KOMATSU GALEO PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00193-00) – PDF DOWNLOAD

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KOMATSU GALEO PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00193-00)

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KOMATSU GALEO PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00193-00)

• 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 PC40MR-2 PC50MR-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00193-00)

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............................................................................. 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................................................................... 29
		NO PERSONS ON ATTACHMENTS.................................................................. 29
		BURN PREVENTION............................................................................ 29
		FIRE PREVENTION AND EXPLOSION PREVENTION................................................... 30
		ACTION IF FIRE OCCURS...................................................................... 30
		WINDSHIELD WASHER FLUID.................................................................... 31
		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.......................................................................................... 56
	MACHINE VIEW ILLUSTRATIONS..................................................................... 57
		OVERALL MACHINE VIEW....................................................................... 57
		CONTROLS AND GAUGES........................................................................ 58
	DETAILED CONTROLS AND GAUGES................................................................... 59
		MONITORING SYSTEM.......................................................................... 59
		SWITCHES................................................................................... 67
		CONTROL LEVERS AND PEDALS.................................................................. 71
		WINDSHIELD................................................................................. 77
		SLIDING DOOR............................................................................... 81
		SLIDING WINDOW............................................................................. 81
		EMERGENCY ESCAPE HAMMER.................................................................... 82
		COVER WITH LOCK............................................................................ 83
		ENGINE REAR COVER.......................................................................... 84
		COOLING COVER.............................................................................. 84
		MUD COVER.................................................................................. 85
		METHOD OF OPENING (TILTING) FLOOR.......................................................... 86
		FUSE....................................................................................... 91
		BLOCK FUSE................................................................................. 92
		AUXILIARY ELECTRIC POWER................................................................... 93
		OPERATION MANUAL STORAGE................................................................... 94
		TOOL BOX................................................................................... 94
		GREASE GUN HOLDER.......................................................................... 94
		ASHTRAY.................................................................................... 94
	MACHINE OPERATIONS AND CONTROLS................................................................ 95
		BEFORE STARTING ENGINE..................................................................... 95
		STARTING ENGINE............................................................................109
		AFTER STARTING ENGINE......................................................................113
		STOPPING THE ENGINE........................................................................116
		MACHINE OPERATION..........................................................................117
		STEERING THE MACHINE.......................................................................122
		SWINGING...................................................................................124
		WORK EQUIPMENT CONTROLS AND OPERATIONS.....................................................125
		PROHIBITED OPERATIONS......................................................................127
		GENERAL OPERATION INFORMATION..............................................................129
		TRAVELING ON SLOPES........................................................................130
		ESCAPE FROM MUD............................................................................132
		WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR............................................133
		BUCKET REPLACEMENT.........................................................................135
		PARKING MACHINE............................................................................136
		MACHINE INSPECTION AFTER DAILY WORK........................................................137
		LOCKING....................................................................................138
		RUBBER SHOES AND ROAD LINERS...............................................................139
	TRANSPORTATION.................................................................................144
		TRANSPORTATION PROCEDURE...................................................................144
		LOADING AND UNLOADING WITH TRAILER.........................................................145
		LIFTING MACHINE............................................................................151
	COLD WEATHER OPERATION.........................................................................154
		COLD WEATHER OPERATION INFORMATION.........................................................154
		CAB HEATER IN COLD WEATHER.................................................................155
		AFTER DAILY WORK COMPLETION................................................................156
		AFTER COLD WEATHER SEASON..................................................................156
	LONG TERM STORAGE..............................................................................157
		BEFORE STORAGE.............................................................................157
		DURING STORAGE.............................................................................158
		AFTER STORAGE..............................................................................158
	TROUBLES AND ACTIONS...........................................................................159
		RUNNING OUT OF FUEL........................................................................159
		PHENOMENA THAT ARE NOT FAILURES............................................................159
		TOWING THE MACHINE.........................................................................160
		SEVERE JOB CONDITION.......................................................................160
		DISCHARGED BATTERY.........................................................................161
		OTHER TROUBLE..............................................................................165
MAINTENANCE........................................................................................170
	MAINTENANCE INFORMATION........................................................................171
	OUTLINE OF SERVICE.............................................................................173
		HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....................................173
		ELECTRIC SYSTEM MAINTENANCE................................................................176
		HANDLING HYDRAULIC SYSTEM..................................................................177
	WEAR PARTS.....................................................................................178
		WEAR PARTS LIST............................................................................178
	RECOMMENDED FUEL, COOLANT, AND LUBRICANT.......................................................179
		RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL........181
	TIGHTENING TORQUE SPECIFICATIONS...............................................................182
		TIGHTENING TORQUE LIST.....................................................................182
	SAFETY CRITICAL PARTS..........................................................................183
		SAFETY CRITICAL PARTS LIST.................................................................183
	MAINTENANCE SCHEDULE...........................................................................184
		MAINTENANCE SCHEDULE CHART.................................................................184
		MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.................................................185
	MAINTENANCE PROCEDURE..........................................................................186
		WHEN REQUIRED..............................................................................186
			CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...........................................186
			CLEAN INSIDE OF COOLING SYSTEM.........................................................192
			CHECK LEVEL OF BATTERY ELECTROLYTE.....................................................195
			CLEAN WATER SEPARATOR ELEMENT..........................................................197
			DRAIN WATER AND SEDIMENT FROM FUEL TANK................................................197
			CHECK AND TIGHTEN TRACK SHOE BOLTS (MACHINE EQUIPPED WITH ROAD LINER, STEEL SHOE)......198
			CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH ROAD LINER, STEEL SHOE)..........199
			CHECK, RUBBER SHOES OR ROAD LINERS (MACHINE EQUIPPED WITH RUBBER SHOES, ROAD LINER)....201
			CHECK AND ADJUST RUBBER SHOE TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)..............203
			REPLACE RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)..............................205
			REPLACE ROAD LINERS (MACHINE EQUIPPED WITH ROAD LINER).................................207
			REPLACE BUCKET TEETH...................................................................208
			CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.............................................211
			CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER..............................212
			LUBRICATING............................................................................212
			BLEEDING AIR FROM HYDRAULIC SYSTEM.....................................................213
		CHECK BEFORE STARTING......................................................................215
		EVERY 500 HOURS MAINTENANCE................................................................216
			LUBRICATING............................................................................216
			CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE......................219
			REPLACE FUEL FILTER CARTRIDGE..........................................................220
			CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...........................................222
			CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS....................................223
			CLEAN NET (IF EQUIPPED)................................................................223
			CHECK AND ADJUST COOLING FAN BELT TENSION..............................................224
			CHECK SWING PINION GREASE LEVEL, ADD GREASE............................................225
		EVERY 1000 HOURS MAINTENANCE...............................................................226
			REPLACE HYDRAULIC OIL FILTER ELEMENT...................................................226
			CHANGE OIL IN FINAL DRIVE CASE.........................................................227
			CHECK ENGINE VALVE CLEARANCE, ADJUST...................................................227
		EVERY 2000 HOURS MAINTENANCE...............................................................228
			CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER...........................................228
			CHECK ALTERNATOR, STARTING MOTOR.......................................................230
SPECIFICATIONS.....................................................................................232
	SPECIFICATIONS.................................................................................233
ATTACHMENTS, OPTIONS...............................................................................236
	ATTACHMENTS AND OPTIONS - GENERAL INFORMATION..................................................237
		SAFETY FIRST...............................................................................237
		ATTACHMENT INSTALLATION....................................................................238
	BUCKET WITH HOOK...............................................................................239
		PROHIBITED OPERATIONS......................................................................239
	AIR CONDITIONER................................................................................240
		CONTROL PANEL AND COMPONENTS...............................................................240
		AIR CONDITIONER CONTROLS...................................................................241
		AIR CONDITIONER MAINTENANCE................................................................242
	WINDSHIELD WASHER..............................................................................246
		WINDSHIELD WASHER OPERATION................................................................246
		CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.................................................246
	MACHINE READY FOR ATTACHMENT...................................................................247
		LOCATIONS..................................................................................247
		HYDRAULIC CIRCUIT..........................................................................249
		ATTACHMENT OPERATIONS......................................................................252
		LONG TERM STORAGE..........................................................................253
		SPECIFICATIONS.............................................................................254
	CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)............................255
		CONTROL PATTERN CHANGE PROCEDURE...........................................................255
		MACHINE CONTROL PATTERNS...................................................................256
	POWER ANGLE BLADE..............................................................................257
		BLADE CONTROL LEVER........................................................................257
		WHEN REQUIRED..............................................................................258
		EVERY 500 HOURS SERVICE....................................................................258
		WEAR PARTS LIST............................................................................259
		SPECIFICATIONS.............................................................................259
	ATTACHMENT GUIDE...............................................................................260
		ATTACHMENT COMBINATIONS....................................................................260
	RECOMMENDED ATTACHMENT OPERATIONS..............................................................261
		HYDRAULIC BREAKER..........................................................................261
HIGH-ALTITUDE SPECIFICATION MACHINE................................................................266
	LOCATIONS......................................................................................267
	MACHINE OPERATIONS AND CONTROLS................................................................268
		STARTING ENGINE............................................................................268
	WEAR PARTS.....................................................................................270
		WEAR PARTS LIST............................................................................270
	MAINTENANCE PROCEDURE..........................................................................271
		EVERY 2000 HOURS MAINTENANCE...............................................................271
	SPECIFICATIONS.................................................................................272
INDEX..............................................................................................274

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