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Komatsu PC27MR-2, PC35MR-2 Galeo Hydraulic Excavator Operation & Maintenance Manual – PDF Download
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Komatsu PC27MR-2, PC35MR-2 Galeo Hydraulic Excavator Operation & Maintenance Manual
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Description
Komatsu PC27MR-2, PC35MR-2 Galeo Hydraulic Excavator Operation & Maintenance Manual
Description:
Komatsu PC27MR-2, PC35MR-2 Galeo Hydraulic Excavator Operation & Maintenance Manual
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 PC27MR-2, PC35MR-2 Galeo Hydraulic Excavator Operation & Maintenance Manual
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.......................................................................................... 15 SAFETY INFORMATION.......................................................................... 16 SAFETY LABELS............................................................................... 18 LOCATION OF SAFETY LABELS............................................................... 18 SAFETY LABELS........................................................................... 19 SAFETY INFORMATION.......................................................................... 24 SAFETY RULES............................................................................ 24 IF PROBLEMS ARE FOUND................................................................... 24 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS.............................................. 24 FIRE EXTINGUISHER AND FIRST AID KIT..................................................... 24 SAFETY EQUIPMENT........................................................................ 25 KEEP MACHINE CLEAN...................................................................... 25 KEEP OPERATOR'S COMPARTMENT CLEAN....................................................... 25 LEAVING OPERATOR'S SEAT WITH LOCK....................................................... 25 HANDRAILS AND STEPS..................................................................... 26 MOUNTING AND DISMOUNTING................................................................ 26 NO PERSONS ON ATTACHMENTS............................................................... 26 BURN PREVENTION......................................................................... 27 FIRE PREVENTION AND EXPLOSION PREVENTION................................................ 27 ACTION IF FIRE OCCURS................................................................... 28 WINDSHIELD WASHER FLUID................................................................. 28 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION........................ 29 CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM)................................... 29 ATTACHMENT INSTALLATION................................................................. 30 ATTACHMENT COMBINATIONS................................................................. 30 CAB WINDOW GLASSES...................................................................... 30 UNAUTHORIZED MODIFICATIONS.............................................................. 30 SAFETY AT JOBSITE....................................................................... 30 WORKING ON LOOSE GROUND................................................................. 30 DISTANCE TO HIGH VOLTAGE CABLES......................................................... 31 ENSURE GOOD VISIBILITY.................................................................. 31 VENTILATION FOR ENCLOSED AREA........................................................... 31 SIGNALMAN'S SIGNAL AND SIGNS............................................................ 32 EMERGENCY EXIT FROM OPERATOR'S CAB...................................................... 32 ASBESTOS DUST HAZARD PREVENTION......................................................... 32 SAFETY MACHINE OPERATION.................................................................... 33 STARTING ENGINE......................................................................... 33 CHECKS BEFORE STARTING ENGINE....................................................... 33 SAFETY RULES FOR STARTING ENGINE.................................................... 34 STARTING ENGINE IN COLD WEATHER..................................................... 34 OPERATION............................................................................... 35 CHECKS BEFORE OPERATION............................................................. 35 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS........................................ 35 SAFETY RULES FOR TRAVELING.......................................................... 36 TRAVELING ON SLOPES................................................................. 37 OPERATIONS ON SLOPES................................................................ 38 PROHIBITED OPERATIONS............................................................... 38 OPERATIONS ON SNOW.................................................................. 40 PARKING MACHINE..................................................................... 40 TRANSPORTATION.......................................................................... 41 LOADING AND UNLOADING............................................................... 41 SHIPPING THE MACHINE................................................................ 41 BATTERY................................................................................. 42 BATTERY HAZARD PREVENTION........................................................... 42 STARTING ENGINE WITH BOOSTER CABLES................................................. 43 TOWING.................................................................................. 44 SAFETY RULES FOR TOWING............................................................. 44 LIFTING OBJECTS WITH BUCKET............................................................. 45 SAFETY RULES FOR LIFTING OBJECTS.................................................... 45 SAFETY MAINTENANCE INFORMATION.............................................................. 46 WARNING TAG............................................................................. 46 KEEP WORK PLACE CLEAN AND TIDY.......................................................... 46 APPOINT LEADER WHEN WORKING WITH OTHERS................................................. 46 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE............................................. 47 CAUTIONS FOR OPENING (TILTING) FLOOR.................................................... 48 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...................................... 49 PROPER TOOLS............................................................................ 49 PERSONNEL............................................................................... 49 ATTACHMENTS............................................................................. 50 WORK UNDER THE MACHINE.................................................................. 50 NOISE................................................................................... 50 WHEN USING HAMMER....................................................................... 50 WELDING WORKS........................................................................... 50 REMOVING BATTERY TERMINALS.............................................................. 51 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION.................... 51 DO NOT DISASSEMBLE RECOIL SPRINGS....................................................... 51 SAFETY RULES FOR HIGH-PRESSURE OIL...................................................... 51 SAFETY HANDLING HIGH-PRESSURE HOSES..................................................... 52 WASTE MATERIALS......................................................................... 52 AIR CONDITIONER MAINTENANCE............................................................. 52 COMPRESSED AIR.......................................................................... 52 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS........................................... 52 OPERATION....................................................................................... 53 MACHINE VIEW ILLUSTRATIONS.................................................................. 54 OVERALL MACHINE VIEW.................................................................... 54 CONTROLS AND GAUGES..................................................................... 55 DETAILED CONTROLS AND GAUGES................................................................ 56 MONITORING SYSTEM....................................................................... 56 SWITCHES................................................................................ 64 CONTROL LEVERS AND PEDALS............................................................... 68 WINDSHIELD.............................................................................. 74 SLIDING DOOR............................................................................ 78 SLIDING WINDOW.......................................................................... 78 EMERGENCY ESCAPE HAMMER................................................................. 79 COVER WITH LOCK......................................................................... 80 ENGINE REAR COVER....................................................................... 81 COOLING COVER........................................................................... 81 MUD COVER............................................................................... 82 METHOD OF OPENING (TILTING) FLOOR....................................................... 83 FUSE.................................................................................... 88 BLOCK FUSE.............................................................................. 89 OPERATION MANUAL STORAGE................................................................ 90 TOOL BOX................................................................................ 90 GREASE GUN HOLDER....................................................................... 90 ASHTRAY................................................................................. 90 MACHINE OPERATIONS AND CONTROLS............................................................. 91 BEFORE STARTING ENGINE.................................................................. 91 STARTING ENGINE.........................................................................106 AFTER STARTING ENGINE...................................................................110 STOPPING THE ENGINE.....................................................................113 MACHINE OPERATION.......................................................................114 STEERING THE MACHINE....................................................................119 SWINGING................................................................................121 WORK EQUIPMENT CONTROLS AND OPERATIONS..................................................122 PROHIBITED OPERATIONS...................................................................124 GENERAL OPERATION INFORMATION...........................................................126 TRAVELING ON SLOPES.....................................................................128 ESCAPE FROM MUD.........................................................................130 WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR.........................................131 BUCKET REPLACEMENT......................................................................133 PARKING MACHINE.........................................................................134 MACHINE INSPECTION AFTER DAILY WORK.....................................................135 LOCKING.................................................................................136 RUBBER SHOES AND ROAD LINERS............................................................137 TRANSPORTATION..............................................................................142 TRANSPORTATION PROCEDURE................................................................142 LOADING AND UNLOADING WITH TRAILER......................................................143 LIFTING MACHINE.........................................................................149 COLD WEATHER OPERATION......................................................................152 COLD WEATHER OPERATION INFORMATION......................................................152 CAB HEATER IN COLD WEATHER..............................................................153 AFTER DAILY WORK COMPLETION.............................................................154 AFTER COLD WEATHER SEASON...............................................................154 LONG TERM STORAGE...........................................................................155 BEFORE STORAGE..........................................................................155 DURING STORAGE..........................................................................156 AFTER STORAGE...........................................................................156 TROUBLES AND ACTIONS........................................................................157 RUNNING OUT OF FUEL.....................................................................157 PHENOMENA THAT ARE NOT FAILURES.........................................................157 TOWING THE MACHINE......................................................................158 SEVERE JOB CONDITION....................................................................158 DISCHARGED BATTERY......................................................................159 OTHER TROUBLE...........................................................................163 MAINTENANCE.....................................................................................166 MAINTENANCE INFORMATION.....................................................................167 OUTLINE OF SERVICE..........................................................................169 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC..................................169 ELECTRIC SYSTEM MAINTENANCE.............................................................172 HANDLING HYDRAULIC SYSTEM...............................................................172 WEAR PARTS..................................................................................173 WEAR PARTS LIST.........................................................................173 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS.................................................174 TIGHTENING TORQUE SPECIFICATIONS............................................................178 TIGHTENING TORQUE LIST..................................................................178 SAFETY CRITICAL PARTS.......................................................................179 SAFETY CRITICAL PARTS LIST..............................................................179 MAINTENANCE SCHEDULE........................................................................180 MAINTENANCE SCHEDULE CHART..............................................................180 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER..............................................181 MAINTENANCE PROCEDURE.......................................................................182 WHEN REQUIRED...........................................................................182 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT........................................182 CLEAN INSIDE OF COOLING SYSTEM......................................................185 CHECK LEVEL OF BATTERY ELECTROLYTE..................................................189 CLEAN WATER SEPARATOR ELEMENT.......................................................191 DRAIN WATER AND SEDIMENT FROM FUEL TANK.............................................191 CHECK AND TIGHTEN TRACK SHOE BOLTS (MACHINE EQUIPPED WITH ROAD LINER)...............192 CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH ROAD LINER,STEEL SHOE)........193 CHECK,RUBBER SHOES OR ROAD LINERS(MACHINE EQUIPPED WITH RUBBER SHOES,ROAD LINER)....195 CHECK AND ADJUST RUBBER SHOE TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)...........197 REPLACE RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)...........................199 REPLACE ROAD LINERS(MACHINE EQUIPPED WITH ROAD LINER)...............................201 REPLACE BUCKET TEETH................................................................202 CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID...........................................205 CHECK,CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER............................206 LUBRICATING.........................................................................206 BLEEDING AIR FROM HYDRAULIC SYSTEM..................................................207 CHECK BEFORE STARTING...................................................................209 EVERY 500 HOURS MAINTENANCE.............................................................210 LUBRICATING.........................................................................210 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...................213 REPLACE FUEL FILTER CARTRIDGE.......................................................214 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL........................................216 CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS.................................217 CHECK AND ADJUST COOLING FAN BELT TENSION...........................................218 EVERY 1000 HOURS MAINTENANCE............................................................219 REPLACE HYDRAULIC OIL FILTER ELEMENT................................................219 CHANGE OIL IN FINAL DRIVE CASE......................................................220 CHECK ENGINE VALVE CLEARANCE, ADJUST................................................220 EVERY 2000 HOURS MAINTENANCE............................................................221 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER........................................221 CHECK ALTERNATOR, STARTING MOTOR....................................................223 SPECIFICATIONS..................................................................................224 SPECIFICATIONS..............................................................................225 ATTACHMENTS, OPTIONS............................................................................227 ATTACHMENTS AND OPTIONS-GENERAL INFORMATION.................................................228 SAFETY FIRST............................................................................228 ATTACHMENT INSTALLATION.................................................................229 BUCKET WITH HOOK............................................................................230 PROHIBITED OPERATIONS...................................................................230 AIR CONDITIONER.............................................................................231 CONTROL PANEL AND COMPONENTS............................................................231 AIR CONDITIONER CONTROLS................................................................232 AIR CONDITIONER MAINTENANCE.............................................................233 WINDSHIELD WASHER...........................................................................237 WINDSHIELD WASHER OPERATION.............................................................237 CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID...............................................237 MACHINE READY FOR ATTACHMENT................................................................238 LOCATIONS...............................................................................238 HYDRAULIC CIRCUIT.......................................................................240 ATTACHMENT OPERATIONS...................................................................242 LONG TERM STORAGE.......................................................................243 SPECIFICATIONS..........................................................................243 CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED).........................244 CONTROL PATTERN CHANGE PROCEDURE........................................................244 MACHINE CONTROL PATTERNS................................................................245 POWER ANGLE BLADE...........................................................................246 BLADE CONTROL LEVER.....................................................................246 WHEN REQUIRED...........................................................................247 EVERY 500 HOURS SERVICE.................................................................247 WEAR PARTS LIST.........................................................................248 SPECIFICATIONS..........................................................................248 ATTACHMENT GUIDE............................................................................249 ATTACHMENT COMBINATIONS.................................................................249 RECOMMENDED ATTACHMENT OPERATIONS...........................................................250 HYDRAULIC BREAKER.......................................................................250 HIGH-ALTITUDE SPECIFICATION MACHINE.............................................................255 LOCATIONS...................................................................................256 MAINTENANCE PROCEDURE.......................................................................257 EVERY 2000 HOURS MAINTENANCE............................................................257 SPECIFICATIONS..............................................................................258 INDEX...........................................................................................259
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KOMATSU PC27MR-2, PC35MR-2 GALEO HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:
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