PDF Operation & Maintenance Manual Komatsu Galeo PC228US-3 PC228USLC-3 Hydraulic Excavator - 1 MB
This manual provides essential operation and maintenance instructions for the Komatsu Galeo PC228US-3 and PC228USLC-3 hydraulic excavators.
Operators will learn about the machine's controls, safety features, and correct operating procedures.
It also outlines a complete maintenance schedule to ensure the excavator's longevity and reliability.
Following this guide is the key to safe and productive operation.
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TEN00030-01
Operation & Maintenance
Manual
PC228US-3
PC228USLC-3
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PC228US-3 30001 and up
PC228USLC-3 30001 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2005 Komatsu
Printed in U.S.A.
Komatsu America Corp.
July 2005
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CONTENTS FOREWORD
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
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 8
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION 1- 8
SERVICE METER LOCATION 1- 9
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1- 9
SAFETY 2- 1
SAFETY INFORMATION 2- 2
SAFETY LABELS 2- 4
LOCATION OF SAFETY LABELS 2- 4
SAFETY LABELS 2- 5
SAFETY INFORMATION 2- 11
SAFETY MACHINE OPERATION 2- 19
STARTING ENGINE 2- 19
OPERATION 2- 21
TRANSPORTATION 2- 27
BATTERY 2- 28
TOWING 2- 29
LIFTING OBJECTS WITH BUCKET 2- 30
SAFETY MAINTENANCE INFORMATION 2- 31
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- 28
CONTROL LEVERS AND PEDALS 3- 34
SUN ROOF 3- 38
WINDSHIELD 3- 39
SLIDING DOOR 3- 44
ASHTRAY 3- 44
CONTROLLERS 3- 44
REAR UNDERVIEW MIRROR 3- 45
EMERGENCY ESCAPE HAMMER 3- 45
CAP WITH LOCK 3- 46
HOT AND COOL BOX 3- 47
AIR CONDITIONER CONTROLS 3- 48
RADIO 3- 54
AUXILIARY ELECTRIC POWER 3- 59
FUSE 3- 60
FUSIBLE LINK 3- 61
TOOL BOX 3- 61
GREASE GUN HOLDER 3- 61
1 - 10
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SAFETY LABELS SAFETY
(4) Warnings for high voltage (09801-03001)
(5) Caution when opening or closing front window
(09839-03000)
2-6
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SAFETY INFORMATION SAFETY
ATTACHMENT INSTALLATION
When installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore
contact your Komatsu distributor for advice.
Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be
the responsibility of Komatsu.
When installing and using optional attachments, read the instruction manual for the attachment, and the general
information related to attachments in this manual.
ATTACHMENT COMBINATIONS
Depending on the type or combination of work equipment, there is a hazard that the work equipment may hit the cab
or other parts of the machine. Before using unfamiliar work equipment, check if there is any hazard of interference,
and operate with caution.
CAB WINDOW GLASSES
If the cab glass on the work equipment side is broken, there is a hazard that the work equipment may contact the
operator's body directly. Stop operation immediately and replace the glass.
The ceiling window is made of organic glass (polycarbonate), and as such it is apt to break easily when receiving
damage on the surface, thereby deteriorating its protective characteristic. If there is a crack or damage caused
by a fallen rock, or when any sign of them is noticed, replace it with a new window.
UNAUTHORIZED MODIFICATIONS
Any modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting
from modifications made without authorization from Komatsu.
SAFETY AT JOBSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there
is a hazard of fire, so be careful when operating.
Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do
not carry out operations at places where there is a hazard of landslides or falling rocks.
If water lines, gas lines, or high-voltage electrical lines may be
buried under the worksite, contact each utility and identify their
locations. Be careful not to sever or damage any of these lines.
Take action to prevent unauthorized people from approaching
the jobsite.
When working on public roads, position flagmen and erect
barriers to ensure the safety of passing traffic and pedestrians.
When traveling or operating in shallow water or on soft ground,
check the shape and condition of the bedrock, and the depth
and speed of flow of the water before starting operations.
WORKING ON LOOSE GROUND
Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after
earthquakes is weak in these areas.
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SAFETY MACHINE OPERATION SAFETY
PARKING MACHINE
Park the machine on firm, level ground.
Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
Lower the work equipment completely to the ground.
When leaving the machine, set lock lever (1) to the LOCK
position, then stop the engine.
Always close the operator's cab door, and use the key to lock all
the equipment in order to prevent any unauthorized person from
moving the machine. Always remove the key, take it with you,
and leave it in the specified place.
If it is necessary to park the machine on a slope, always do as
follows.
Set the bucket on the downhill side, then dig it into the
ground.
Put blocks under the tracks to prevent the machine from
moving.
2 - 26
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SAFETY MAINTENANCE INFORMATION SAFETY
SAFETY RULES FOR HIGH-PRESSURE OIL
The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always
check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to
serious injury, so always do as follows.
For details of the method of releasing the pressure, see "METHOD FOR RELEASING INTERNAL PRESSURE
IN HYDRAULIC CIRCUIT (PAGE 4-43)". If the circuit is still under pressure, do not carry out any inspection or
replacement operation.
If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping
and hoses and for swelling in the hoses.
When carry out inspection, wear safety glasses and leather gloves.
There is a hazard that high-pressure oil leaking from small holes
may penetrate your skin or cause blindness if it contacts your
eyes directly. If you are hit by a jet of high-pressure oil and suffer
injury to your skin or eyes, wash the place with clean water, and
consult a doctor immediately for medical attention.
SAFETY HANDLING HIGH-PRESSURE HOSES
If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found,
stop operations immediately and contact your Komatsu distributor.
Replace the hose if any of the following problems are found.
Damaged or leaking hydraulic fitting.
Frayed or cut covering or exposed reinforcement wire layer.
Covering swollen in places.
Twisted or crushed movable portion.
Foreign material embedded in covering.
WASTE MATERIALS
To prevent pollution, pay careful attention to the method of disposing of waste materials.
Always put oil drained from your machine in containers. Never
drain oil directly onto the ground or dump into the sewage
system, rivers, the sea, or lakes.
Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters, and
batteries.
AIR CONDITIONER MAINTENANCE
If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frostbite.
Never touch refrigerant.
2 - 36
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DETAILED CONTROLS AND GAUGES OPERATION
Basic Check Monitors
CAUTION
These monitors DO NOT ensure that the machine is in good condition. When performing checks before starting (daily checks),
do not simply rely on the monitors. Always dismount the machine and check each item directly.
Displays basic items among the check before starting items that must be checked before starting the engine. If there
is any abnormality, monitor for the location of abnormality will light up.
A(1) Radiator coolant level monitor A(3) Maintenance interval monitor
A(2) Engine oil level monitor
Radiator Coolant Level Monitor
Monitor (1) warns the operator that there has been a drop in the
radiator coolant level.
If the radiator coolant is low, the lamp lights up red, so check
coolant level in the radiator and subtank, and add coolant.
3-8
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DETAILED CONTROLS AND GAUGES OPERATION
Monitor Switches Portion
E(1) Working mode selector switch (basic switch) E(7) Select switch
E(2) Auto-deceleration switch (selection switch) E(8) Back switch
E(3) Travel speed selector switch E(9) Up switch
E(4) Wiper switch E(10) Down switch
E(5) Window washer switch E(11) Input confirmation switch
E(6) Maintenance switch E(12) Adjusting brightness and contrast
Working Mode Selector Switch (Basic Switch)
Switch (1) is used to set the power and movement of the work
equipment.
Operations can easily be performed by selecting the mode to
match the type of operation.
A mode: For heavy-duty operations
E mode: For operations prioritizing fuel consumption
L mode: For fine-control operations
B mode: For breaker operations
When the engine is started, the working mode is set automatically to A mode. When the switch is pressed, it is
possible to select the other modes. The monitor display on the monitor display portion changes for each mode.
If it is desired to have the working mode set to start automatically in E, L, or B mode (default options setting),
please contact your Komatsu distributor to change the setting.
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DETAILED CONTROLS AND GAUGES OPERATION
SWITCHES
(1) Starting switch (8) Knob switch
(2) Fuel control dial (9) Room lamp switch
(3) Cigarette lighter (10) Pump drive emergency switch
(4) Swing lock Switch (11) Swing holding brake release switch
(5) Lamp switch (12) Emergency work equipment actuation switch
(6) Alarm buzzer stop switch (13) Rotating lamp switch (if Equipped)
(7) Horn switch
Starting Switch
This switch (1) is used to start or stop the engine.
OFF position
The key can be inserted or withdrawn. The switches for the electric
system except the room lamp, are all turned off and the engine is
stopped.
ON position
Electric current flows in the charging and lamp circuits. Keep the
starting switch key at the ON position while the engine is running.
START position
This is the engine-start position. Keep the key at this position
during cranking. Immediately after starting the engine, release the
key. It will automatically return to the ON position.
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DETAILED CONTROLS AND GAUGES OPERATION
SUN ROOF
WARNING
When leaving the operator's compartment, set the lock lever securely to the LOCK position.
If the control levers are not locked, and they are touched by mistake, this may lead to a serious accident.
When opening or closing the roof hatch, carry out the operation on horizontal ground. If you open or close the hatch when the
footing conditions are poor, there is danger that you may fall.
Opening
1. Set the lock lever securely to the LOCK position.
2. Release lock (A) provided on both side of the ceiling and check
that it moves freely. Then push it up to open, holding handle
(B).
Closing
Pull the ceiling down, holding handle (B) and set locks (A). If the locks do not engage properly, open the ceiling once
again and try to shut it.
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DETAILED CONTROLS AND GAUGES OPERATION
AIR CONDITIONER CONTROLS
Air Conditioner Control Panel
(1) Vent selector switch (5) Air conditioner switch
(2) Air circulation selector switch (external/internal) (6) Off switch
(3) Temperature control switch (7) Defroster selector lever
(4) Air flow selector switch
Vent Selector Switch (Air Flow to Upper Part of Body)
If this switch (1) is pressed, the air from the air conditioner is all
directed to the face. This can be used to send a cool breeze to the
face during hot weather.
3 - 48
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DETAILED CONTROLS AND GAUGES OPERATION
Setting Correct Time
1. Press display selector button (4) to display the time.
After 5 seconds, the display will return to the frequency display
and the time cannot be corrected. If this happens, press
display selector button (4) again.
2. Press time adjustment button (8) to set to Hour or Minute.
H button: Adjusts the hour (each time the button is pressed, the
time advances by one hour)
M button: Adjusts the minute (each time the button is pressed,
the time advances by one minute)
If the H or M button is kept pressed, the time will advance
continuously until the button is released.
ADJ button: When the ADJ button is pressed, the time is reset
as follows.
When display is 00 - 05 minutes, time is returned to 00 min.
00 sec. (No change in hour)
When display is 55 - 59 minutes, time is advanced to 00 min.
00 sec. (Hour advances)
When display is 06 - 54 minutes, time cannot be reset. (Time
stays same)
Example
10:05 J 10:00
10:59 J 11:00
10:26 J 10:26
Use the H, M, and ADJ buttons to set to the correct time.
Antenna
NOTICE
Before transporting the machine or putting it inside a building, stored the
antenna to prevent any interference.
Use Radio with Care
To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during operation.
If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water
on the equipment.
Do not wipe the scales or buttons with benzene, thinner, or any other solvent. Wipe with a soft dry cloth. Use a
cloth soaked in alcohol if the equipment is extremely dirty.
When the battery is replaced, the settings for the preset buttons are all cleared, so set them again.
3 - 58
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MACHINE OPERATIONS AND CONTROLS OPERATION
Drain Water And Sediment from Fuel Tank
1. Open the pump room door (1) at the rear right of the machine.
2. Put a container to catch the drained fuel under drain valve (2).
3. Open drain valve (2) at the rear of the fuel tank and drain the
water and sediment accumulated at the bottom of the tank
together with the fuel.
4. When only clean fuel comes out, close drain valve (2).
5. Close the pump room door (1) at the rear right of the machine.
3 - 68
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MACHINE OPERATIONS AND CONTROLS OPERATION
3) If the hydraulic oil temperature gauge goes out and caution
lamp (15) stays lighted up red, perform inspection
immediately for the item which is lighted up red.
4) If there are any items where the maintenance time has
passed, maintenance interval monitor (16) lights up for 30
seconds. Press maintenance switch (17), check the item,
then perform maintenance immediately.
For details of the method of checking the maintenance
interval, see "Maintenance Switch (PAGE 3-22)" in the
Detailed controls and gauges.
3 - 78
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MACHINE OPERATIONS AND CONTROLS OPERATION
4. Set lock lever (1) to the FREE position and raise the bucket
from the ground.
5. Operate bucket control lever (3) and arm control lever (4)
slowly to move the bucket cylinder and arm cylinder to the end
of the stroke.
6. Operate the bucket for 30 seconds and the arm for 30 seconds
in turn fully for 5 minutes.
REMARK
If swing lock switch (5) is operated to the ON position, it is possible
to raise the oil temperature faster.
NOTICE
When the work equipment is retracted, take care that it does not interfere
with the machine body or ground.
3 - 88
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MACHINE OPERATIONS AND CONTROLS OPERATION
Changing Direction of the Machine
When turning to the left:
If the left travel lever is returned to the neutral position, the machine
will turn to the left.
REMARK
When turning to the right, operate the right travel lever in the same
way.
Counter-rotation Turn (Spin Turn)
When using counter-rotation (spin turn) to turn left, pull the left
travel lever back and push the right travel lever forward.
REMARK
When using counter-rotation to turn right, pull the right travel lever
back and push the left travel lever forward.
3 - 98
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MACHINE OPERATIONS AND CONTROLS OPERATION
ESCAPE FROM MUD
Always operate carefully to avoid getting stuck in mud. If the machine does get stuck in mud, do as follows to get
the machine out.
Track on One Side Stuck
NOTICE
When using the boom or arm to raise the machine, always have the bottom
of the bucket in contact with the ground. The angle between the boom and
arm should be 90° to 110°.
The same applies when using the bucket installed in the reverse direction.
When only one side is stuck in mud, use the bucket to raise the
track, then lay boards or logs and drive the machine out.
Tracks on Both Sides Stuck
When the tracks on both sides are stuck in mud and they slip,
making it impossible for the machine to move, lay boards or logs as
explained above, and dig the bucket into the ground in front. Then
pull in the arm as in normal digging operations and put the travel
levers in the FORWARD position to pull the machine out.
3 - 108
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TRANSPORTATION OPERATION
Loading
1. Load and unload on firm level ground only.
Maintain a safe distance from the edge of a road.
2. Properly apply the brakes on the trailer and put blocks under
the tires to ensure that the trailer does not move.
Make the slope of the ramps a maximum of 15°.
3. Set the travel speed selector switch to Lo (low speed travel).
To switch the travel speed, press travel speed selector
switch (1). The travel speed is displayed as Lo, Mi, or Hi on
the monitor display.
4. Turn auto-deceleration switch (1) OFF and operate the fuel
control dial to set the engine speed to low idle.
Each time auto-deceleration switch (1) is pressed, it
switches OFF J ON J OFF in turn.
When auto-deceleration switch (1) is turned OFF, display
monitor (2) goes out.
5. Turn the swing lock switch ON to apply the swing lock.
When the swing lock switch is turned ON, display monitor
(3) lights up.
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COLD WEATHER OPERATION OPERATION
Battery
WARNING
The battery generates flammable gas. Do not bring fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a
doctor.
Battery electrolyte dissolves paint. If it gets on the bodywork, wash it off immediately with water.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is danger
that the battery may explode.
Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.
When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low, the
battery electrolyte may freeze. Maintain the battery charge as close as possible to 100%. Insulate it against cold
temperature to ensure the machine can be started easily the next morning.
REMARK
Measure the specific gravity and calculate the charging rate from the following conversion table.
Electrolyte
Temperature
20 0 -10 -20
Charging (°C)
Rate (%)
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
As the battery capacity drastically drops in low temperatures, cover or remove the battery from the machine, store
the battery in a warm place, and install it again the next morning.
If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add water after the
day's work to prevent diluted electrolyte in the battery from freezing during the night.
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TROUBLES AND ACTIONS OPERATION
Starting the Engine
WARNING
Always check that the lock lever is set to the LOCK position, regardless of whether the machine is working normally or has failed.
Check also that all the control levers are in the neutral position.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start engine of the normal machine and run it at high idle speed.
3. Turn the starting switch of the problem machine to the START position and start the engine.
If the engine doesn't start at first, try again after 2 minutes or so.
Booster Cable Disconnection
After the engine has started, disconnect booster cables in the
reverse order in which they were connected.
1. Remove one clip of booster cable (B) from the revolving frame
of the problem machine.
2. Remove the other clip of booster cable (B) from the negative (-)
terminal of the normal machine.
3. Remove one clip of booster cable (A) from the positive (+)
terminal of the normal machine.
4. Remove the other clip of booster cable (A) from the positive (+)
terminal of the problem machine.
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OUTLINE OF SERVICE MAINTENANCE
OUTLINE OF SERVICE
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
Oil
Even if oil in not dirty, always change the oil at the specified interval.
Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high
pressure), and it deteriorates with use.
Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual.
Never mix oils of different grades or brands.
Oil corresponds to blood in the human body, so always be careful when handling it to prevent any impurities
(water, metal particles, dirt, etc.) from getting in.
Take particular care not to let any impurities get in when adding oil.
The majority of problems with machines are caused by the entry of such impurities.
Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
When changing the oil, always replace the related filters at the same time.
If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
please contact your Komatsu distributor.
We recommend you have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, please contact your Komatsu distributor.
Fuel
The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
Be extremely careful not to let impurities get in when storing or adding fuel.
Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal, depending on the temperature, when it is used (particularly in low temperature below -15°C
(5°F)). It is necessary to change to the fuel that is suitable for the temperature.
To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank
after completing the day's work.
Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from
the fuel tank.
If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.
If there is any foreign material in the fuel tank, wash the tank and fuel system.
Cooling System Coolant
If the coolant level is low, it will cause overheating, and will also cause problems with corrosion due to air entering
the coolant.
River water contains large amount of calcium and other impurities, so if it is used, scale will stick to the engine and
radiator, and this will cause defective heat exchange and overheating.
Do not use water that is not suitable for drinking.
Antifreeze is also effective in preventing corrosion on the parts of the engine cooling system. It may be
continuously used for two years or 4000 hours of operation, therefore it may be used throughout the year.
When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.
Anti-freeze is flammable, so be extremely careful not to expose it to flame or fire.
The proper mixing proportion of the antifreeze depends on the ambient temperature. For the mixing proportion,
see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-24)".
Grease
Grease is used to prevent seizure and noises at the joints.
4-4
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MAINTENANCE SCHEDULE MAINTENANCE
MAINTENANCE SCHEDULE
If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts will be different. For
details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-16)" to confirm the correct
maintenance schedule when carrying out maintenance.
MAINTENANCE SCHEDULE CHART
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)
REPLACE FUEL FILTER CARTRIDGE 4- 55
CHECK ENGINE VALVE CLEARANCE, ADJUST 4- 69
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)
CHECK ENGINE VALVE CLEARANCE, ADJUST 4- 69
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CREANER ELEMENT 4- 18
CLEAN INSIDE OF COOLING SYSTEM 4- 24
CHECK AND TIGHTEN TRACK SHOE BOLTS 4- 26
CHECK AND ADJUST TRACK TENSION 4- 27
CHECK ELECTRICAL INTAKE AIR HEATER 4- 29
REPLACE BUCKET TEETH (VERTICAL PIN TYPE) 4- 30
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) 4- 33
ADJUST BUCKET CREARANCE 4- 34