPMENT CONTROLS AND OPERATIONS....................................................................................167 WORKING MODE..............................................................................................................169 PROHIBITED OPERATIONS.....................................................................................................170 GENERAL OPERATION INFORMATION.............................................................................................172 TRAVELING ON SLOPES.......................................................................................................174 ESCAPE FROM MUD...........................................................................................................176 STUCK ONE SIDE OF TRACK ..............................................................................................176 STUCK BOTH SIDES OF TRACKS ...........................................................................................176 RECOMMENDED APPLICATIONS..................................................................................................177 BACKHOE WORK .........................................................................................................177 DITCHING WORK ........................................................................................................177 LOADING WORK .........................................................................................................177 BUCKET REPLACEMENT .......................................................................................................178 REPLACEMENT ..........................................................................................................178 PARKING MACHINE...........................................................................................................180 CHECK AFTER SHUT OFF ENGINE...............................................................................................181 LOCKING...................................................................................................................182 TRANSPORTATION................................................................................................................183 PRECAUTIONS FOR TRANSPORTATION ...........................................................................................183 LIFTING MACHINE...........................................................................................................183 SHIPPING MACHINE INFORMATION .............................................................................................184 TRANSPORTATION POSTURE ...................................................................................................185 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE....................................................................190 COLD WEATHER OPERATION........................................................................................................192 COLD WEATHER OPERATION INFORMATION........................................................................................192 AFTER DAILY WORK COMPLETION...............................................................................................194 AFTER COLD WEATHER SEASON.................................................................................................194 LONG TERM STORAGE.............................................................................................................195 BEFORE STORAGE............................................................................................................195 DURING STORAGE............................................................................................................195 AFTER STORAGE.............................................................................................................196 STARTING MACHINE AFTER LONG-TERM STORAGE..................................................................................196 TROUBLES AND ACTIONS..........................................................................................................197 RUNNING OUT OF FUEL.......................................................................................................197 PHENOMENA THAT ARE NOT FAILURES...........................................................................................199 TOWING THE MACHINE........................................................................................................200 SEVERE JOB CONDITION......................................................................................................200 DISCHARGED BATTERY........................................................................................................201 BATTERY REMOVAL AND INSTALLATION......................................................................................201 BATTERY CHARGES.......................................................................................................202 STARTING ENGINE WITH BOOSTER CABLES...................................................................................203 OTHER TROUBLE.............................................................................................................205 ELECTRICAL SYSTEM.....................................................................................................205 CHASSIS...............................................................................................................206 ENGINE................................................................................................................207 ELECTRONIC CONTROL SYSTEM.............................................................................................209 POINT OF CONTACT TO TELEPHONE WHEN ERROR OCCURS.......................................................................210 MAINTENANCE.......................................................................................................................211 MAINTENANCE INFORMATION.......................................................................................................212 LUBRICANTS, COOLANT AND FILTERS...............................................................................................214 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ...................................................................214 OIL...................................................................................................................214 FUEL..................................................................................................................214 COOLING SYSTEM COOLANT ...............................................................................................215 GREASE ...............................................................................................................215 CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS).........................................................................215 OIL AND FUEL STORAGE .................................................................................................216 FILTERS...............................................................................................................217 ELECTRIC SYSTEM MAINTENANCE...............................................................................................217 WEAR PARTS....................................................................................................................218 WEAR PARTS LIST...........................................................................................................218 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS...................................................................................219 TIGHTENING TORQUE SPECIFICATIONS..............................................................................................223 TIGHTENING TORQUE LIST....................................................................................................223 SAFETY CRITICAL PARTS.........................................................................................................224 SAFETY CRITICAL PARTS LIST................................................................................................225 MAINTENANCE SCHEDULE..........................................................................................................226 MAINTENANCE SCHEDULE CHART................................................................................................226 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER................................................................................228 MAINTENANCE PROCEDURE.........................................................................................................229 INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)............................................................229 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)............................................................229 WHEN REQUIRED.............................................................................................................230 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..........................................................................230 CLEAN INSIDE OF COOLING SYSTEM........................................................................................235 CHECK AND TIGHTEN TRACK SHOE BOLTS....................................................................................237 CHECK AND ADJUST TRACK TENSION........................................................................................238 CHECK ELECTRICAL INTAKE AIR HEATER....................................................................................239 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)............................................................................240 ADJUST BUCHET CLEARANCE...............................................................................................241 REPLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER..............................................................242 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID............................................................................242 CHECK AND ADJUST AIR CONDITIONER......................................................................................243 CLEAN LINE FILTER, REMOVE DIRT........................................................................................244 REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT.................................................................245 CLEAN PILOT LINE FILTER, REMOVE DIRT..................................................................................246 BLEEDING AIR FROM HYDRAULIC SYSTEM....................................................................................247 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...........................................................250 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT) ..................................................251 CHECK BEFORE STARTING.....................................................................................................252 EVERY 10 HOURS MAINTENANCE................................................................................................253 LUBRICATING...........................................................................................................253 EVERY 100 HOURS MAINTENANCE...............................................................................................256 LUBRICATING SWING CIRCLE..............................................................................................256 EVERY 250 HOURS MAINTENANCE...............................................................................................257 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL..........................................................................257 CHECK LEVEL OF BATTERY ELECTROLYTE....................................................................................258 CHECK, CLEAN FUEL TANK STRAINER.......................................................................................260 CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS...............................................................260 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST...........................................................................261 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.................................................................262 EVERY 500 HOURS MAINTENANCE...............................................................................................263 REPLACE FUEL FILTER CARTRIDGE.........................................................................................263 CHECK SWING PINION GREASE LEVEL, ADD GREASE...........................................................................265 CLEAN, CHECK RADIATOR FIN, OIL COOLER FIN, FUEL COOLER FIN, CONDENSER FIN (MACHINES EQUIPPED WITH AIR CONDITIONER)....266 CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)...................267 REPLACE BREATHER ELEMENT IN HYDRAULIC TANK............................................................................268 CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER........................................................................269 CHECK FAN BELT........................................................................................................269 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.....................................................270 EVERY 1000 HOURS MAINTENANCE..............................................................................................272 REPLACE HYDRAULIC OIL FILTER ELEMENT..................................................................................272 CHANGE OIL IN SWING MACHINERY CASE....................................................................................273 CHANGE OIL IN P.T.O CASE..............................................................................................274 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER............................................................................274 CHECK PLAY TURBOCHARGE ROTOR..........................................................................................274 REPLACE CORROSION RESISITOR CARTRIDGE.................................................................................275 GREASE FAN PULLEY AND TENSION PULLEY..................................................................................275 CHECK WELDED STRUCTURE................................................................................................276 CHECK NITRIGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER).......................................................278 EVERY 2000 HOURS MAINTENANCE..............................................................................................279 CHANGE OIL IN FINAL DRIVE CASE........................................................................................279 CLEAN HYDRAULIC TANK STRAINER.........................................................................................280 CLEAN ENGINE BREATHER.................................................................................................281 CLEAN, CHECK TURBOCHARGER.............................................................................................281 CHECK ALTERNATOR, STARTING MOTOR......................................................................................281 CHECK ENGINE VALVE CLEARANCE, ADJUST..................................................................................281 CHECK INJECTOR........................................................................................................281 EVERY 4000 HOURS MAINTENANCE..............................................................................................282 CHECK WATER PUMP......................................................................................................282 CHECK VIBRATION DAMPER................................................................................................282 CHECK FAN PULLEY AND TENSION PULLEY...................................................................................282 REPLACE INJECTOR ASSEMBLY.............................................................................................282 CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.......................................................283 CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER......................................................284 EVERY 5000 HOURS MAINTENANCE..............................................................................................285 CHANGE OIL IN HYDRAULIC TANK..........................................................................................285 EVERY 8000 HOURS MAINTENANCE..............................................................................................287 REPLACE HIGH-PRESSURE PIPING CLAMP....................................................................................287 REPLACE FUEL SPRAY PREVENTION CAP.....................................................................................287 SPECIFICATIONS....................................................................................................................288 SPECIFICATIONS................................................................................................................289 ATTACHMENTS AND OPTIONS...........................................................................................................291 GENERAL PRECAUTIONS FOR SAFETY................................................................................................292 PRECAUTIONS WHEN SELECTING................................................................................................292 READ THE INSTRUCTION MANUAL THOROUGHLY....................................................................................292 PRECAUTIONS WHEN REMOVING OR INSTALLING...................................................................................292 PRECAUTIONS WHEN USING....................................................................................................293 ATTACHMENT GUIDE..............................................................................................................294 COMBINATIONS OF WORK EQUIPMENT............................................................................................294 WORKING RANGE DIAGRAM.................................................................................................295 TRACK SHOES SELECTION.....................................................................................................296 INDEX.............................................................................................................................297
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