Komatsu Galeo PC1250-7 Backhoe Manual

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FOREWORD
FOREWORD
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 for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when
performing operation and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you
understand them fully.
Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it
periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu
or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety
devices and specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before
operating the machine.
Storage location for the Operation and Maintenance Manual:
magazine box on the left side of the operator's seat.
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FOREWORD FOREWORD
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FOREWORD
FOREWORD
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FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the lock lever in
the LOCK position.
If you accidentally touch the control levers when they are not locked, this
may cause a serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
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FOREWORD
SAFETY INFORMATION
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the top
or left side, and the method of avoiding the hazardous condition at
the bottom or right side. In addition, the type of hazardous condition
is displayed inside a triangle and the method of avoiding the
hazardous condition is shown inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1J(1))
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FOREWORD INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
Digging work
Leveling work
Ditching work
Loading work
See the section "RECOMMENDED APPLICATIONS (PAGE 3-116)" for further details.
DIRECTIONS OF MACHINE
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when
the operator's seat is facing the front and the sprocket is at the rear of the machine.
BREAKING-IN THE NEW MACHINE
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the
machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points when
breaking in the machine.
Run the engine at idle for 15 seconds after starting it. During this time, do not operate the control levers or fuel
control dial.
Idle the engine for 5 minutes after starting it up.
Avoid operation with heavy loads or at high speeds.
Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops, and
sudden changes in direction.
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FOREWORD
PRODUCT INFORMATION
PRODUCT INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION
On the front bottom right of the operator's cab (side of upper frame)
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION
This is at the top of the starting motor on the right side face of the engine (rear of machine)
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FOREWORD PRODUCT INFORMATION
This is the exhaust manifold on the left side face of the engine (front of machine).
SERVICE METER LOCATION
On top of the machine monitor
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FOREWORD
PRODUCT INFORMATION
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Distributor name
Address
Service Personnel
Phone/Fax
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FOREWORD CONTENTS
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
INTRODUCTION 1- 7
DIRECTIONS OF MACHINE 1- 7
BREAKING-IN THE NEW MACHINE 1- 7
PRODUCT INFORMATION 1- 8
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION 1- 8
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION 1- 8
SERVICE METER LOCATION 1- 9
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1- 10
CONTENTS 1- 11
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 4
LOCATION OF SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS 2- 12
SAFETY MACHINE OPERATION 2- 20
STARTING ENGINE 2- 20
OPERATION 2- 22
TRANSPORTATION 2- 28
BATTERY 2- 29
TOWING 2- 31
SAFETY MAINTENANCE INFORMATION 2- 32
OPERATION 3- 1
MACHINE VIEW ILLUSTRATIONS 3- 2
OVERALL MACHINE VIEW 3- 2
CONTROLS AND GAUGES 3- 3
DETAILED CONTROLS AND GAUGES 3- 5
MONITORING SYSTEM 3- 5
SWITCHES 3- 29
CONTROL LEVERS AND PEDALS 3- 35
EMERGENCY EXIT FROM OPERATOR'S CAB 3- 37
DOOR LOCK 3- 37
CAP WITH LOCK 3- 38
HOT AND COOL BOX 3- 40
MAGAZINE BOX 3- 40
ASHTRAY 3- 40
AIR CONDITIONER CONTROLS 3- 41
RADIO 3- 56
AUXILIARY ELECTRIC POWER 3- 60
FUSE 3- 61
CIRCUIT BREAKER 3- 62
CONTROLLER 3- 64
TOOL BOX 3- 64
GREASE PUMP 3- 65
ACCUMULATOR 3- 68
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FOREWORD
CONTENTS
MACHINE OPERATIONS AND CONTROLS 3- 69
BEFORE STARTING ENGINE 3- 69
STARTING ENGINE 3- 87
AFTER STARTING ENGINE 3- 91
STOPPING THE ENGINE 3- 99
MACHINE OPERATION 3-100
STEERING THE MACHINE 3-104
SWINGING 3-106
WORK EQUIPMENT CONTROLS AND OPERATIONS 3-107
WORKING MODE 3-108
PROHIBITED OPERATIONS 3-109
GENERAL OPERATION INFORMATION 3-111
TRAVELING ON SLOPES 3-113
ESCAPE FROM MUD 3-115
RECOMMENDED APPLICATIONS 3-116
BUCKET REPLACEMENT 3-117
PARKING MACHINE 3-119
CHECK AFTER SHUT OFF ENGINE 3-121
MACHINE INSPECTION AFTER DAILY WORK 3-121
LOCKING 3-121
TRANSPORTATION 3-122
PRECAUTIONS FOR TRANSPORTATION 3-122
LIFTING MACHINE 3-122
SHIPPING MACHINE INFORMATION 3-123
TRANSPORTATION POSTURE 3-124
COLD WEATHER OPERATION 3-131
COLD WEATHER OPERATION INFORMATION 3-131
AFTER DAILY WORK COMPLETION 3-133
AFTER COLD WEATHER SEASON 3-133
LONG TERM STORAGE 3-134
BEFORE STORAGE 3-134
DURING STORAGE 3-134
AFTER STORAGE 3-134
STARTING MACHINE AFTER LONG-TERM STORAGE 3-135
TROUBLES AND ACTIONS 3-136
RUNNING OUT OF FUEL 3-136
PHENOMENA THAT ARE NOT FAILURES 3-136
TOWING THE MACHINE 3-137
SEVERE JOB CONDITION 3-137
DISCHARGED BATTERY 3-138
OTHER TROUBLE 3-142
MAINTENANCE 4- 1
MAINTENANCE INFORMATION 4- 2
OUTLINE OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
ELECTRIC SYSTEM MAINTENANCE 4- 8
WEAR PARTS 4- 9
WEAR PARTS LIST 4- 9
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS 4- 10
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FOREWORD CONTENTS
TIGHTENING TORQUE SPECIFICATIONS 4- 14
TIGHTENING TORQUE LIST 4- 14
SAFETY CRITICAL PARTS 4- 15
SAFETY CRITICAL PARTS LIST 4- 15
MAINTENANCE SCHEDULE 4- 16
MAINTENANCE SCHEDULE CHART 4- 16
MAINTENANCE PROCEDURE 4- 18
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) 4- 18
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) 4- 18
WHEN REQUIRED 4- 19
CHECK BEFORE STARTING 4- 42
EVERY 10 HOURS MAINTENANCE 4- 43
EVERY 100 HOURS MAINTENANCE 4- 45
EVERY 250 HOURS MAINTENANCE 4- 46
EVERY 500 HOURS MAINTENANCE 4- 54
EVERY 1000 HOURS MAINTENANCE 4- 69
EVERY 2000 HOURS MAINTENANCE 4- 78
EVERY 4000 HOURS MAINTENANCE 4- 80
EVERY 5000 HOURS MAINTENANCE 4- 81
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS AND OPTIONS 6- 1
GENERAL PRECAUTIONS FOR SAFETY 6- 2
PRECAUTIONS WHEN SELECTING 6- 2
READ THE INSTRUCTION MANUAL THOROUGHLY 6- 2
PRECAUTIONS WHEN REMOVING OR INSTALLING 6- 2
PRECAUTIONS WHEN USING 6- 2
ATTACHMENT GUIDE 6- 3
COMBINATIONS OF WORK EQUIPMENT 6- 3
SELECTION OF TRACK SHOES 6- 5
AUTO-GREASING SYSTEM 6- 6
EXPLANATION OF COMPONENTS 6- 6
OPERATION 6- 12
TROUBLESHOOTING 6- 16
MAINTENANCE 6- 17
LOADING SHOVEL 7- 1
EXPLANATION OF COMPONENTS 7- 2
SWITCHES 7- 2
FUSE 7- 5
OPERATIONS 7- 6
OPERATION OF WORK EQUIPMENT 7- 6
PRECAUTIONS DURING OPERATION 7- 8
EXCAVATOR WORK 7- 12
PRECAUTIONS WHEN DISASSEMBLING MACHINE 7- 13
RELEASING PRESSURE 7- 13
TRANSPORTATION 7- 14
MACHINE CONFIGURATION FOR TRANSPORT 7- 14
WEAR PARTS 7- 22
WEAR PARTS LIST 7- 22
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FOREWORD
CONTENTS
MAINTENANCE 7- 23
CHECK BEFORE STARTING 7- 23
EVERY 10 HOURS MAINTENANCE 7- 25
EVERY 5000 HOURS MAINTENANCE 7- 26
SPECIFICATION 7- 28
COMBINATION OF WORK EQUIPMENT 7- 29
COMBINATION OF WORK EQUIPMENT 7- 29
INDEX 8- 1
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SAFETY
SAFETY
SAFETY
SAFETY LABELS 2- 4
LOCATION OF SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
SAFETY INFORMATION 2- 12
Safety Rules 2- 12
If Problems are Found 2- 12
Working Wear and Personal Protective Items 2- 12
Fire Extinguisher and First Aid Kit 2- 12
Safety Equipment 2- 12
Keep Machine Clean 2- 13
Keep Operator's Compartment Clean 2- 13
Leaving Operator's Seat with Lock 2- 13
Handrails and Steps 2- 14
Mounting and Dismounting 2- 14
No Persons on Attachments 2- 14
Burn Prevention 2- 15
Fire Prevention and Explosion Prevention 2- 15
Action if Fire Occurs 2- 16
Windshield Washer Fluid 2- 16
Falling Objects, Flying Objects and Intruding Objects Prevention 2- 16
Attachment Installation 2- 17
Attachment Combinations 2- 17
Cab Window Glasses 2- 17
Unauthorized Modifications 2- 17
Safety at Jobsite 2- 17
Working on Loose Ground 2- 18
Distance to High Voltage Cables 2- 18
Ensure Good Visibility 2- 18
Ventilation for Enclosed Area 2- 19
Signalman's Signal and Signs 2- 19
Emergency Exit from Operator's Cab 2- 19
Asbestos Dust Hazard Prevention 2- 19
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SAFETY SAFETY
SAFETY MACHINE OPERATION 2- 20
Starting Engine 2- 20
Checks Before Starting Engine 2- 20
Safety Rules for Starting Engine 2- 20
Starting Engine in Cold Weather 2- 21
Operation 2- 22
Checks Before Operation 2- 22
Safety Rules for Changing Machine Directions 2- 22
Safety Rules for Traveling 2- 23
Traveling on Slopes 2- 23
Operations on Slopes 2- 24
Prohibited Operations 2- 25
Operations on Snow 2- 26
Parking Machine 2- 27
Transportation 2- 28
Shipping the Machine 2- 28
Battery 2- 29
Battery Hazard Prevention 2- 29
Starting Engine with Booster Cables 2- 30
Towing 2- 31
Safety Rules for Towing 2- 31
SAFETY MAINTENANCE INFORMATION 2- 32
Warning tag 2- 32
Keep work place clean and tidy 2- 32
Appoint leader when working with others 2- 32
Stop engine before carrying out maintenance 2- 33
Two workers for maintenance when engine is running 2- 34
Proper tools 2- 34
Accumulator 2- 34
Personnel 2- 35
Attachments 2- 35
Work under the machine 2- 35
Noise 2- 35
When using hammer 2- 35
Welding works 2- 36
Removing battery terminals 2- 36
Safety first when using high-pressure grease to adjust track tension 2- 36
Do not disassemble recoil springs 2- 36
Safety rules for high-pressure oil 2- 37
Safety handling high-pressure hoses 2- 37
Waste materials 2- 37
Air conditioner maintenance 2- 38
Compressed air 2- 38
Periodic replacement of safety critical parts 2- 38
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SAFETY
SAFETY LABELS
SAFETY LABELS
The following warning signs and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to
peel off.
There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
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SAFETY SAFETY LABELS
LOCATION OF SAFETY LABELS
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