This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the Komatsu PC200-8, PC200LC-8, PC220-8, PC220LC-8 Galeo Hydraulic Excavator. It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.
APPLICABLE MODELS :
Komatsu PC200 - SN: 300001 and up
Komatsu PC220 - SN: 70001 and up
TABLE OF CONTENTS :
- SAFETY
- OPERATION
- MAINTENANCE
- SPECIFICATIONS
- OPTIONS, ATTACHMENTS
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : TEN00116-03
Total Pages : 379
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.
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COVER
FOREWORD
FOREWORD
SAFETY INFORMATION
INTRODUCTION
DIRECTIONS OF MACHINE
BREAKING-IN THE NEW MACHINE
PRODUCT INFORMATION
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
EPA REGULATIONS, ENGINE NUMBER PLATE
SERVICE METER LOCATION
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
CONTENTS
SAFETY
SAFETY INFORMATION
SAFETY LABELS
LOCATION OF SAFETY LABELS
SAFETY LABELS
SAFETY INFORMATION
SAFETY RULES
IF PROBLEMS ARE FOUND
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS
FIRE EXTINGUISHER AND FIRST AID KIT
SAFETY EQUIPMENT
KEEP MACHINE CLEAN
KEEP OPERATOR'S COMPARTMENT CLEAN
LEAVING OPERATOR'S SEAT WITH LOCK
HANDRAILS AND STEPS
PRECAUTIONS WHEN WORKING IN HIGH PLACES
MOUNTING AND DISMOUNTING
NO PERSONS ON ATTACHMENTS
DO NOT GET CAUGHT IN ARTICULATED PORTION
BURN PREVENTION
FIRE PREVENTION AND EXPLOSION PREVENTION
ACTION IF FIRE OCCURS
WINDSHIELD WASHER FLUID
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION
ATTACHMENT INSTALLATION
ATTACHMENT COMBINATIONS
CAB WINDOW GLASSES
UNAUTHORIZED MODIFICATIONS
SAFETY AT JOBSITE
WORKING ON LOOSE GROUND
DISTANCE TO HIGH VOLTAGE CABLES
ENSURE GOOD VISIBILITY
VENTILATION FOR ENCLOSED AREA
SIGNALMAN'S SIGNAL AND SIGNS
EMERGENCY EXIT FROM OPERATOR'S CAB
ASBESTOS DUST HAZARD PREVENTION
SAFETY MACHINE OPERATION
STARTING ENGINE
CHECKS BEFORE STARTING ENGINE
SAFETY RULES FOR STARTING ENGINE
STARTING ENGINE IN COLD WEATHER
OPERATION
CHECKS BEFORE OPERATION
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS
SAFETY RULES FOR TRAVELING
TRAVELING ON SLOPES
OPERATIONS ON SLOPES
PROHIBITED OPERATIONS
OPERATIONS ON SNOW
PARKING MACHINE
TRANSPORTATION
LOADING AND UNLOADING
SHIPPING THE MACHINE
BATTERY
BATTERY HAZARD PREVENTION
STARTING ENGINE WITH BOOSTER CABLES
TOWING
SAFETY RULES FOR TOWING
LIFTING OBJECTS WITH BUCKET
SAFETY RULES FOR LIFTING OBJECTS
SAFETY MAINTENANCE INFORMATION
WARNING TAG
KEEP WORK PLACE CLEAN AND TIDY
APPOINT LEADER WHEN WORKING WITH OTHERS
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING
PROPER TOOLS
ACCUMULATOR, GAS SPRING
PERSONNEL
ATTACHMENTS
WORK UNDER THE MACHINE
NOISE
WHEN USING HAMMER
WELDING WORKS
REMOVING BATTERY TERMINALS
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION
DO NOT DISASSEMBLE RECOIL SPRINGS
SAFETY RULES FOR HIGH-PRESSURE OIL
PRECAUTION FOR HIGH FUEL PRESSURE
SAFETY HANDLING HIGH-PRESSURE HOSES
PRECAUTION FOR HIGH VOLTAGE
WASTE MATERIALS
AIR CONDITIONER MAINTENANCE
COMPRESSED AIR
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
OPERATION
MACHINE VIEW ILLUSTRATIONS
OVERALL MACHINE VIEW
CONTROLS AND GAUGES
DETAILED CONTROLS AND GAUGES
MONITORING SYSTEM
SWITCHES
CONTROL LEVERS AND PEDALS
SUN ROOF
WINDSHIELD
EMERGENCY ESCAPE HAMMER
DOOR LOCK
CAP WITH LOCK
DRINK BOX
MAGAZINE BOX
ASHTRAY
AIR CONDITIONER CONTROLS
RADIO
AUXILIARY ELECTRIC POWER
FUSE
FUSIBLE LINK
CONTROLLER
TOOL BOX
GREASE PUMP HOLDER
FIRE EXTINGUISHER
MACHINE OPERATIONS AND CONTROLS
BEFORE STARTING ENGINE
STARTING ENGINE
AFTER STARTING ENGINE
STOPPING THE ENGINE
MACHINE OPERATION
STEERING THE MACHINE
SWINGING
WORK EQUIPMENT CONTROLS AND OPERATIONS
WORKING MODE
PROHIBITED OPERATIONS
GENERAL OPERATION INFORMATION
TRAVELING ON SLOPES
ESCAPE FROM MUD
RECOMMENDED APPLICATIONS
BUCKET REPLACEMENT AND INVERSION
PARKING MACHINE
MACHINE INSPECTION AFTER DAILY WORK
LOCKING
TRANSPORTATION
TRANSPORTATION PROCEDURE
LOADING AND UNLOADING WITH TRAILER
LIFTING MACHINE
COLD WEATHER OPERATION
COLD WEATHER OPERATION INFORMATION
AFTER DAILY WORK COMPLETION
AFTER COLD WEATHER SEASON
LONG TERM STORAGE
BEFORE STORAGE
DURING STORAGE
AFTER STORAGE
STARTING MACHINE AFTER LONG-TERM STORAGE
TROUBLES AND ACTIONS
RUNNING OUT OF FUEL
PHENOMENA THAT ARE NOT FAILURES
TOWING THE MACHINE
LIGHTWEIGHT TOWING HOLE
SEVERE JOB CONDITION
DISCHARGED BATTERY
OTHER TROUBLE
MAINTENANCE
MAINTENANCE INFORMATION
OUTLINE OF SERVICE
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
ELECTRIC SYSTEM MAINTENANCE
WEAR PARTS
WEAR PARTS LIST
RECOMMENDED FUEL, COOLANT, AND LUBRICANT
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL
TIGHTENING TORQUE SPECIFICATIONS
TIGHTENING TORQUE LIST
SAFETY CRITICAL PARTS
SAFETY CRITICAL PARTS LIST
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE CHART
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER
MAINTENANCE PROCEDURE
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
CLEAN INSIDE OF COOLING SYSTEM
CHECK AND TIGHTEN TRACK SHOE BOLTS
CHECK AND ADJUST TRACK TENSION
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)
ADJUST BUCKET CLEARANCE
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID
CHECK AND MAINTENANCE AIR CONDITIONER
WASH WASHABLE FLOOR
CHECK GAS SPRING
BLEEDING AIR FROM HYDRAULIC SYSTEM
CHECK BEFORE STARTING
EVERY 100 HOURS MAINTENANCE
LUBRICATING
EVERY 250 HOURS MAINTENANCE
CHECK LEVEL OF BATTERY ELECTROLYTE
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST
EVERY 500 HOURS MAINTENANCE
LUBRICATING
LUBRICATE SWING CIRCLE
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
REPLACE FUEL PRE-FILTER CARTRIDGE
CHECK SWING PINION GREASE LEVEL, ADD GREASE
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER
FINS, AND AIR CONDITIONER CONDENSER FINS
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
EVERY 1000 HOURS MAINTENANCE
REPLACE HYDRAULIC OIL FILTER ELEMENT
CHANGE OIL IN SWING MACHINERY CASE
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL
REPLACE FUEL MAIN FILTER CARTRIDGE
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS
REPLACE CORROSION RESISTOR CARTRIDGE
CHECK FAN BELT TENSION AND REPLACE FAN BELT
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)
EVERY 2000 HOURS MAINTENANCE
CHANGE OIL IN FINAL DRIVE CASE
CLEAN HYDRAULIC TANK STRAINER
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL
CIRCUIT)
CHECK ALTERNATOR
CHECK ENGINE VALVE CLEARANCE, ADJUST
EVERY 4000 HOURS MAINTENANCE
CHECK WATER PUMP
CHECK VIBRATION DAMPER
CHECK STARTING MOTOR
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER
CHECK OPERATING CONDITION OF COMPRESSOR
EVERY 5000 HOURS MAINTENANCE
CHANGE OIL IN HYDRAULIC TANK
EVERY 8000 HOURS MAINTENANCE
REPLACE HIGH-PRESSURE PIPING CLAMP
REPLACE FUEL SPRAY PREVENTION CAP
SPECIFICATIONS
SPECIFICATIONS
ATTACHMENTS, OPTIONS
GENERAL PRECAUTIONS FOR SAFETY
PRECAUTIONS WHEN SELECTING
READ THE INSTRUCTION MANUAL THOROUGHLY
PRECAUTIONS WHEN REMOVING OR INSTALLING
PRECAUTIONS WHEN USING
BUCKET WITH HOOK
HOOK CONDITION
PROHIBITED OPERATIONS
MACHINE READY FOR ATTACHMENT
LOCATIONS
HYDRAULIC CIRCUIT
ATTACHMENT REMOVAL AND INSTALLATION
ATTACHMENT OPERATIONS
LONG TERM STORAGE
SPECIFICATIONS
ATTACHMENT GUIDE
ATTACHMENT COMBINATIONS
TRACK SHOES SELECTION
BUCKET TEETH SELECTION
HANDLING OF RUBBER PAD SHOE AND ROAD LINER
TRAPEZOIDAL BUCKET
HANDLING EXTENSION ARM
HANDLING CLAMSHELL BUCKET
RECOMMENDED ATTACHMENT OPERATIONS
HYDRAULIC BREAKER
HANDLING MACHINES EQUIPPED WITH KOMTRAX
BASIC PRECAUTIONS
INDEX
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