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KOMATSU GALEO PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00054-03) – PDF DOWNLOAD
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- KOMATSU GALEO PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL
- PUBLICATION NUMBER:TEN00054-03
- SERIAL NUMBER:PC40MR-8772 and up
PC50MR-5587 and up
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Description
KOMATSU GALEO PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00054-03)
KOMATSU GALEO PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00054-03) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00054-03)
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.
TABLE OF CONTENTS:
KOMATSU GALEO PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00054-03)
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......................................................................... 26 SAFETY RULES........................................................................... 26 IF PROBLEMS ARE FOUND.................................................................. 26 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS............................................. 26 FIRE EXTINGUISHER AND FIRST AID KIT.................................................... 26 SAFETY EQUIPMENT....................................................................... 27 KEEP MACHINE CLEAN..................................................................... 27 KEEP OPERATOR'S COMPARTMENT CLEAN...................................................... 27 LEAVING OPERATOR'S SEAT WITH LOCK...................................................... 27 HANDRAILS AND STEPS.................................................................... 28 MOUNTING AND DISMOUNTING............................................................... 28 NO PERSONS ON ATTACHMENTS.............................................................. 28 BURN PREVENTION........................................................................ 29 FIRE PREVENTION AND EXPLOSION PREVENTION............................................... 29 ACTION IF FIRE OCCURS.................................................................. 30 WINDSHIELD WASHER FLUID................................................................ 30 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION....................... 31 CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM).................................. 31 ATTACHMENT INSTALLATION................................................................ 32 ATTACHMENT COMBINATIONS................................................................ 32 CAB WINDOW GLASSES..................................................................... 32 UNAUTHORIZED MODIFICATIONS............................................................. 32 SAFETY AT JOBSITE...................................................................... 32 WORKING ON LOOSE GROUND................................................................ 32 DISTANCE TO HIGH VOLTAGE CABLES........................................................ 33 ENSURE GOOD VISIBILITY................................................................. 33 VENTILATION FOR ENCLOSED AREA.......................................................... 33 SIGNALMAN'S SIGNAL AND SIGNS........................................................... 34 EMERGENCY EXIT FROM OPERATOR'S CAB..................................................... 34 ASBESTOS DUST HAZARD PREVENTION........................................................ 34 SAFETY MACHINE OPERATION................................................................... 35 STARTING ENGINE........................................................................ 35 CHECKS BEFORE STARTING ENGINE...................................................... 35 SAFETY RULES FOR STARTING ENGINE................................................... 36 STARTING ENGINE IN COLD WEATHER.................................................... 36 OPERATION.............................................................................. 37 CHECKS BEFORE OPERATION............................................................ 37 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS....................................... 37 SAFETY RULES FOR TRAVELING......................................................... 38 TRAVELING ON SLOPES................................................................ 39 OPERATIONS ON SLOPES............................................................... 40 PROHIBITED OPERATIONS.............................................................. 40 OPERATIONS ON SNOW................................................................. 42 PARKING MACHINE.................................................................... 42 TRANSPORTATION......................................................................... 43 LOADING AND UNLOADING.............................................................. 43 SHIPPING THE MACHINE............................................................... 43 BATTERY................................................................................ 44 BATTERY HAZARD PREVENTION.......................................................... 44 STARTING ENGINE WITH BOOSTER CABLES................................................ 45 TOWING................................................................................. 46 SAFETY RULES FOR TOWING............................................................ 46 LIFTING OBJECTS WITH BUCKET............................................................ 47 SAFETY RULES FOR LIFTING OBJECTS................................................... 47 SAFETY MAINTENANCE INFORMATION............................................................. 48 WARNING TAG............................................................................ 48 KEEP WORK PLACE CLEAN AND TIDY......................................................... 48 APPOINT LEADER WHEN WORKING WITH OTHERS................................................ 48 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE............................................ 49 CAUTIONS FOR OPENING (TILTING) FLOOR................................................... 50 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING..................................... 51 PROPER TOOLS........................................................................... 51 PERSONNEL.............................................................................. 51 ATTACHMENTS............................................................................ 52 WORK UNDER THE MACHINE................................................................. 52 NOISE.................................................................................. 52 WHEN USING HAMMER...................................................................... 52 WELDING WORKS.......................................................................... 52 REMOVING BATTERY TERMINALS............................................................. 53 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION................... 53 DO NOT DISASSEMBLE RECOIL SPRINGS...................................................... 53 SAFETY RULES FOR HIGH-PRESSURE OIL..................................................... 53 SAFETY HANDLING HIGH-PRESSURE HOSES.................................................... 54 WASTE MATERIALS........................................................................ 54 AIR CONDITIONER MAINTENANCE............................................................ 54 COMPRESSED AIR......................................................................... 54 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.......................................... 54 OPERATION...................................................................................... 55 MACHINE VIEW ILLUSTRATIONS................................................................. 56 OVERALL MACHINE VIEW................................................................... 56 CONTROLS AND GAUGES.................................................................... 57 DETAILED CONTROLS AND GAUGES............................................................... 58 MONITORING SYSTEM...................................................................... 58 SWITCHES............................................................................... 66 CONTROL LEVERS AND PEDALS.............................................................. 70 WINDSHIELD............................................................................. 76 SLIDING DOOR........................................................................... 80 SLIDING WINDOW......................................................................... 80 EMERGENCY ESCAPE HAMMER................................................................ 81 COVER WITH LOCK........................................................................ 82 ENGINE REAR COVER...................................................................... 83 COOLING COVER.......................................................................... 83 MUD COVER.............................................................................. 84 METHOD OF OPENING (TILTING) FLOOR...................................................... 85 FUSE................................................................................... 90 BLOCK FUSE............................................................................. 91 AUXILIARY ELECTRIC POWER............................................................... 92 OPERATION MANUAL STORAGE............................................................... 93 TOOL BOX............................................................................... 93 GREASE GUN HOLDER...................................................................... 93 ASHTRAY................................................................................ 93 MACHINE OPERATIONS AND CONTROLS............................................................ 94 BEFORE STARTING ENGINE................................................................. 94 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..............................................................175 WEAR PARTS.................................................................................176 WEAR PARTS LIST........................................................................176 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................177 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....179 TIGHTENING TORQUE SPECIFICATIONS...........................................................180 TIGHTENING TORQUE LIST.................................................................180 SAFETY CRITICAL PARTS......................................................................181 SAFETY CRITICAL PARTS LIST.............................................................181 MAINTENANCE SCHEDULE.......................................................................182 MAINTENANCE SCHEDULE CHART.............................................................182 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.............................................183 MAINTENANCE PROCEDURE......................................................................184 WHEN REQUIRED..........................................................................184 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.......................................184 CLEAN INSIDE OF COOLING SYSTEM.....................................................190 CHECK LEVEL OF BATTERY ELECTROLYTE.................................................193 CLEAN WATER SEPARATOR ELEMENT......................................................195 DRAIN WATER AND SEDIMENT FROM FUEL TANK............................................195 CHECK AND TIGHTEN TRACK SHOE BOLTS.................................................196 CHECK AND ADJUST TRACK TENSION.....................................................197 CHECK, RUBBER SHOES OR ROAD LINERS.................................................199 CHECK AND ADJUST RUBBER SHOE TENSION...............................................201 REPLACE RUBBER SHOES...............................................................203 REPLACE ROAD LINERS................................................................205 REPLACE BUCKET TEETH...............................................................206 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.........................................209 CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER..........................210 LUBRICATING........................................................................210 BLEEDING AIR FROM HYDRAULIC SYSTEM.................................................211 CHECK BEFORE STARTING..................................................................213 EVERY 500 HOURS MAINTENANCE............................................................214 LUBRICATING........................................................................214 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................217 REPLACE FUEL FILTER CARTRIDGE......................................................218 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................220 CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS................................221 CLEAN NET..........................................................................221 CHECK AND ADJUST COOLING FAN BELT TENSION..........................................222 CHECK SWING PINION GREASE LEVEL, ADD GREASE........................................223 EVERY 1000 HOURS MAINTENANCE...........................................................224 REPLACE HYDRAULIC OIL FILTER ELEMENT...............................................224 CHANGE OIL IN FINAL DRIVE CASE.....................................................225 CHECK ENGINE VALVE CLEARANCE, ADJUST...............................................225 EVERY 2000 HOURS MAINTENANCE...........................................................226 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER.......................................226 CHECK ALTERNATOR, STARTING MOTOR...................................................228 SPECIFICATIONS.................................................................................229 SPECIFICATIONS.............................................................................230 ATTACHMENTS, OPTIONS...........................................................................232 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION..............................................233 SAFETY FIRST...........................................................................233 ATTACHMENT INSTALLATION................................................................234 BUCKET WITH HOOK...........................................................................235 PROHIBITED OPERATIONS..................................................................235 AIR CONDITIONER............................................................................236 CONTROL PANEL AND COMPONENTS...........................................................236 AIR CONDITIONER CONTROLS...............................................................237 AIR CONDITIONER MAINTENANCE............................................................238 WINDSHIELD WASHER..........................................................................242 WINDSHIELD WASHER OPERATION............................................................242 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.............................................242 MACHINE READY FOR ATTACHMENT...............................................................243 LOCATIONS..............................................................................243 HYDRAULIC CIRCUIT......................................................................245 ATTACHMENT OPERATIONS..................................................................248 LONG TERM STORAGE......................................................................249 SPECIFICATIONS.........................................................................250 CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)........................251 CONTROL PATTERN CHANGE PROCEDURE.......................................................251 MACHINE CONTROL PATTERNS...............................................................252 POWER ANGLE BLADE..........................................................................253 BLADE CONTROL LEVER....................................................................253 WHEN REQUIRED..........................................................................254 EVERY 500 HOURS SERVICE................................................................254 WEAR PARTS LIST........................................................................255 SPECIFICATIONS.........................................................................255 ATTACHMENT GUIDE...........................................................................256 ATTACHMENT COMBINATIONS................................................................256 RECOMMENDED ATTACHMENT OPERATIONS..........................................................257 HYDRAULIC BREAKER......................................................................257 HIGH-ALTITUDE SPECIFICATION MACHINE............................................................262 LOCATIONS..................................................................................263 MACHINE OPERATIONS AND CONTROLS............................................................264 STARTING ENGINE........................................................................264 WEAR PARTS.................................................................................266 WEAR PARTS LIST........................................................................266 MAINTENANCE PROCEDURE......................................................................267 EVERY 2000 HOURS MAINTENANCE...........................................................267 SPECIFICATIONS.............................................................................268 INDEX..........................................................................................269
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