Komatsu PC2000-8 Galeo Mining Shovels Hydraulic Excavator Operation & Maintenance Manual

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the PC2000-8 Komatsu Galeo Hydraulic Excavator (S/N: 20001 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.

APPLICABLE MODELS :

Komatsu PC2000-8 Mining Shovels
Serial Numbers : 20001 and up
Loading Shovel Cold-Terrain

TABLE OF CONTENTS :

– SAFETY
– OPERATION
– MAINTENANCE
– SPECIFICATIONS
– OPTIONS AND ATTACHMENTS
– LOADING SHOVEL
– INDEX

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : PEN00237-00
Total Pages : 481

This page sometime can be found use following keyword : service manual, repair manual, workshop manual, technical manual, owner manual, operating manual, maintenance manual, parts manual. Please make sure you read and understand the title of this manual before decided to buy.

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FOREWORD
FOREWORD
SAFETY INFORMATION
INTRODUCTION
DIRECTIONS OF MACHINE
VISIBILITY FROM OPERATOR’S SEAT
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
SAFETY LABELS
LOCATION OF SAFETY LABELS
SAFETY LABELS
GENERAL PRECAUTIONS
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
BATTERY
BATTERY HAZARD PREVENTION
STARTING ENGINE WITH BOOSTER CABLES
TOWING
SAFETY RULES FOR TOWING
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
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
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
LAMP
CONTROL LEVERS AND PEDALS
DOOR LOCK
EMERGENCY EXIT FROM OPERATOR’S CAB
EMERGENCY ESCAPE HAMMER
EMERGENCY ESCAPE EQUIPMENT
FIRE EXTINGUISHER
CAP WITH LOCK
ASHTRAY
CUP HOLDER
MAGAZINE BOX
HOOK
UTILITY BOX
AIR CONDITIONER CONTROLS
RADIO
AUXILIARY ELECTRIC POWER
FUSE
CIRCUIT BREAKER
FUSE (IF EQUIPPED)
CONTROLLER
TOOL, CAN STORAGE PLACE
HANDLING GREASE PUMP AND GREASE GUN
ACCUMULATOR
HANDLING OF SLIDING LADDER
HANDLING MACHINES EQUIPPED WITH VHMS
EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER
HANDLING PORTABLE COMBUSTION TYPE PREHEATING HEATER
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
PARKING MACHINE
CHECK BEFORE SHUT OFF ENGINE
MACHINE INSPECTION AFTER DAILY WORK
LOCKING
TRANSPORTATION
TRANSPORTATION PROCEDURE
PRECAUTIONS FOR TRANSPORTATION
METHOD OF LIFTING UNITS FOR TRANSPORTATION
TRANSPORTATION POSTURE
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
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 THANKOMATSU GENUINE OIL
TIGHTENING TORQUE SPECIFICATIONS
TIGHTENING TORQUE LIST
SAFETY CRITICAL PARTS
SAFETY CRITICAL PARTS LIST
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE CHART
MAINTENANCE PROCEDURE
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)
INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 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 (KMAX)
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID
CHECK AND MAINTENANCE AIR CONDITIONER
CLEAN LINE FILTER, REMOVE DIRT
GREASE LADDER
CHECK SEALS AROUND ENGINE COOLING
BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM HYDRAULIC SYSTEM
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT
INSPECTION OF ADDITIONAL WATER SEPARATOR AND CLEANING OF CASING INTERIOR
CHECK BEFORE STARTING
EVERY 250 HOURS MAINTENANCE
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
CHECK LEVEL OF BATTERY ELECTROLYTE
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)
EVERY 500 HOURS MAINTENANCE
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, FUEL COOLER AND AFTER COOLER FINS
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS
CHECK, REPLACE HYDRAULIC PUMP DRAIN FILTER CARTRIDGE
REPLACE SWING, TRAVEL MOTOR DRAIN FILTER CARTRIDGE
REPLACE PILOT FILTER CARTRIDGE
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL
REPLACE FUEL PRE-FILTER CARTRIDGE
EVERY 1000 HOURS MAINTENANCE
REPLACE FUEL FILTER CARTRIDGE
REPLACE FUEL TANK BREATHER ELEMENT
REPLACE CORROSION RESISTOR CARTRIDGE
CHANGE OIL IN SWING MACHINERY CASE
CHANGE OIL IN PTO CASE
CLEAN PTO LUBRICATION OIL FILTER STRAINER
REPLACE HYDRAULIC OIL FILTER ELEMENT
REPLACE HYDRAULIC TANK BREATHER FILTER ELEMENT
CHECK EMERGENCY ESCAPE EQUIPMENT AND MOUNTS
INSPECTION OF ENGINE SUCTION HOSE CLAMP FOR LOOSENING
CHECK FOR LOOSE CLAMPS OF AFTERCOOLER HOSE
CHECK GAS PRESSURE IN ACCUMULATOR FOR OPERATION CONTROL CIRCUIT
CHECK WELDED STRUCTURE
EVERY 2000 HOURS MAINTENANCE
CHANGE OIL IN FINAL DRIVE CASE
CHECK GREASE LEVEL IN SWING PINION, ADD GREASE
CHECK ALTERNATOR, STARTING MOTOR
CHECK ENGINE VALVE CLEARANCE, ADJUST
EVERY 4000 HOURS MAINTENANCE
GREASE ENGINE MOUNT (FRONT SIDE)
CHECK WATER PUMP
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER
REPLACE ACCUMULATOR IN OIL COOLER CIRCUIT
EVERY 5000 HOURS MAINTENANCE
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER
EVERY 8000 HOURS MAINTENANCE
REPLACE INJECTOR NOZZLE ASSEMBLY
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
ATTACHMENT GUIDE
COMBINATIONS OF WORK EQUIPMENT
FRONT GUARD
ORBCOM CONTROLLER (COMMUNICATIONS TERMINAL)
LOADING SHOVEL
MACHINE VIEW ILLUSTRATIONS
OVERALL MACHINE VIEW
EXPLANATION OF COMPONENTS
SWITCHES
OPERATIONS
OPERATION OF WORK EQUIPMENT
PRECAUTIONS DURING OPERATION
EXCAVATOR WORK
PRECAUTIONS WHEN DISASSEMBLING MACHINE
RELEASING PRESSURE
TRANSPORTATION
MACHINE CONFIGURATION FOR TRANSPORT
MAINTENANCE
EVERY 10 HOURS MAINTENANCE
SPECIFICATION
WEAR PARTS
WEAR PARTS LIST
COMBINATION OF WORK EQUIPMENT
COMBINATION OF WORK EQUIPMENT

INDEX

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