Komatsu PC200,200LC,220,220LC-8 Galeo Hydraulic Excavator Operation & Maintenance Manual

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the PC200-8, PC200LC-8, PC220-8, PC220LC-8 Galeo Komatsu Hydraulic Excavator. It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu PC200-8 - S/N: 300001 and up
Komatsu PC200LC-8 - S/N: 300001 and up
Komatsu PC220-8 - S/N: 70001 and up
Komatsu PC220LC-8 - S/N: 70001 and up


TABLE OF CONTENTS :

- SAFETY
- OPERATION
- MAINTENANCE
- SPECIFICATIONS
- ATTACHMENTS, OPTIONS
- INDEX


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : PEN00108-00
Total Pages : 373


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
- - ENGINE SERIAL NUMBER PLATE AND ITS LOCATION
- - 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
- - 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
- - HANDLING 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
- - REPCAUTION 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 GUN HOLDER
- 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
- - CHECK AFTER SHUT OFF ENGINE
- - 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 LUBRICANTS
- - 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
- - - 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 INSPECTRADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, FUEL COOLER FINS, AND CONDENSER FINS(ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)
- - - 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 CARTRIOGE
- - - CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS
- - - REPLACE CORROSION RESISTOR CARTRIDGE (IF EQUIPPED)
- - - 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, STARTING MOTOR
- - - CHECK ENGINE VALVE CLEARANCE, ADJUST
- - EVERY 4000 HOURS MAINTENANCE
- - - CHECK WATER PUMP
- - - CHECK VIBRATION DAMPER
- - - 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 FUEL SPRAY PREVENTION CAP
- - - REPLACE HIGH-PRESSURE PIPING CLAMP

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
INDEX

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