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KOMATSU GALEO PC27MR-2 PC35MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00194-00) – PDF DOWNLOAD
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- KOMATSU GALEO PC27MR-2 PC35MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL
- PUBLICATION NUMBER:TEN00194-00
- SERIAL NUMBERS: PC27MR-17902 and up
PC35MR- 9242 and up
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KOMATSU GALEO PC27MR-2 PC35MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00194-00)
KOMATSU GALEO PC27MR-2 PC35MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00194-00) – PDF DOWNLOAD:
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KOMATSU GALEO PC27MR-2 PC35MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00194-00)
- 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.
- 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.
TABLE OF CONTENTS:
KOMATSU GALEO PC27MR-2 PC35MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00194-00)
COVER.............................................................................................. 1 FOREWORD........................................................................................... 2 FOREWORD....................................................................................... 3 SAFETY INFORMATION............................................................................. 6 INTRODUCTION................................................................................... 8 DIRECTIONS OF MACHINE...................................................................... 8 PRODUCT INFORMATION............................................................................ 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE............................... 9 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION................................................ 9 EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION........................................ 10 SERVICE METER LOCATION..................................................................... 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR................................................ 11 CONTENTS........................................................................................... 12 SAFETY............................................................................................. 16 SAFETY INFORMATION............................................................................. 17 SAFETY LABELS.................................................................................. 19 LOCATION OF SAFETY LABELS.................................................................. 19 SAFETY LABELS.............................................................................. 20 SAFETY INFORMATION............................................................................. 25 SAFETY RULES............................................................................... 25 IF PROBLEMS ARE FOUND...................................................................... 25 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS................................................. 25 FIRE EXTINGUISHER AND FIRST AID KIT........................................................ 25 SAFETY EQUIPMENT........................................................................... 26 KEEP MACHINE CLEAN......................................................................... 26 KEEP OPERATOR'S COMPARTMENT CLEAN.......................................................... 26 LEAVING OPERATOR'S SEAT WITH LOCK.......................................................... 26 HANDRAILS AND STEPS........................................................................ 27 MOUNTING AND DISMOUNTING................................................................... 27 NO PERSONS ON ATTACHMENTS.................................................................. 27 BURN PREVENTION............................................................................ 28 FIRE PREVENTION AND EXPLOSION PREVENTION................................................... 28 ACTION IF FIRE OCCURS...................................................................... 29 WINDSHIELD WASHER FLUID.................................................................... 29 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION........................... 30 CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM)...................................... 30 ATTACHMENT INSTALLATION.................................................................... 31 ATTACHMENT COMBINATIONS.................................................................... 31 CAB WINDOW GLASSES......................................................................... 31 UNAUTHORIZED MODIFICATIONS................................................................. 31 SAFETY AT JOBSITE.......................................................................... 31 WORKING ON LOOSE GROUND.................................................................... 31 DISTANCE TO HIGH VOLTAGE CABLES............................................................ 32 ENSURE GOOD VISIBILITY..................................................................... 32 VENTILATION FOR ENCLOSED AREA.............................................................. 32 SIGNALMAN'S SIGNAL AND SIGNS............................................................... 33 EMERGENCY EXIT FROM OPERATOR'S CAB......................................................... 33 ASBESTOS DUST HAZARD PREVENTION............................................................ 33 SAFETY MACHINE OPERATION....................................................................... 34 STARTING ENGINE............................................................................ 34 CHECKS BEFORE STARTING ENGINE.......................................................... 34 SAFETY RULES FOR STARTING ENGINE....................................................... 35 STARTING ENGINE IN COLD WEATHER........................................................ 35 OPERATION.................................................................................. 36 CHECKS BEFORE OPERATION................................................................ 36 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS........................................... 36 SAFETY RULES FOR TRAVELING............................................................. 37 TRAVELING ON SLOPES.................................................................... 38 OPERATIONS ON SLOPES................................................................... 39 PROHIBITED OPERATIONS.................................................................. 39 OPERATIONS ON SNOW..................................................................... 41 PARKING MACHINE........................................................................ 41 TRANSPORTATION............................................................................. 42 LOADING AND UNLOADING.................................................................. 42 SHIPPING THE MACHINE................................................................... 42 BATTERY.................................................................................... 43 BATTERY HAZARD PREVENTION.............................................................. 43 STARTING ENGINE WITH BOOSTER CABLES.................................................... 44 TOWING..................................................................................... 45 SAFETY RULES FOR TOWING................................................................ 45 LIFTING OBJECTS WITH BUCKET................................................................ 46 SAFETY RULES FOR LIFTING OBJECTS....................................................... 46 SAFETY MAINTENANCE INFORMATION................................................................. 47 WARNING TAG................................................................................ 47 KEEP WORK PLACE CLEAN AND TIDY............................................................. 47 APPOINT LEADER WHEN WORKING WITH OTHERS.................................................... 47 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE................................................ 48 CAUTIONS FOR OPENING (TILTING) FLOOR....................................................... 49 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING......................................... 50 PROPER TOOLS............................................................................... 50 PERSONNEL.................................................................................. 50 ATTACHMENTS................................................................................ 51 WORK UNDER THE MACHINE..................................................................... 51 NOISE...................................................................................... 51 WHEN USING HAMMER.......................................................................... 51 WELDING WORKS.............................................................................. 51 REMOVING BATTERY TERMINALS................................................................. 52 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION....................... 52 DO NOT DISASSEMBLE RECOIL SPRINGS.......................................................... 52 SAFETY RULES FOR HIGH-PRESSURE OIL......................................................... 52 SAFETY HANDLING HIGH-PRESSURE HOSES........................................................ 53 WASTE MATERIALS............................................................................ 53 AIR CONDITIONER MAINTENANCE................................................................ 53 COMPRESSED AIR............................................................................. 53 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.............................................. 53 OPERATION.......................................................................................... 54 MACHINE VIEW ILLUSTRATIONS..................................................................... 55 OVERALL MACHINE VIEW....................................................................... 55 CONTROLS AND GAUGES........................................................................ 56 DETAILED CONTROLS AND GAUGES................................................................... 57 MONITORING SYSTEM.......................................................................... 57 SWITCHES................................................................................... 65 CONTROL LEVERS AND PEDALS.................................................................. 69 WINDSHIELD................................................................................. 75 SLIDING DOOR............................................................................... 79 SLIDING WINDOW............................................................................. 79 EMERGENCY ESCAPE HAMMER.................................................................... 80 COVER WITH LOCK............................................................................ 81 ENGINE REAR COVER.......................................................................... 82 COOLING COVER.............................................................................. 82 MUD COVER.................................................................................. 83 METHOD OF OPENING (TILTING) FLOOR.......................................................... 84 FUSE....................................................................................... 90 BLOCK FUSE................................................................................. 91 OPERATION MANUAL STORAGE................................................................... 92 TOOL BOX................................................................................... 92 ASHTRAY.................................................................................... 92 MACHINE OPERATIONS AND CONTROLS................................................................ 93 BEFORE STARTING ENGINE..................................................................... 93 STARTING ENGINE............................................................................108 AFTER STARTING ENGINE......................................................................112 STOPPING THE ENGINE........................................................................115 MACHINE OPERATION..........................................................................116 STEERING THE MACHINE.......................................................................121 SWINGING...................................................................................123 WORK EQUIPMENT CONTROLS AND OPERATIONS.....................................................124 PROHIBITED OPERATIONS......................................................................126 GENERAL OPERATION INFORMATION..............................................................128 TRAVELING ON SLOPES........................................................................129 ESCAPE FROM MUD............................................................................131 WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR............................................132 BUCKET REPLACEMENT.........................................................................134 PARKING MACHINE............................................................................135 MACHINE INSPECTION AFTER DAILY WORK........................................................136 LOCKING....................................................................................137 RUBBER SHOES AND ROAD LINERS...............................................................138 TRANSPORTATION.................................................................................143 TRANSPORTATION PROCEDURE...................................................................143 LOADING AND UNLOADING WITH TRAILER.........................................................144 LIFTING MACHINE............................................................................150 COLD WEATHER OPERATION.........................................................................153 COLD WEATHER OPERATION INFORMATION.........................................................153 CAB HEATER IN COLD WEATHER.................................................................154 AFTER DAILY WORK COMPLETION................................................................155 AFTER COLD WEATHER SEASON..................................................................155 LONG TERM STORAGE..............................................................................156 BEFORE STORAGE.............................................................................156 DURING STORAGE.............................................................................157 AFTER STORAGE..............................................................................157 TROUBLES AND ACTIONS...........................................................................158 RUNNING OUT OF FUEL........................................................................158 PHENOMENA THAT ARE NOT FAILURES............................................................158 TOWING THE MACHINE.........................................................................159 SEVERE JOB CONDITION.......................................................................159 DISCHARGED BATTERY.........................................................................160 OTHER TROUBLE..............................................................................164 MAINTENANCE........................................................................................168 MAINTENANCE INFORMATION........................................................................169 OUTLINE OF SERVICE.............................................................................171 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....................................171 ELECTRIC SYSTEM MAINTENANCE................................................................174 HANDLING HYDRAULIC SYSTEM..................................................................174 WEAR PARTS.....................................................................................175 WEAR PARTS LIST............................................................................175 RECOMMENDED FUEL, COOLANT, AND LUBRICANT.......................................................176 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL........178 TIGHTENING TORQUE SPECIFICATIONS...............................................................179 TIGHTENING TORQUE LIST.....................................................................179 SAFETY CRITICAL PARTS..........................................................................180 SAFETY CRITICAL PARTS LIST.................................................................180 MAINTENANCE SCHEDULE...........................................................................181 MAINTENANCE SCHEDULE CHART.................................................................181 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.................................................182 MAINTENANCE PROCEDURE..........................................................................183 WHEN REQUIRED..............................................................................183 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...........................................183 CLEAN INSIDE OF COOLING SYSTEM.........................................................186 CHECK LEVEL OF BATTERY ELECTROLYTE.....................................................190 CLEAN WATER SEPARATOR ELEMENT..........................................................192 DRAIN WATER AND SEDIMENT FROM FUEL TANK................................................192 CHECK AND TIGHTEN TRACK SHOE BOLTS (MACHINE EQUIPPED WITH ROAD LINER)..................193 CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH ROAD LINER, STEEL SHOE)..........194 CHECK, RUBBER SHOES OR ROAD LINERS (MACHINE EQUIPPED WITH RUBBER SHOES, ROAD LINER)....196 CHECK AND ADJUST RUBBER SHOE TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)..............198 REPLACE RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)..............................200 REPLACE ROAD LINERS (MACHINE EQUIPPED WITH ROAD LINER).................................202 REPLACE BUCKET TEETH...................................................................203 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.............................................206 CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER..............................207 LUBRICATING............................................................................207 BLEEDING AIR FROM HYDRAULIC SYSTEM.....................................................208 CHECK BEFORE STARTING......................................................................210 EVERY 500 HOURS MAINTENANCE................................................................211 LUBRICATING............................................................................211 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE......................214 REPLACE FUEL FILTER CARTRIDGE..........................................................215 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...........................................217 CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS....................................218 CHECK AND ADJUST COOLING FAN BELT TENSION..............................................219 EVERY 1000 HOURS MAINTENANCE...............................................................220 REPLACE HYDRAULIC OIL FILTER ELEMENT...................................................220 CHANGE OIL IN FINAL DRIVE CASE.........................................................221 CHECK ENGINE VALVE CLEARANCE, ADJUST...................................................221 EVERY 2000 HOURS MAINTENANCE...............................................................222 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER...........................................222 CHECK ALTERNATOR, STARTING MOTOR.......................................................224 SPECIFICATIONS.....................................................................................226 SPECIFICATIONS.................................................................................227 ATTACHMENTS, OPTIONS...............................................................................230 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION..................................................231 SAFETY FIRST...............................................................................231 ATTACHMENT INSTALLATION....................................................................232 BUCKET WITH HOOK...............................................................................233 PROHIBITED OPERATIONS......................................................................233 AIR CONDITIONER................................................................................234 CONTROL PANEL AND COMPONENTS...............................................................234 AIR CONDITIONER CONTROLS...................................................................235 AIR CONDITIONER MAINTENANCE................................................................236 WINDSHIELD WASHER..............................................................................240 WINDSHIELD WASHER OPERATION................................................................240 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.................................................240 MACHINE READY FOR ATTACHMENT...................................................................241 LOCATIONS..................................................................................241 HYDRAULIC CIRCUIT..........................................................................243 ATTACHMENT OPERATIONS......................................................................245 LONG TERM STORAGE..........................................................................246 SPECIFICATIONS.............................................................................246 CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)............................247 CONTROL PATTERN CHANGE PROCEDURE...........................................................247 MACHINE CONTROL PATTERNS...................................................................248 POWER ANGLE BLADE..............................................................................249 BLADE CONTROL LEVER........................................................................249 WHEN REQUIRED..............................................................................250 EVERY 500 HOURS SERVICE....................................................................250 WEAR PARTS LIST............................................................................251 SPECIFICATIONS.............................................................................251 ATTACHMENT GUIDE...............................................................................252 ATTACHMENT COMBINATIONS....................................................................252 RECOMMENDED ATTACHMENT OPERATIONS..............................................................253 HYDRAULIC BREAKER..........................................................................253 HIGH-ALTITUDE SPECIFICATION MACHINE................................................................258 LOCATIONS......................................................................................259 MAINTENANCE PROCEDURE..........................................................................260 EVERY 2000 HOURS MAINTENANCE...............................................................260 SPECIFICATIONS.................................................................................261 INDEX..............................................................................................262
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⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
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