Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC27MRX, PC30MRX, PC35MRX, PC40MRX, PC45MRX, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC27MRX-1, PC30MRX-1, PC35MRX-1, PC40MRX-1, PC45MRX-1 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEBM016808 – Hydraulic Excavators PC27MRX-1, PC30MRX-1, PC35MRX-1, PC40MRX-1, PC45MRX-1 Shop Manual.pdf
SEAM035305T – Hydraulic Excavator PC27MR-x1, PC30MR-x1, PC35MR-x1 Operation & Maintenance Manual.pdf
SEAM043000 – Hydraulic Excavator PC40MRx-1, PC45MRx-1 Operation & Maintenance Manual.pdf
SEAM043006T – Hydraulic Excavator PC40MRx-1, PC45MRx-1 Operation & Maintenance Manual.pdf
SEAM055301T – Hydraulic Excavator GALEO PC40MR-2, PC50MR-2 Operation & Maintenance Manual.pdf
TEN00054-03 – Hydraulic Excavator GALEO PC40MR-2, PC50MR-2 Operation & Maintenance Manual.pdf
TEN00193-00 – Hydraulic Excavator GALEO PC40MR-2, PC50MR-2 Operation & Maintenance Manual.pdf
Total Pages: 2,477 pages
File Format: PDF
Language: English
SEAM035305T – Hydraulic Excavator PC27MR-x1, PC30MR-x1, PC35MR-x1 Operation & Maintenance Manual…2
COVER…2
FOREWORD…3
FOREWORD…4
SAFETY INFORMATION…7
INTRODUCTION…9
DIRCTIONS OF MACHINE…9
PRODUCT INFORMATION…10
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…10
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…10
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…11
SERVICE METER LOCATION…11
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…12
CONTENTS…13
SAFETY…16
SAFETY INFORMATION…17
SAFETY LABELS…19
LOCATION OF SAFETY LABELS…19
SAFETY LABELS…20
SAFETY INFORMATION…25
SAFTY RULES…25
IF ABNORMALITIES ARE FOUND…25
WORKING WEAR AND PERSONAL PROTECTIVE LTEMS…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…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 ARES…32
SIGNALMAN'S SIGNAL AND SIGNS…32
EMERGENCY EXIT FROM OPERATOR'S CAB…32
ASBESTOS DUST HAZARD PREVENTION…32
SAFETY MACHINE OPREATION…33
STARTING ENGINE…33
CHECKS BEFORE STARTING ENGINE…33
SAFETY RULES FOR STARTING ENGINE…33
STARTING ENGINE IN CILD 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…39
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
TOWINE…44
SAFETY RULES FOR TOWING…44
LIFTING OBJECTS WITH BUCKET…45
SAFETY RULES FOR LIFTING OBJECTS…45
SAFETY MACHINE INFORMATION…46
WARNING TAG…46
KEEP WORK PLACE CLEAN AN TIDY…46
APPOINT LEADER WHEN WORKING WITH OTHERS…46
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…47
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…48
PROPER TOOLS…48
ACCUMULATOR…49
PERSONNEL…49
ATTACHMENTS…49
WORK UNDER TE MACHINE…49
NOISE…49
WHEN USING HARMMER…50
WELDING WORKS…50
REMOVING BATTERY TERMINALS…50
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…50
DO NOT DISASSEMBLE RECOIL SPRINGS…50
SAFETY RULES FOR HIGH-PRSSURE OIL…51
SAFETY HANDLING HIGH-PRESSURE HOSES…51
WASTE MATERIALS…51
AIR CONDITIONER MAINTENANCE…52
COMPRESSED AIR…52
PERIODIC REPLACEMENT OF SAFETY CIRTICAL 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…62
CONTROL LEVERS AND PEDALS…65
WINSHIELD…70
SLIDING DOOR…74
REAR WINDOW…75
EMERGENCY ESCAPE HAMMER…76
COVER WITH LOCK…77
ENGINE HOOD…78
FUSE…79
BLOCK FUSE…79
OPERATION MANUAL STORAGE …80
TOOL BOX…80
GRASE GUN HOLDER…80
MACHINE OPERATIONS AND COTROLS…81
BEFORE STARTING ENGINE…81
STARTING ENGINE…93
AFTER STARTING ENGINE…96
STOPPING THE ENGINE…99
CHECK AFTER SHUT OFF ENGINE…99
MACHINE OPERATION…100
STEERING THE MACHINE…104
SWINGING…106
WORK EQUIPMENT CONTROLS AND OPERATIONS…107
PROHIBITED OPERATIONS …109
GENERAL OPERATION INFORMATION…112
TRAVELING ON SLOPES…113
ESCAPE FROM MUD…115
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…116
BUCKET REPLACEMENT…118
PARKING MACHINE…119
MACHINE INSPECTION AFTER DAILY WORK…120
LOCKING…121
RUBBER SHOES AND ROAD LINERS…122
TRANSPORTATION…127
TRANSPOTRATION PROCEDURE…127
LOADING AND UNLOADING WITH TRAILERS…127
LIFTING MACHINE…132
COLD WEATHER OPERATION…134
COLD WEATHER OPERATION INFORMATION…134
CAB HEATER COLD WEATHER…135
AFTER DAILY WORK COMPLETION…136
AFTER COLD WEATHER SEASON…136
LONG TERM STORAGE…137
BEFORE STORAGE…137
DURING STORAGE…138
AFTER STORAGE…138
STARTING MACHINE AFTER LONG-TERM STORAGE…138
TROUBLES AND ACTIONS…139
RUNNING OUT OF FUEL…139
PHENOMENA THAT ARE NOT FAILURES…139
TOWING THE MACHINE…140
SEVERE JOB CONDITION …140
DISCHARGED BATTERY…141
OTHER TROUBLE…145
MAINTENANCE…149
MAINTENANCE INFORMATION…150
LUBRICANTS, COOLANT AND FILTERS…152
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…152
ELECTRIC SYSTEM MAINTENANCE…155
WEAR PARTS…156
WEAR PARTS LIST…156
LUBRCANTS, FUEL AND COOLANT SPECIFICATIONS…157
PROPER SELECTION…157
TIGHTENING TORQUE SPECIFICATIONS…161
TIGHTENING TORQUE LIST…161
SAFETY CRITICAL PARTS…162
SAFETY CRITICAL PARTS LIST…162
MAINTENANCE SCHEDULE…163
MAINTENANCE SCHEDULE CHART…163
MAINTENANCE INTERVAL FOR HYDRAURIC BREAKER…164
MAINTENANCE PROCEDURE…165
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) …165
REPLACE ENGINE OIL FILTER CARTRIDGE…165
REPLACE FUEL FILTER ELEMENT…165
CHECK ENGINE VALVE CLEARANCE, ADJUST…165
WHEN REQUIPED…166
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…166
CLEAN INSIDE OF COOLING SYSTEM…169
CHECK BATTERY ELECTROLYTE LEVEL…172
CLEAN FUEL FILTER ELEMENT…175
CHECK AND TIGHTEN TRACK SHOE BOLTS…176
CHECK AND ADJUST TRACK TENSION …177
CHECK, RUBBER SHOES OR ROAD LINERS…179
CHECK AND ADJUST RUBBER SHOE TENSION …181
REPLACE RUBBER SHOES…183
REPLACE ROAD LINERS…186
REPLACE BUCKET TEETH…187
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…190
DRAIN WATER AND SEDIMENT FROM FUEL TANK…191
BLEEDING AIR…191
CHECK BEFORE STARTING…192
EVERY 100 HOURS MAINTENANCE…193
LUBRICATING…193
EVERY 250 HOURS MANTENANCE…195
REPLACE ENGINE OIL IN ENINE OIL PAN…195
CHECK OIL LEVEL IN FINAL DRIVE CASES, ADD OIL…196
REPLACE HYDRAULIC FILTER ELEMENT…197
CHECK AND ADJUST COOLING FAN BELT TENSION…199
EVERY 500 HOURS MANTENANCE…200
LUBRICATION…200
REPLACE ENGINE OIL FILTER CARTRIDGE…201
REPLACE FUEL FILTER ELEMENT…202
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…203
REPLACE FUEL FEED PUMP PRE-FILTER…204
EVERY 1000 HOURS MANTENANCE…205
CHANGE OIL IN FINAL DRIVE CASE…205
EVERY 2000 HOURS MANTENANCE…206
CHANGE OIL IN HYDRAURIC TANK, CLEAN STRAINER…206
CHECK ALTERNATOR, STARTING MOTOR…208
CHECK ENGINE VALVE CLEARANCES,ADJUST…208
SPECIFICATIONS…209
SPECIFICATIONS…210
ATTACHMENTS, OPTIONS…212
ATTACHMENTS AND OPTIONS-GENERAL INFORMATION…213
SAFETY FIRST…213
ATTACHMENT INSTALLATION…214
BUCKET WITH HOOK…215
HOOK CONDITION…215
PROHIBITED OPERATIONS…215
AIR CONDITIONER…216
CONTROL PANEL AND COMPONENTS…216
AIR CONDITIONER CONTROLS…218
AIR CONDITIONER MAINTENANCE…219
RADIO…222
CONTROL PANEL…222
CONTROLS OF RADIO…225
CARE FOR RADIO…226
WINDSHIELD WASHER…227
WINDSHIELD WASHER OPERATION…227
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…227
MACHINE READY FOR ATTACHMENT…228
LOCATIONS…228
HYDRAULIC CIRCUIT…230
ATTACHMENT OPERATONS…232
LONG TERM STORAGE …233
SPECIRCATIONS…233
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…234
CONTROL PATTREN CHANGE PROCEDURE…234
MACHINE CONTROL PATTERNS…235
ATTACHMENT GUIDE…236
ATTACHMENT COMBINATIONS…237
HYDRAULIC BREAKER…238
INDEX…241
SEAM043000 – Hydraulic Excavator PC40MRx-1, PC45MRx-1 Operation & Maintenance Manual…244
COVER…244
FOREWORD…245
FOREWORD…246
SAFETY INFORMATION…249
INTRODUCTION…251
DIRECTIONS OF MACHINE…251
PRODUCT INFORMATION…252
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…252
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…252
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…253
SERVICE METER LOCATION…253
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…254
CONTENTS…255
SAFETY…258
SAFETY INFORMATION…259
WARNING LABELS AND PICTOGRAMS…261
WARNING LABELS AND PICTOGRAMS – LOCATION…262
WARNING LABELS AND PICTOGRAMS – ACTUAL…263
SAFETY INFORMATION…269
SAFETY MACHINE OPERATION…277
STARTING ENGINE…277
OPERATION…279
TRANSPORTATION…285
BATTERY…286
TOWING…288
LIFTING OBJECTS WITH BUCKET…289
SAFETY MAINTENANCE INFORMATION…290
OPERATION…296
MACHINE VIEW ILLUSTRATIONS…297
OVERALL MACHINE VIEW…297
CONTROLS AND GAUGES…298
DETAILED CONTROL AND GAUGES…299
MONITORING SYSTEM…299
SWITCHES…304
CONTROL LEVERS AND PEDALS…307
WINDSHEILD…312
SLIDING DOOR…315
SLIDING WINDOW…316
REAR WINDOW…316
EMERGENCY ESCAPE HAMMER…317
CAP WITH LOCK…318
ENGINE HOOD…319
MUD COVER…320
FUSE…321
BLOCK FUSE…321
AUXILARY ELECTRIC POWER…322
OPERATION MANUAL STORAGE…322
TOOL BOX…322
GREASE PUMP HOLDER…323
ASHTRAY…323
MACHINE OPERATIONS AND CONTROLS…324
BEFORE STARTING ENGINE…324
STARTING ENGINE…338
AFTER STARTING ENGINE…341
STOPPING THE ENGINE…343
CHECK AFTER SHUT OFF ENGINE…343
MACHINE OPERATION…344
STEERING THE MACHINE…348
SWINGING…350
WORK EQUIPMENT CONTROLS AND OPERATIONS…351
PROHIBITED OPERATIONS…353
GENERAL OPERATION INFORMATION…355
TRAVELING ON SLOPES…357
ESCAPE FROM MUD…359
RECOMMENDED APPLICATIONS …360
BUCKET REPLACEMENT…362
PARKING MACHINE…363
MACHINE INSPECTION AFTER DAILY WORK…364
LOCKING…364
RUBBER SHOES AND ROAD LINERS…365
TRANSPORTATION…370
TRANSPORTATION PROCEDURE…370
LOADING AND UNLOADING WITH TRAILER…370
LIFTING MACHINE…375
COLD WEATHER OPERATION…377
COLD WEATHER OPERATION INFORMATION…377
CAB HEATER IN COLD WEATHER…378
AFTER DAILY WORK COMPLETION…379
AFTER COLD WEATHER SEASON…379
LONG TERM STORAGE…380
BEFORE STORAGE…380
DURING STORAGE…380
AFTER STORAGE…381
TROUBLES AND ACTIONS…382
RUNNING OUT OF FUEL…382
PHENOMENA THAT ARE NOT FAILURES…382
TOWING THE MACHINE…382
SEVERE JOB CONDITION…383
DISCHARGED BATTERY…383
OTHER TROUBLE…387
MAINTENANCE…392
MAINTENANCE INFORMATION…393
LUBRICANTS, COOLANT AND FILTERS…395
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…395
ELECTRIC SYSTEM MAINTENANCE…397
WEAR PARTS…398
WEAR PARTS LIST…398
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…399
PROPER SELECTION…399
TIGHTENING TORQUE SPECIFICATIONS…403
TIGHTENING TORQUE LIST…403
SAFETY CRITICAL PARTS…404
SAFETY CRITICAL PARTS LIST…404
MAINTENANCE SCHEDULE…405
MAINTENANCE SCHEDULE CHART…405
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…406
MAINTENANCE PROCEDURE…407
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…407
WHEN REQUIRED…408
CHECK BEFORE STARTING…431
EVERY 100 HOURS MAINTENANCE…432
EVERY 250 HOURS MAINTENANCE…433
EVERY 500 HOURS MAINTENANCE…439
EVERY 1000 HOURS MAINTENANCE…444
EVERY 2000 HOURS MAINTENANCE…445
SPECIFICATIONS…448
SPECIFICATIONS…449
ATTACHMENTS AND OPTIONS…452
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…453
SAFETY FIRST…453
ATTACHMENT INSTALLATION…454
BUCKET WITH HOOK…455
HOOK CONDITION…455
PROHIBITED OPERATIONS…455
DEFROSTER CONTROLS…456
CONTROL PANEL…456
MACHINE READY FOR ATTACHMENT…458
LOCATIONS…458
HYDRAULIC CIRCUIT…460
ATTACHMENTS OPERATIONS…461
LONG-TERM STORAGE…463
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…464
CONTROL PATTERN CHANGE PROCEDURE…464
MACHINE CONTROL PATTERNS…465
ATTACHMENT GUIDE…466
ATTACHMENT COMBINATIONS…466
RECOMMENDED ATTACHMENT OPERATIONS…467
HYDRAULIC BREAKER…467
INDEX…472
SEAM043006T – Hydraulic Excavator PC40MRx-1, PC45MRx-1 Operation & Maintenance Manual…474
COVER…474
FOREWORD…475
FOREWORD…476
SAFETY INFORMATION…479
INTRODUCTION…481
DIRECTIONS OF MACHINE…481
PRODUCT INFORMATION…482
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…482
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…482
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…483
SERVICE METER LOCATION…483
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…484
CONTENTS…485
SAFETY…489
SAFETY INFORMATION…490
SAFETY LABELS…492
LOCATION OF SAFETY LABELS…493
SAFETY LABELS…494
SAFETY INFORMATION…500
SAFETY RULES…500
IF ABNORMALITIES ARE FOUND…500
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…500
FIRE EXTINGUISHER AND FIRST AID KIT…500
SAFETY EQUIPMENT…500
KEEP MACHINE CLEAN…501
KEEP OPERATOR'S COMPARTMENT CLEAN…501
LEAVING OPERATOR'S SEAT WITH LOCK…501
HANDRAILS AND STEPS…502
MOUNTING AND DISMOUNTING…502
NO PERSONS ON ATTACHMENTS…502
DO NOT GET CAUGHT IN ARTICULATED PORTION…502
BURN PREVENTION…503
FIRE PREVENTION AND EXPLOSION PREVENTION…503
ACTION IF FIRE OCCURS…504
WINDSHIELD WASHER FLUID…504
FALLING OBJECTS,FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…504
ATTACHMENT INSTALLATION…505
ATTACHMENT COMBINATIONS…505
CAB WINDOW GLASSES…505
UNAUTHORIZED MODIFICATIONS…505
SAFETY AT JOBSITE…505
WORKING ON LOOSE GROUND…505
DISTANCE TO HIGH VOLTAGE CABLES…506
ENSURE GOOD VISIBILITY…506
VENTILATION FOR ENCLOSED AREA…506
SIGNALMAN'S SIGNAL AND SIGNS…507
EMERGENCY EXIT FROM OPERATOR'S CAB…507
ASBESTOS DUST HAZARD PREVENTION…507
SAFETY MACHINE OPERATION…508
STARTING ENGINE…508
CHECKS BEFORE STARTING ENGINE…508
SAFETY RULES FOR STARTING ENGINE…508
STARTING ENGINE IN COLD WEATHER…509
OPERATION…510
CHECKS BEFORE OPERATION…510
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…510
SAFETY RULES FOR TRAVELING…511
TRAVELING ON SLOPES…512
OPERATIONS ON SLOPES…513
PROHIBITED OPERATIONS…513
OPERATIONS ON SNOW…514
PARKING MACHINE…515
TRANSPORTATION…516
LOADING AND UNLOADING…516
SHIPPING THE MACHINE…516
BATTERY…517
BATTERY HAZARD PREVENTION…517
STARTING ENGINE WITH BOOSTER CABLES…518
TOWING…519
SAFETY RULES FOR TOWING…519
LIFTING OBJECTS WITH BUCKET…520
SAFETY RULES FOR LIFTING OBJECTS…520
SAFETY MAINTENANCE INFORMATION…521
WARNING TAG…521
KEEP WORK PLACE CLEAN AND TIDY…521
APPOINT LEADER WHEN WORKING WITH OTHERS…521
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…521
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…522
PROPER TOOLS…523
PERSONNEL…523
ATTACHMENTS…523
WORK UNDER THE MACHINE…523
NOISE…523
WHEN USING HAMMER…524
WELDING WORKS…524
REMOVING BATTERY TERMINALS…524
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…524
DO NOT DISASSEMBLE RECOIL SPRINGS…524
SAFETY RULES FOR HIGH-PRESSURE OIL…525
SAFETY HANDLING HIGH-PRESSURE HOSES…525
WASTE MATERIALS…525
AIR CONDITIONER MAINTENANCE…525
COMPRESSED AIR…526
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…526
OPERATION…527
MACHINE VIEW ILLUSTRATIONS…528
OVERALL MACHINE VIEW…528
CONTROLS AND GAUGES…529
DETAILED CONTROLS AND GAUGES…530
MONITORING SYSTEM…530
SWITCHES…535
CONTROL LEVERS AND PEDALS…538
WINDSHIELD…543
SLIDING DOOR…547
SLIDING WINDOW…547
REAR WINDOW…548
EMERGENCY ESCAPE HAMMER…549
CAP WITH LOCK…550
ENGINE HOOD…551
MUD COVER…552
FUSE …553
BLOCK FUSE…553
AUXILIARY ELECTRIC POWER…554
OPERATION MANUAL STORAGE…554
TOOL BOX…554
GREASE PUMP HOLDER…555
ASHTRAY…555
MACHINE OPERATIONS AND CONTROLS…556
BEFORE STARTING ENGINE…556
STARTING ENGINE…570
AFTER STARTING ENGINE…573
STOPPING THE ENGINE…576
CHECK AFTER SHUT OFF ENGINE…576
MACHINE OPERATION…577
STEERING THE MACHINE…581
SWINGING…583
WORK EQUIPMENT CONTROLS AND OPERATIONS…584
PROHIBITED OPERATIONS…586
GENERAL OPERATION INFORMATION…588
TRAVELING ON SLOPES…590
ESCAPE FROM MUD…592
RECOMMENDED APPLICATIONS…593
BUCKET REPLACEMENT…595
PARKING MACHINE…596
MACHINE INSPECTION AFTER DAILY WORK…597
LOCKING…597
RUBBER SHOES AND ROAD LINERS…598
TRANSPORTATION…603
TRANSPORTATION PROCEDURE…603
LOADING AND UNLOADING WITH TRAILER…603
LIFTING MACHINE…608
COLD WEATHER OPERATION…610
COLD WEATHER OPERATION INFORMATION…610
CAB HEATER IN COLD WEATHER…611
AFTER DAILY WORK COMPLETION…612
AFTER COLD WEATHER SEASON…612
LONG TERM STORAGE…613
BEFORE STORAGE…613
DURING STORAGE…613
AFTER STORAGE…613
TROUBLES AND ACTIONS…614
RUNNING OUT OF FUEL…614
PHENOMENA THAT ARE NOT FAILURES…614
TOWING THE MACHINE…615
SEVERE JOB CONDITION…615
DISCHARGED BATTERY…616
OTHER TROUBLE…619
MAINTENANCE…622
MAINTENANCE INFORMATION…623
LUBRICANTS, COOLANT AND FILTERS…625
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…625
ELECTRIC SYSTEM MAINTENANCE…627
WEAR PARTS…628
WEAR PARTS LIST…628
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…629
TIGHTENING TORQUE SPECIFICATIONS…633
TIGHTENING TORQUE LIST…633
SAFETY CRITICAL PARTS…634
SAFETY CRITICAL PARTS LIST…634
MAINTENANCE SCHEDULE…635
MAINTENANCE SCHEDULE CHART…635
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…636
MAINTENANCE PROCEDURE…637
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…637
WHEN REQUIRED…638
CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT…638
CLEAN INSIDE OF COOLING SYSTEM…640
CLEAN WATER SEPARATOR ELEMENT…643
DRAIN WATER AND SEDIMENT FROM FUEL TANK…643
CHECK AND TIGHTEN TRACK SHOE BOLTS…644
CHECK AND ADJUST TRACK TENSION…645
CHECK,RUBBER SHOES OR ROAD LINERS…647
CHECK AND ADJUST RUBBER SHOE TENSION…649
REPLACE RUBBER SHOES…651
REPLACE ROAD LINERS…653
CHANGE ROAD LINER OR STEEL SHOES TO RUBBER SHOES…654
REPLACE BUCKET TEETH…655
CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID…658
CHECK,CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…659
BLEEDING AIR FROM HYDRAULIC SYSTEM…660
CHECK BEFORE STARTING…661
EVERY 100 HOURS MAINTENANCE…662
LUBRICATING…662
EVERY 250 HOURS MAINTENANCE…663
REPLACE ENGINE OIL IN ENGINE OIL PAN…663
REPLACE HYDRAULIC FILTER ELEMENT…664
CHECK AND ADJUST COOLING FAN BELT TENSION…665
CHECK LEVEL OF BATTERY ELECTROLYTE…667
EVERY 500 HOURS MAINTENANCE…669
REPLACE ENGINE OIL FILTER CARTRIDGE…669
REPLACE FUEL FILTER ELEMENT…670
CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL…671
LUBRICATING…672
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…673
EVERY 1000 HOURS MAINTENANCE…674
CHANGE OIL IN FINAL DRIVE CASE…674
CHECK ENGINE VALVE CLEARANCE,ADJUST…674
EVERY 2000 HOURS MAINTENANCE…675
CHANGE OIL IN HYDRAULIC TANK,CLEAN STRAINER…675
CHECK ALTERNATOR,STARTING MOTOR…676
SPECIFICATIONS…677
SPECIFICATIONS…678
ATTACHMENTS, OPTIONS…681
ATTACHMENTS AND OPTIONS-GENERAL INFORMATION…682
SAFETY FIRST…682
ATTACHMENT INSTALLATION…683
BUCKET WITH HOOK…684
HOOK CONDITION…684
PROHIBITED OPERATIONS…684
AIR CONDITIONER…685
CONTROL PANEL AND COMPONENTS…685
AIR CONDITIONER CONTROLS…687
AIR CONDITIONER MAINTENANCE…688
DEFROSTER CONTROLS…693
CONTROL PANEL…693
MACHINE READY FOR ATTACHMENT…695
LOCATIONS…695
HYDRAULIC CIRCUIT…697
ATTACHMENT OPERATIONS…698
LONG TERM STORAGE…700
CHANGING MACHINE CONTROL PATTERN(IF PATTERN CHANGE VALVE EQUIPPED)…701
CONTROL PATTERN CHANGE PROCEDURE…701
MACHINE CONTROL PATTERNS…702
TELESCOPIC ARM…703
EXTENSION AND RETRACTION OF ARM…703
PRECAUTIONS IN USE…705
MAINTENANCE PROCEDURE…708
SPECIFICATIONS…709
POWER ANGLE,POWER TILT BLADE…711
BLADE CONTROL LEVER…711
EVERY 100 HOURS SERVICE…712
EVERY 500 HOURS SERVICE…713
WEAR PARTS LIST…713
SPECIFICATIONS…713
ATTACHMENT GUIDE…714
ATTACHMENT COMBINATIONS…714
RECOMMENDED ATTACHMENT OPERATIONS…715
HYDRAULIC BREAKER…715
INDEX…720
SEAM055301T – Hydraulic Excavator GALEO PC40MR-2, PC50MR-2 Operation & Maintenance Manual…723
COVER…723
FOREWORD…724
FOREWORD…725
SAFETY INFORMATION…728
INTRODUCTION…730
DIRECTIONS OF MACHINE…730
PRODUCT INFORMATION…731
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO.PLATE…731
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…731
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…732
SERVICE METER LOCATION…732
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…733
CONTENTS…734
SAFETY…737
SAFETY INFORMATION…738
SAFETY LABELS…740
LOCATION OF SAFETY LABELS…740
SAFETY LABELS…741
SAFETY INFORMATION…747
SAFETY RULES…747
IF ABNORMALITIES ARE FOUND…747
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…747
FIRE EXTINGUISHER AND FIRST AID KIT…747
SAFETY EQUIPMENT…748
KEEP MACHINE CLEAN…748
KEEP OPERATOR'S COMPARTMENT CLEAN…748
LEAVING OPERATOR'S SEAT WITH LOCK…748
HANDRAILS AND STEPS…749
MOUNTING AND DISMOUNTING…749
NO PERSONS ON ATTACHMENTS…749
BURN PREVENTION…750
FIRE PREVENTION AND EXPLOSION PREVENTION…750
ACTION IF FIRE OCCURS…751
WINDSHIELD WASHER FLUID…751
FALLING OBJECTS, FLYING OBJEECTS AND INTRUDING OBJECTS PREVENTION…752
CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM)…752
ATTACHMENT INSTALLATION…753
ATTACHMENT COMBINATIONS…753
CAB WINDOW GLASSES…753
UNAUTHORIZED MODIFICATIONS…753
SAFETY AT JOBSITE…753
WORKING ON LOOSE GROUND…753
DISTANCE TO HIGH VOLTAGE CABLES…754
ENSURE GOOD VISIBILITY…754
VENTILATION FOR ENCLOSED AREA…755
SIGNALMAN'S SIGNAL AND SIGNS…755
EMERGENCY EXIT FROM OPERATOR'S CAB…755
ASBESTOS DUST HAZARD PREVENTION…755
SAFETY MACHINE OPERATION…756
STARTING ENGINE…756
CHECKS BEFORE STARTING ENGINE…756
SAFETY RULES FOR STARTING ENGINE…757
STARTING ENGINE IN COLD WEATHER…757
OPERATION…758
CHECKS BEFORE OPERATION…758
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…758
SAFETY RULES FOR TRAVELING…759
TRAVELING ON SLOPES…760
OPERATIONS ON SLOPES…761
PROHIBITED OPERATIONS…761
OPERATIONS ON SNOW…763
PARKING MACHINE…763
TRANSPORTION…764
LOADING AND UNLOADING…764
SHIPPING THE MACHINE…764
BATTERY…765
BATTERY HAZARD PREVENTION…765
STARTING ENGINE WITH BOOSTER CABLES…766
TOWING…767
SAFETY RULES FOR TOWING…767
LIFTING OBJECTS WITH BUCKET…768
SAFETY RULES FOR LIFTING OBJECTS…768
SAFETY MAINTENANCE INFORMATION…769
WARNING TAG…769
KEEP WORK PLACE AND TIDY…769
APPOINT LEADER WHEN WORKING WITH OTHERS…769
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…770
CAUTIONS FOR OPENING (TILTING) FLOOR…771
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…772
PROPER TOOLS…772
PERSONNEL…772
ATTACHMENTS…773
WORK UNDER THE MACHINE…773
NOISE…773
WHEN USING HAMMER…773
WELDING WORKS…773
REMOVING BATTERY TERMINALS…774
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…774
DO NOT DISASSEMBLE RECOIL SPRINGS…774
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…774
SAFETY HANDLING HIGH-PRESSURE HOSES…775
WASTE MATERIALS…775
AIR CONDITIONER MAINTENANCE…775
COMPRESSED AIR…775
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…775
OPERATION…776
MACHINE VIEW ILLUSTRATIONS…777
OVERALL MACHINE VIEW…777
CONTROLS AND GAUGES…778
DETAILED CONTROLS AND GAUGES…779
MONITORING SYSTEM…779
SWITCHES…787
CONTROL LEVERS, PEDALS…791
WINDSHIELD…797
SLIDING DOOR…801
SLIDING WINDOW…801
EMERGENCY ESCAPE HAMMER…802
COVER WITHLOCK…803
ENGINE REAR COVER…804
COOLING COVER…804
MUD COVER…805
METHOD OF OPENING (TILTING) FLOOR…806
FUSE…811
BLOCK FUSE…812
AUXILIARY ELECTRIC POWER…813
OPERATION MANUAL STORAGE…814
TOOL BOX…814
GREASE GUN HOLDER…814
MACHINE OPERATIONS AND CONTROLS…815
BEFORE STARTING ENGINE…815
STARTING ENGINE…829
AFTER STARTING ENGINE…833
STOPPING THE ENGINE…836
MACHINE OPERATION…837
STEERING THE MACHINE…842
SWINGING…844
WORK EQUIPMENT CONTROLS AND OPERATIONS…845
PROHIBITED OPERATIONS…847
GENERAL OPERATION INFORMATION…849
TRAVELING ON SLOPES…850
ESCAPE FROM MUD…852
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…853
BUCKET REPLACEMENT…855
PARKING MACHINE…856
CHECK AFTER SHUT OFF ENGINE…857
MACHINE INSPECTION AFTER DAILY WORK…857
LOCKING…858
RUBBER SHOES AND ROAD LINERS…859
TRANSPORTATION…864
TRANSPORTATION PROCEDURE…864
LOADING, UNLOADING WITH TRAILER…865
LIFTING MACHINE…871
COLD WEATHER OPERATION…874
COLD WEATHER OPERATION INFORMATION…874
AFTER DAILY WORK COMPLETION…876
AFTER COLD WEATHER SEASON…876
LONG TERM STORAGE…877
BEFORE STORAGE…877
DURING STORAGE…878
AFTER STORAGE…878
TROUBLES AND ACTIONS…879
RUNNING OUT OF FUEL…879
PHENOMENA THAT ARE NOT FAILURES…879
TOWING THE MACHINE…880
SEVERE JOB CONDITION…880
DISCHARGED BATTERY…881
OTHER TROUBLE…885
MAINTENANCE…889
MAINTENANCE INFORMATION…890
LUBRICANTS, COOLANT AND FILTERS…892
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…892
ELECTRIC SYSTEM MAINTENANCE…895
HANDLING HYDRAULIC SYSTEM…896
WEAR PARTS…897
WEAR PARTS LIST…897
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…898
TIGHTENING TORQUE SPECIFICATIONS…902
TIGHTENING TORQUE LIST…902
SAFETY CRITICAL PARTS…903
SAFETY CRITICAL PARTS LIST…903
MAINTENANCE SCHEDULE…904
MAINTENANCE SCHEDULE CHART…904
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…905
MAINTENANCE PROCEDURE…906
WHEN REQUIRED…906
CHECK, CLEAN AND REPLACEMENT AIR CLEANER ELEMNET…906
CLEAN INSIDE OF COOLING SYSTEM…911
CHECK LEVEL OF BATTERY ELECTROLYTE…914
CLEAN WATR SEPARATOR ELEMENT…916
DRAIN WATER AND SEDIMENT FROM FUEL TANK…916
CHECK AND TIGHTEN TRACK SHOE BOLTS (MACHINE EQUIPPED WITH ROAD LINER, STEEL SHOE)…917
CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH ROAD LINER, STEEL SHOE)…918
CHECK, RUBBER SHOES OR ROAD LINERS (MACHINE EQUIPPED WITH RUBBER SHOES, ROAD LINER)…920
CHECK AND ADJUST RUBBER SHOE TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)…922
REPLACE RUBBER SHOE (MACHINE EQUIPPED WITH RUBBER SHOES)…924
REPLACE ROAD LINERS (MACHINE EQUIPPED WITH RUBBER SHOES)…926
REPLACE BUCKET TEETH…927
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…930
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…931
LUBRICATING…931
BLEEDING AIR FROM HYDRAULIC SYSTEM…932
CHECK BEFORE STARTING…934
EVERY 500 HOURS MAINTENANCE…935
LUBRICATING…935
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…938
REPLACE FUEL FILTER CARTRIDGE…939
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…941
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…942
CHECK AND ADJUST COOLING FAN BELT TENSION…943
EVERY 1000 HOURS MAINTENANCE…944
REPLACE HYDRAULIC OIL FILTER ELEMENT…944
CHANGE OIL IN FINAL DRIVE CASE…945
CHECK ENGINE VALVE CLEARANCE, ADJUST…945
EVERY 2000 HOURS MAINTENANCE…946
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…946
CHECK ALTERNATOR, STARTING MOTOR…948
SPECIFICATIONS…949
SPECIFICATIONS…950
ATTACHMENTS, OPTIONS…952
ATTACHMENTS AND OPTIONS-GENERAL INFORMATION…953
SAFETY FIRST…953
ATTACHMENT INSTALLATION…954
BUCKET WITH HOOK…955
PROHIBITED OPERATIONS…955
AIR CONDITIONER…956
CONTROL PANEL AND COMPONENTS…956
AIR CONDITIONER CONTROLS…957
AIR CONDITIONER MAINTENANCE…958
WINDSHIELD WASHER…962
WINDSHIELD WASHER OPERATION…962
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…962
MACHINE READY FOR ATTACHMENT…963
LOCATIONS…963
HYDRAULIC CIRCUIT…966
ATTACHMENT OPERATIONS…969
LONG TERM STORAGE…970
SPECIFICATIONS…971
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…972
CONTROL PATTERN CHANGE PROCEDURE…972
MACHINE CONTROL PATTERNS…973
ATTACHMENT GUIDE…974
ATTACHMENT COMBINATIONS…974
RECOMMENDED ATTACHMENT OPERATIONS…975
HYDRAULIC BREAKER…975
INDEX…980
SEBM016808 – Hydraulic Excavators PC27MRX-1, PC30MRX-1, PC35MRX-1, PC40MRX-1, PC45MRX-1 Shop Manual…983
COVER…983
CONTENTS…984
01 GENERAL…1009
GENERAL ASSEMBLY DRAWING…1010
SPECIFICATIONS…1020
WEIGHT TABLE…1048
LIST OF LUBRICANT AND WATER…1058
10 STRUCTURE AND FUNCTION…1060
ENGINE CONTROL…1061
PTO…1063
RADIATOR AND OIL COOLER…1065
POWER TRAIN…1069
SWING CIRCLE…1072
SWING MACHINERY…1073
TRACK FRAME…1075
IDLER CUSHION…1077
HYDRAULIC PIPING…1079
VALVE CONTROL…1083
HYDRAULIC TANK…1089
CLSS…1093
HYDRAULIC PUMP(PISTON PUMP)…1168
LS/PC VALVE AND SERVO PISTON…1183
SOLENOID VALVE…1188
CONTROL VALVE…1191
SWING MOTOR…1211
CENTER SWIVEL JOINT…1219
TRAVEL MOTOR…1222
PPC VALVE…1246
SERVICE PPC VALVE…1255
WORK EQUIPMENT…1259
AIR CONDITIONER…1260
ACTUAL ELECTRIC WIRING DIAGRAM…1261
MACHINE MONITOR SYSTEM…1265
20 TESTING AND ADJUSTING…1272
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…1273
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…1278
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…1319
TESTING AND ADJUSTING…1321
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING…1322
MEASURING ENGINE SPEED…1323
MEASURING EXHAUST COLOR…1324
ADJUSTING VALVE CLEARANCE…1325
MEASURING COMPRESSION PRESSURE…1326
MEASURING ENGINE OIL PRESSURE…1328
TESTING AND ADJUSING FUEL INJECTION TIMING…1329
TESTING AND ADJUSTING FAN BELT TENSION…1330
ADJUSTING FUEL CONTROL LEVER…1332
MEASURING SPROCKET WEAR…1334
TESTING AND ADJUSTING TRACK SHOE TENSION…1335
HYDRAULIC EQUIPMENT ADJUSTING CONTROL LEVERS AND PEDAL…1336
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT,SWING,TRAVEL CIRCUIT…1339
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE…1349
ADJUSTING PC VALVE…1354
TESTING CONTROL CIRCUIT PRESSURE…1355
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE…1357
MEASURING OUTPUT PRESSURE OF SOLENOID VALVE…1359
MEASURING OUTPUT PRESSURE OF PPC VALVE…1362
ADJUSTING WORK EQUIPMENT,SWING PPC VALVE…1364
TESTING SWING HOLDING BRAKE INLET PORT PRESSURE…1365
TESTING AND ADJUSTING TRAVEL DEVIATION…1369
MEASURING OIL LEAKAGE INSIDE WORK EQUIPMENT CYLINDER…1371
BLEEDING AIR…1373
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…1375
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK…1375
PRESSURIZING HYDRAULIC TANK…1375
TESTING AND ADJUSTING HYDRAULIC BREAKER SERVICE VALVE…1376
TESTING AND CHARGING PRESSURE OF HYDRAULIC BREAKER GAS(N2)…1377
ELECTRICAL RELATED PARTS PROCEDURE FOR CHECKING DIODE…1380
TROUBLESHOOTING…1381
POINTS TO REMEMBER WHEN TROUBLESHOOTING…1382
SEQUENCE OF EVENTS IN TROUBLESHOOTING…1383
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…1384
CHECKS BEFORE TROUBLESHOOTING …1392
CONNECTOR TYPES AND MOUNTING LOCATIONS…1393
CONNECTOR PIN ALLOCATION DRAWING…1397
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…1403
METHOD OF USING TROUBLESHOOTING CHARTS…1417
TROUBLESHOOTING OF ELECTRICAL SYSTEM(E MODE)…1419
E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…1420
E-1 ENGINE DOES NOT START…1429
a) WHEN STARTING MOTOR DOES NOT TURN (STARTING SYSTEM)…1429
b) WHEN STARTING MOTOR TURNS (ENGINE STOP SOLENOID SYSTEM)…1432
E-2 ENGINE DOES NOT STOP…1448
E-3 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS CANCELED…1452
E-4 WORK EQUIPMENT MOVES EVEN WHEN WORK EQUIPMENT LOCK LEVER IS LOCKED…1456
E-5 TRAVEL SPEED DOES NOT INCREASE EVEN WHEN TRAVEL BOOST PEDAL IS DEPRESSED…1460
E-6 TRAVEL SPEED DOES NOT DECREASE EVEN WHEN TRAVEL BOOST PEDAL IS RELEASED…1463
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM(H MODE)…1466
TABLE OF FAILURE MODES AND CAUSES…1467
H-1 SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE SLOW OR LACK POWER …1471
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS…1474
H-3 NO WORK EQUIPMENT,TRAVEL,SWING MOVE…1477
H-4 ABNORMAL NOISE GENERATED(FROM AROUND PUMP)…1478
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…1479
H-6 BOOM IS SLOW OR LACKS POWER…1480
H-7 ARM IS SLOW OR LACKS POWER…1482
H-8 BUCKET IS SLOW OR LACKS POWER…1484
H-9 BOOM SWING IS SLOW OR LACKS POWER…1486
H-10 BLADE IS SLOW OR LACKS POWER…1489
H-11 BOOM,ARM,BUCKET DO NOT MOVE(BOOM SWING,BLADE,TRAVEL AND SWING ARE NORMAL)…1490
H-12 EXCESSIVE HYDRAULIC DRIFT(BOOM,ARM,BUCKET,BOOM SWING,BLADE)…1491
a)BOOM…1491
b)ARM,BUCKET,BOOM SWING…1491
c)BLADE…1491
H-13 EXCESSIVE TIME LAG(ENGINE AT LOW IDLING)…1492
H-14 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW…1492
H-15 TRAVEL DEVIATION…1493
a) WHEN THERE IS DEVIATION DURING NORMAL TRAVEL…1493
b) THERE IS DEVIATION WHEN MACHINE MOVES OFF…1493
H-16 TRAVEL SPEED IS SLOW OR LACKS POWER…1497
H-17 STEERING DOES NOT TURN EASILY…1498
H-18 TRAVEL SPEED DOES NOT SWITCH…1498
H-19 TRAVEL DOES NOT MOVE(ONE SIDE ONLY)…1498
H-20 SWING SPEED IS SLOW OR LACKS POWER…1499
a) SPEED IS SLOW OR LACKS POWER IN BOTH DIRECTIONS…1499
b) SPEED IS SLOW OR LACKS POWER IN ONE DIRECTION ONLY(LEFT OR RIGHT)…1499
H-21 DOES NOT SWING…1501
a) DOES NOT SWING IN EITHER DIRECTION…1501
b) DOES NOT SWING IN ONE DIRECTION(LEFT OR RIGHT)…1501
H-22 SWING ACCELERATION IS POOR…1502
a) ACCELERATION IS POOR IN BOTH DIRECTIONS…1502
b) ACCELERATION IS POOR IN ONE DIRECTION ONLY(LEFT OR RIGHT)…1502
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING…1503
a) OVERRUN WHEN STOPPING IS EXCESSIVE IN BOTH DIRECTIONS(LEFT AND RIGHT)…1503
b) OVERRUN WHEN STOPPING IS EXCESSIVE IN ONE DIRECTION ONLY(LEFT OR RIGHT)…1503
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING(IN ONE DIRECTION ONLY)…1504
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…1504
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING…1504
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM(M MODE)…1505
M-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…1506
M-1 WHEN STARTING SWITCH IS TURNED ON,NO DISPLAY IS GIVEN…1510
M-2 WHEN STARTING SWITCH IS TURNED ON,EVEN WHEN SELF CHECK IS COMPLETED(ALL LAMPS LIGHT UP FOR 3 SECONDS),LAMPS DO NOT GO OUT…1512
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS…1513
a) NO GAUGE LAMPS LIGHT UP(FUEL,COOLANT TEMPERATURE)…1513
b) CAUTION LAMPS(ENGINE OIL PRESSURE,BATTERY CHARGE),PILOT LAMP(PREHEATING) DO NOT LIGHT UP…1513
M-4 DURING SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS),EVEN IF STARTING SWITCH IS TURNED TO START,SELF CHECK IS NOT COMPLETED FOR 3 SECONDS…1513
M-5 WHEN STARTING SWITCH IS ON(ENGINE STOPPED),ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP…1514
M-6 WHEN STARTING SWITCH IS ON(ENGINE STOPPED),CHARGE CAUTION LAMP DOES NOT LIGHT UP…1515
M-7 WHEN STARTING SWITCH IS TURNED TO HEAT,PREHEATING PILOT LAMP DOES NOT LIGHT UP…1516
M-8 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP…1517
M-9 WHEN ENGINE IS RUNNING, CHARGE CAUTION LAMP LIGHTS UP…1518
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE…1519
a) LEVEL DOES NOT RISE FROM SEGMENT C…1519
b) LEVEL DOES NOT GO DOWN FROM SEGMENT H,OR ALL SEGMENTS GO OUT…1519
c) COOLANT TEMPERATURE DOES NOT MATCH GAUGE DISPLAY…1520
M-11 ABNORMALITY IN FUEL GAUGE…1525
a) LEVEL DOES NOT RISE FROM SEGMENT E OR ALL SEGMENTS GO OUT…1525
b) LEVEL DOES NOT GO DOWN FROM SEGMENT F…1525
c) FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY…1526
M-12 DEFECTIVE OPERATION OF ALARM BUZZER…1529
a) BUZZER DOES NOT SOUND…1529
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP…1529
M-13 WHEN ENGINE IS RUNNING,SERVICE METER DOES NOT ADVANCE…1532
a) WHEN CHARGE CAUTION LAMP DOSE NOT LIGHT UP…1532
b) WHEN CHARGE CAUTION LAMP LIGHTS UP…1532
c) PILOT LAMP DOES NOT FLASH(SERVICE METER IS ACTUATED)…1532
M-14 NIGHT LIGHTING DOES NOT LIGHT UP…1533
a) GAUGE LIGHTING DOES NOT LIGHT UP…1533
b) SERVICE METER LIGHTING DOES NOT LIGHT UP…1533
30 DISASSEMBLY AND ASSEMBLY…1537
METHOD OF USING MANUAL…1539
PRECAUTIONS WHEN CARRYING OUT OPERATION…1540
SPECIAL TOOL LIST…1542
SKETCHES OF SPECIAL TOOLS…1547
STARTING MOTOR…1553
REMOVAL AND INSTALLATION…1553
ALTERNATOR…1555
REMOVAL AND INSTALLATION…1555
FUEL INJECTION PUMP…1558
REMOVAL…1558
INSTALLATION…1559
NOZZLE HOLDER…1562
REMOVAL AND INSTALLATION …1562
WATER PUMP…1564
REMOVAL AND INSTALLATION…1564
THERMOSTAT…1565
REMOVAL AND INSTALLATION…1565
ENGINE FRONT SEAL…1566
REMOVAL AND INSTALLATION…1566
ENGINE REAR SEAL…1567
REMOVING…1567
INSTALLATION…1568
CYLINDER HEAD …1569
REMOVAL…1569
INSTALLATION…1571
RADIATOR,HYDRAULIC COOLER…1572
REMOVAL…1572
INSTALLATION…1573
ENGINE,MAIN PUMP…1577
REMOVAL…1577
INSTALLATION…1580
DAMPER…1585
REMOVAL AND INSTALLATION…1585
CENTER SWIVEL JOINT…1586
REMOVAL AND INSTALLATION…1586
DISASSEMBLY AND ASSEMBLY…1590
TRAVEL MOTOR …1594
REMOVAL AND INSTALLATION…1594
TRAVEL MOTOR(PHV-500(FOR PC40MRX-1))…1595
DISASSEMBLY AND ASSEMBLY…1595
SPROCKET…1610
REMOVAL AND INSTALLATION…1610
SWING MOTOR,SWING MACHINERY…1611
REMOVAL AND INSTALLATION…1611
DISASSEMBLY…1616
ASSEMBLY…1619
SWING MOTOR…1622
DISASSEMBLY…1622
ASSEMBLY…1627
REVOLVING FRAME…1635
REMOVAL…1635
INSTALLATION…1636
SWING CIRCLE…1638
REMOVAL AND INSTALLATION…1638
IDLER…1639
REMOVAL AND INSTALLATION…1639
DISASSEMBLY…1640
ASSEMBLY…1641
RECOIL SPRING…1642
REMOVAL AND INSTALLTION…1642
DISASSEMBLY…1643
ASSEMBLY…1645
TRACK ROLLER…1647
REMOVAL AND INSTALLATION…1647
DISASSEMBLY…1648
ASSEMBLY…1649
CARRIER ROLLER…1650
REMOVAL AND INSTALLATION…1650
DISASSEMBLY AND ASSEMBLY…1651
RUBBER SHOE…1652
REMOVAL AND INSTALLATION…1652
HYDRAULIC TANK…1653
REMOVAL AND INSTALLATION…1653
FUEL TANK …1658
REMOVAL…1658
INSTALLATION…1659
MAIN PUMP…1661
REMOVAL AND INSTALLATION …1661
MAIN PUMP(LPV30 (FOR PC30MRX-1))…1662
DISASSEMBLY…1662
ASSEMBLY…1670
MAIN PUMP(LPD25+25(FOR PC40MRX-1))…1681
DISASSEMBLY…1681
ASSEMBLY…1690
SWING GEAR PUMP…1703
REMOVAL AND INSTALLATION…1703
PPC PUMP…1704
REMOVAL AND INSTALLATION…1704
MAIN CONTROL VALVE…1706
REMOVAL …1706
INSTALLATION…1707
DISASSEMBLY…1712
ASSEMBLY…1718
WORK EQUIPMENT LEFT PPC VALVE(FOR ARM,SWING CONTROL)…1741
REMOVAL AND INSTALLATION…1741
WORK EQUIPMENT RIGHT PPC VALVE(FOR BOOM AND BUCKET CONTROL)…1743
REMOVAL AND INSTALLATION…1743
WORK EQUIPMENT PPC VALVE…1745
DISASSEMBLY…1745
ASSEMBLY…1746
BOOM CYLINDER…1747
REMOVAL AND INSTALLATION…1747
ARM CYLINDER…1750
REMOVAL AND INSTALLATION…1750
BUCKET CYLINDER…1753
REMOVAL AND INSTALLATION…1753
SWING CYLINDER…1756
REMOVAL AND INSTALLATION…1756
BLADE CYLINDER …1762
REMOVAL AND INSTALLATION…1762
HYDRAULIC CYLINDER…1765
DISASSEMBLY…1765
ASSEMBLY…1768
WORK EQUIPMENT…1772
REMOVAL AND INSTALLATION…1772
BUCKET…1775
REMOVAL AND INSTALLATION…1775
ARM…1777
REMOVAL AND INSTALLATION…1777
BUCKET,ARM…1780
REMOVAL AND INSTALLATION…1780
SWING BRACKET…1783
REMOVAL AND INSTALLATION…1783
BLADE…1786
REMOVAL AND INSTALLATION…1786
SEAT BRACKET,R.H. AND L.H. PPC VALVE…1789
REMOVAL…1789
INSTALLATION…1791
SEAT BRACKET…1792
REMOVAL AND INSTALLATION…1792
SOLENOID VALVE…1793
REMOVAL…1793
INSTALLATION…1794
HEATER…1797
REMOVAL AND INSTALLATION…1797
FLOOR FRAME…1798
REMOVAL …1798
INSTALLATION…1801
CANOPY…1802
REMOVAL AND INSTALLATION…1802
OPERATOR'S CAB…1803
REMOVAL …1803
INSTALLATION…1804
COUNTERWEIGHT…1805
REMOVAL AND INSTALLATION…1805
HYDRAULIC BREAKER…1806
DISASSEMBLY…1806
ASSEMBLY…1813
40 MAINTENANCE STANDARD…1821
SWING MACHINERY…1822
SWING CIRCLE…1826
TRACK FRAME…1827
IDLER…1831
CARRIER ROLLER…1834
TRACK ROLLER…1836
SPROCKET…1838
TRACK SHOE…1840
HYDRAULIC PUMP…1848
CONTROL VALVE…1852
SWING MOTOR…1869
TRAVEL MOTOR…1871
PPC VALVE…1875
SERVICE PPC VALVE…1878
CENTER SWIVEL JOINT…1880
HYDRAULIC CYLINDER…1883
WORK EQUIPMENT…1890
DIMENSION OF WORK EQUIPMENT…1894
90 OTHERS…1910
HYDRAULIC CIRCUIT DIAGRAM…1911
PC27MRX-1…1911
PC30MRX-1…1912
PC35MRX-1…1913
PC40MRX-1 (SERIAL NO.:1001-5500)…1914
PC40MRX-1 (EU SPEC.)(SERIAL NO.:1001-5500)…1916
PC45MRX-1 (SERIAL NO.:1001-3000)…1918
ELECTRICAL CIRCUIT DIAGRAM…1920
PC27,30MRX-1(CANOPY SPECIFICATION)…1920
PC27,30MRX-1(CAB SPECIFICATION)…1921
PC35MRX-1(CAB SPECIFICATION)…1922
PC40,45MRX-1(CAB SPECIFICATION)…1923
PC40MRX-1(CAB SPECIFICATION)(EU SPEC.)…1925
PC40,45MRX-1(CAB SPECIFICATION)(USA SPEC.)…1927
AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM…1929
TEN00054-03 – Hydraulic Excavator GALEO PC40MR-2, PC50MR-2 Operation & Maintenance Manual…1930
COVER…1930
FOREWORD…1931
FOREWORD…1932
SAFETY INFORMATION…1935
INTRODUCTION…1937
DIRECTIONS OF MACHINE…1937
PRODUCT INFORMATION…1938
PRODUCT IDENTIFICATION NUMBER(PIN)/MACHINE SERIAL NO. PLATE…1938
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1938
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…1939
SERVICE METER LOCATION…1939
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1940
CONTENTS…1941
SAFETY…1945
SAFETY INFORMATION…1946
SAFETY LABELS…1948
LOCATION OF SAFETY LABELS…1948
SAFETY LABELS…1949
SAFETY INFORMATION…1955
SAFETY RULES…1955
IF PROBLEMS ARE FOUND…1955
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…1955
FIRE EXTINGUISHER AND FIRST AID KIT…1955
SAFETY EQUIPMENT…1956
KEEP MACHINE CLEAN…1956
KEEP OPERATOR'S COMPARTMENT CLEAN…1956
LEAVING OPERATOR'S SEAT WITH LOCK…1956
HANDRAILS AND STEPS…1957
MOUNTING AND DISMOUNTING…1957
NO PERSONS ON ATTACHMENTS…1957
BURN PREVENTION…1958
FIRE PREVENTION AND EXPLOSION PREVENTION…1958
ACTION IF FIRE OCCURS…1959
WINDSHIELD WASHER FLUID…1959
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…1960
CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM)…1960
ATTACHMENT INSTALLATION…1961
ATTACHMENT COMBINATIONS…1961
CAB WINDOW GLASSES…1961
UNAUTHORIZED MODIFICATIONS…1961
SAFETY AT JOBSITE…1961
WORKING ON LOOSE GROUND…1961
DISTANCE TO HIGH VOLTAGE CABLES…1962
ENSURE GOOD VISIBILITY…1962
VENTILATION FOR ENCLOSED AREA…1962
SIGNALMAN'S SIGNAL AND SIGNS…1963
EMERGENCY EXIT FROM OPERATOR'S CAB…1963
ASBESTOS DUST HAZARD PREVENTION…1963
SAFETY MACHINE OPERATION…1964
STARTING ENGINE…1964
CHECKS BEFORE STARTING ENGINE…1964
SAFETY RULES FOR STARTING ENGINE…1965
STARTING ENGINE IN COLD WEATHER…1965
OPERATION…1966
CHECKS BEFORE OPERATION…1966
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…1966
SAFETY RULES FOR TRAVELING…1967
TRAVELING ON SLOPES…1968
OPERATIONS ON SLOPES…1969
PROHIBITED OPERATIONS…1969
OPERATIONS ON SNOW…1971
PARKING MACHINE…1971
TRANSPORTATION…1972
LOADING AND UNLOADING…1972
SHIPPING THE MACHINE…1972
BATTERY…1973
BATTERY HAZARD PREVENTION…1973
STARTING ENGINE WITH BOOSTER CABLES…1974
TOWING…1975
SAFETY RULES FOR TOWING…1975
LIFTING OBJECTS WITH BUCKET…1976
SAFETY RULES FOR LIFTING OBJECTS…1976
SAFETY MAINTENANCE INFORMATION…1977
WARNING TAG…1977
KEEP WORK PLACE CLEAN AND TIDY…1977
APPOINT LEADER WHEN WORKING WITH OTHERS…1977
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…1978
CAUTIONS FOR OPENING (TILTING) FLOOR…1979
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…1980
PROPER TOOLS…1980
PERSONNEL…1980
ATTACHMENTS…1981
WORK UNDER THE MACHINE…1981
NOISE…1981
WHEN USING HAMMER…1981
WELDING WORKS…1981
REMOVING BATTERY TERMINALS…1982
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…1982
DO NOT DISASSEMBLE RECOIL SPRINGS…1982
SAFETY RULES FOR HIGH-PRESSURE OIL…1982
SAFETY HANDLING HIGH-PRESSURE HOSES…1983
WASTE MATERIALS…1983
AIR CONDITIONER MAINTENANCE…1983
COMPRESSED AIR…1983
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1983
OPERATION…1984
MACHINE VIEW ILLUSTRATIONS…1985
OVERALL MACHINE VIEW…1985
CONTROLS AND GAUGES…1986
DETAILED CONTROLS AND GAUGES…1987
MONITORING SYSTEM…1987
SWITCHES…1995
CONTROL LEVERS AND PEDALS…1999
WINDSHIELD…2005
SLIDING DOOR…2009
SLIDING WINDOW…2009
EMERGENCY ESCAPE HAMMER…2010
COVER WITH LOCK…2011
ENGINE REAR COVER…2012
COOLING COVER…2012
MUD COVER…2013
METHOD OF OPENING (TILTING) FLOOR…2014
FUSE…2019
BLOCK FUSE…2020
AUXILIARY ELECTRIC POWER…2021
OPERATION MANUAL STORAGE…2022
TOOL BOX…2022
GREASE GUN HOLDER…2022
ASHTRAY…2022
MACHINE OPERATIONS AND CONTROLS…2023
BEFORE STARTING ENGINE…2023
STARTING ENGINE…2037
AFTER STARTING ENGINE…2041
STOPPING THE ENGINE…2044
MACHINE OPERATION…2045
STEERING THE MACHINE…2050
SWINGING…2052
WORK EQUIPMENT CONTROLS AND OPERATIONS…2053
PROHIBITED OPERATIONS…2055
GENERAL OPERATION INFORMATION…2057
TRAVELING ON SLOPES…2058
ESCAPE FROM MUD…2060
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…2061
BUCKET REPLACEMENT…2063
PARKING MACHINE…2064
MACHINE INSPECTION AFTER DAILY WORK…2065
LOCKING…2066
RUBBER SHOES AND ROAD LINERS…2067
TRANSPORTATION…2072
TRANSPORTATION PROCEDURE…2072
LOADING AND UNLOADING WITH TRAILER…2073
LIFTING MACHINE…2079
COLD WEATHER OPERATION…2082
COLD WEATHER OPERATION INFORMATION…2082
CAB HEATER IN COLD WEATHER…2083
AFTER DAILY WORK COMPLETION…2084
AFTER COLD WEATHER SEASON…2084
LONG TERM STORAGE…2085
BEFORE STORAGE…2085
DURING STORAGE…2086
AFTER STORAGE…2086
TROUBLES AND ACTIONS…2087
RUNNING OUT OF FUEL…2087
PHENOMENA THAT ARE NOT FAILURES…2087
TOWING THE MACHINE…2088
SEVERE JOB CONDITION…2088
DISCHARGED BATTERY…2089
OTHER TROUBLE…2093
MAINTENANCE…2097
MAINTENANCE INFORMATION…2098
OUTLINE OF SERVICE…2100
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…2100
ELECTRIC SYSTEM MAINTENANCE…2103
HANDLING HYDRAULIC SYSTEM…2104
WEAR PARTS…2105
WEAR PARTS LIST…2105
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…2106
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…2108
TIGHTENING TORQUE SPECIFICATIONS…2109
TIGHTENING TORQUE LIST…2109
SAFETY CRITICAL PARTS…2110
SAFETY CRITICAL PARTS LIST…2110
MAINTENANCE SCHEDULE…2111
MAINTENANCE SCHEDULE CHART…2111
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…2112
MAINTENANCE PROCEDURE…2113
WHEN REQUIRED…2113
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…2113
CLEAN INSIDE OF COOLING SYSTEM…2119
CHECK LEVEL OF BATTERY ELECTROLYTE…2122
CLEAN WATER SEPARATOR ELEMENT…2124
DRAIN WATER AND SEDIMENT FROM FUEL TANK…2124
CHECK AND TIGHTEN TRACK SHOE BOLTS…2125
CHECK AND ADJUST TRACK TENSION…2126
CHECK, RUBBER SHOES OR ROAD LINERS…2128
CHECK AND ADJUST RUBBER SHOE TENSION…2130
REPLACE RUBBER SHOES…2132
REPLACE ROAD LINERS…2134
REPLACE BUCKET TEETH…2135
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…2138
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…2139
LUBRICATING…2139
BLEEDING AIR FROM HYDRAULIC SYSTEM…2140
CHECK BEFORE STARTING…2142
EVERY 500 HOURS MAINTENANCE…2143
LUBRICATING…2143
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…2146
REPLACE FUEL FILTER CARTRIDGE…2147
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…2149
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…2150
CLEAN NET…2150
CHECK AND ADJUST COOLING FAN BELT TENSION…2151
CHECK SWING PINION GREASE LEVEL, ADD GREASE…2152
EVERY 1000 HOURS MAINTENANCE…2153
REPLACE HYDRAULIC OIL FILTER ELEMENT…2153
CHANGE OIL IN FINAL DRIVE CASE…2154
CHECK ENGINE VALVE CLEARANCE, ADJUST…2154
EVERY 2000 HOURS MAINTENANCE…2155
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…2155
CHECK ALTERNATOR, STARTING MOTOR…2157
SPECIFICATIONS…2158
SPECIFICATIONS…2159
ATTACHMENTS, OPTIONS…2161
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…2162
SAFETY FIRST…2162
ATTACHMENT INSTALLATION…2163
BUCKET WITH HOOK…2164
PROHIBITED OPERATIONS…2164
AIR CONDITIONER…2165
CONTROL PANEL AND COMPONENTS…2165
AIR CONDITIONER CONTROLS…2166
AIR CONDITIONER MAINTENANCE…2167
WINDSHIELD WASHER…2171
WINDSHIELD WASHER OPERATION…2171
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…2171
MACHINE READY FOR ATTACHMENT…2172
LOCATIONS…2172
HYDRAULIC CIRCUIT…2174
ATTACHMENT OPERATIONS…2177
LONG TERM STORAGE…2178
SPECIFICATIONS…2179
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…2180
CONTROL PATTERN CHANGE PROCEDURE…2180
MACHINE CONTROL PATTERNS…2181
POWER ANGLE BLADE…2182
BLADE CONTROL LEVER…2182
WHEN REQUIRED…2183
EVERY 500 HOURS SERVICE…2183
WEAR PARTS LIST…2184
SPECIFICATIONS…2184
ATTACHMENT GUIDE…2185
ATTACHMENT COMBINATIONS…2185
RECOMMENDED ATTACHMENT OPERATIONS…2186
HYDRAULIC BREAKER…2186
HIGH-ALTITUDE SPECIFICATION MACHINE…2191
LOCATIONS…2192
MACHINE OPERATIONS AND CONTROLS…2193
STARTING ENGINE…2193
WEAR PARTS…2195
WEAR PARTS LIST…2195
MAINTENANCE PROCEDURE…2196
EVERY 2000 HOURS MAINTENANCE…2196
SPECIFICATIONS…2197
INDEX…2198
TEN00193-00 – Hydraulic Excavator GALEO PC40MR-2, PC50MR-2 Operation & Maintenance Manual…2201
COVER…2201
FOREWORD…2202
FOREWORD…2203
SAFETY INFORMATION…2206
INTRODUCTION…2208
DIRECTIONS OF MACHINE…2208
PRODUCT INFORMATION…2209
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…2209
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…2209
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…2210
SERVICE METER LOCATION…2210
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…2211
CONTENTS…2212
SAFETY…2216
SAFETY INFORMATION…2217
SAFETY LABELS…2219
LOCATION OF SAFETY LABELS…2219
SAFETY LABELS…2220
SAFETY INFORMATION…2226
SAFETY RULES…2226
IF PROBLEMS ARE FOUND…2226
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…2226
FIRE EXTINGUISHER AND FIRST AID KIT…2226
SAFETY EQUIPMENT…2227
KEEP MACHINE CLEAN…2227
KEEP OPERATOR'S COMPARTMENT CLEAN…2227
LEAVING OPERATOR'S SEAT WITH LOCK…2227
HANDRAILS AND STEPS…2228
MOUNTING AND DISMOUNTING…2229
NO PERSONS ON ATTACHMENTS…2229
BURN PREVENTION…2229
FIRE PREVENTION AND EXPLOSION PREVENTION…2230
ACTION IF FIRE OCCURS…2230
WINDSHIELD WASHER FLUID…2231
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…2231
CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM)…2231
ATTACHMENT INSTALLATION…2232
ATTACHMENT COMBINATIONS…2232
CAB WINDOW GLASSES…2232
UNAUTHORIZED MODIFICATIONS…2232
SAFETY AT JOBSITE…2232
WORKING ON LOOSE GROUND…2232
DISTANCE TO HIGH VOLTAGE CABLES…2233
ENSURE GOOD VISIBILITY…2233
VENTILATION FOR ENCLOSED AREA…2233
SIGNALMAN'S SIGNAL AND SIGNS…2234
EMERGENCY EXIT FROM OPERATOR'S CAB…2234
ASBESTOS DUST HAZARD PREVENTION…2234
SAFETY MACHINE OPERATION…2235
STARTING ENGINE…2235
CHECKS BEFORE STARTING ENGINE…2235
SAFETY RULES FOR STARTING ENGINE…2236
STARTING ENGINE IN COLD WEATHER…2236
OPERATION…2237
CHECKS BEFORE OPERATION…2237
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…2237
SAFETY RULES FOR TRAVELING…2238
TRAVELING ON SLOPES…2239
OPERATIONS ON SLOPES…2240
PROHIBITED OPERATIONS…2240
OPERATIONS ON SNOW…2242
PARKING MACHINE…2242
TRANSPORTATION…2243
LOADING AND UNLOADING…2243
SHIPPING THE MACHINE…2243
BATTERY…2244
BATTERY HAZARD PREVENTION…2244
STARTING ENGINE WITH BOOSTER CABLES…2245
TOWING…2246
SAFETY RULES FOR TOWING…2246
LIFTING OBJECTS WITH BUCKET…2247
SAFETY RULES FOR LIFTING OBJECTS…2247
SAFETY MAINTENANCE INFORMATION…2248
WARNING TAG…2248
KEEP WORK PLACE CLEAN AND TIDY…2248
APPOINT LEADER WHEN WORKING WITH OTHERS…2248
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…2249
CAUTIONS FOR OPENING (TILTING) FLOOR…2250
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…2251
PROPER TOOLS…2251
PERSONNEL…2251
ATTACHMENTS…2252
WORK UNDER THE MACHINE…2252
NOISE…2252
WHEN USING HAMMER…2252
WELDING WORKS…2252
REMOVING BATTERY TERMINALS…2253
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…2253
DO NOT DISASSEMBLE RECOIL SPRINGS…2253
SAFETY RULES FOR HIGH-PRESSURE OIL…2253
SAFETY HANDLING HIGH-PRESSURE HOSES…2254
WASTE MATERIALS…2254
AIR CONDITIONER MAINTENANCE…2254
COMPRESSED AIR…2254
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…2254
OPERATION…2256
MACHINE VIEW ILLUSTRATIONS…2257
OVERALL MACHINE VIEW…2257
CONTROLS AND GAUGES…2258
DETAILED CONTROLS AND GAUGES…2259
MONITORING SYSTEM…2259
SWITCHES…2267
CONTROL LEVERS AND PEDALS…2271
WINDSHIELD…2277
SLIDING DOOR…2281
SLIDING WINDOW…2281
EMERGENCY ESCAPE HAMMER…2282
COVER WITH LOCK…2283
ENGINE REAR COVER…2284
COOLING COVER…2284
MUD COVER…2285
METHOD OF OPENING (TILTING) FLOOR…2286
FUSE…2291
BLOCK FUSE…2292
AUXILIARY ELECTRIC POWER…2293
OPERATION MANUAL STORAGE…2294
TOOL BOX…2294
GREASE GUN HOLDER…2294
ASHTRAY…2294
MACHINE OPERATIONS AND CONTROLS…2295
BEFORE STARTING ENGINE…2295
STARTING ENGINE…2309
AFTER STARTING ENGINE…2313
STOPPING THE ENGINE…2316
MACHINE OPERATION…2317
STEERING THE MACHINE…2322
SWINGING…2324
WORK EQUIPMENT CONTROLS AND OPERATIONS…2325
PROHIBITED OPERATIONS…2327
GENERAL OPERATION INFORMATION…2329
TRAVELING ON SLOPES…2330
ESCAPE FROM MUD…2332
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…2333
BUCKET REPLACEMENT…2335
PARKING MACHINE…2336
MACHINE INSPECTION AFTER DAILY WORK…2337
LOCKING…2338
RUBBER SHOES AND ROAD LINERS…2339
TRANSPORTATION…2344
TRANSPORTATION PROCEDURE…2344
LOADING AND UNLOADING WITH TRAILER…2345
LIFTING MACHINE…2351
COLD WEATHER OPERATION…2354
COLD WEATHER OPERATION INFORMATION…2354
CAB HEATER IN COLD WEATHER…2355
AFTER DAILY WORK COMPLETION…2356
AFTER COLD WEATHER SEASON…2356
LONG TERM STORAGE…2357
BEFORE STORAGE…2357
DURING STORAGE…2358
AFTER STORAGE…2358
TROUBLES AND ACTIONS…2359
RUNNING OUT OF FUEL…2359
PHENOMENA THAT ARE NOT FAILURES…2359
TOWING THE MACHINE…2360
SEVERE JOB CONDITION…2360
DISCHARGED BATTERY…2361
OTHER TROUBLE…2365
MAINTENANCE…2370
MAINTENANCE INFORMATION…2371
OUTLINE OF SERVICE…2373
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…2373
ELECTRIC SYSTEM MAINTENANCE…2376
HANDLING HYDRAULIC SYSTEM…2377
WEAR PARTS…2378
WEAR PARTS LIST…2378
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…2379
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…2381
TIGHTENING TORQUE SPECIFICATIONS…2382
TIGHTENING TORQUE LIST…2382
SAFETY CRITICAL PARTS…2383
SAFETY CRITICAL PARTS LIST…2383
MAINTENANCE SCHEDULE…2384
MAINTENANCE SCHEDULE CHART…2384
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…2385
MAINTENANCE PROCEDURE…2386
WHEN REQUIRED…2386
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…2386
CLEAN INSIDE OF COOLING SYSTEM…2392
CHECK LEVEL OF BATTERY ELECTROLYTE…2395
CLEAN WATER SEPARATOR ELEMENT…2397
DRAIN WATER AND SEDIMENT FROM FUEL TANK…2397
CHECK AND TIGHTEN TRACK SHOE BOLTS (MACHINE EQUIPPED WITH ROAD LINER, STEEL SHOE)…2398
CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH ROAD LINER, STEEL SHOE)…2399
CHECK, RUBBER SHOES OR ROAD LINERS (MACHINE EQUIPPED WITH RUBBER SHOES, ROAD LINER)…2401
CHECK AND ADJUST RUBBER SHOE TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)…2403
REPLACE RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)…2405
REPLACE ROAD LINERS (MACHINE EQUIPPED WITH ROAD LINER)…2407
REPLACE BUCKET TEETH…2408
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…2411
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…2412
LUBRICATING…2412
BLEEDING AIR FROM HYDRAULIC SYSTEM…2413
CHECK BEFORE STARTING…2415
EVERY 500 HOURS MAINTENANCE…2416
LUBRICATING…2416
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…2419
REPLACE FUEL FILTER CARTRIDGE…2420
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…2422
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…2423
CLEAN NET (IF EQUIPPED)…2423
CHECK AND ADJUST COOLING FAN BELT TENSION…2424
CHECK SWING PINION GREASE LEVEL, ADD GREASE…2425
EVERY 1000 HOURS MAINTENANCE…2426
REPLACE HYDRAULIC OIL FILTER ELEMENT…2426
CHANGE OIL IN FINAL DRIVE CASE…2427
CHECK ENGINE VALVE CLEARANCE, ADJUST…2427
EVERY 2000 HOURS MAINTENANCE…2428
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…2428
CHECK ALTERNATOR, STARTING MOTOR…2430
SPECIFICATIONS…2432
SPECIFICATIONS…2433
ATTACHMENTS, OPTIONS…2436
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…2437
SAFETY FIRST…2437
ATTACHMENT INSTALLATION…2438
BUCKET WITH HOOK…2439
PROHIBITED OPERATIONS…2439
AIR CONDITIONER…2440
CONTROL PANEL AND COMPONENTS…2440
AIR CONDITIONER CONTROLS…2441
AIR CONDITIONER MAINTENANCE…2442
WINDSHIELD WASHER…2446
WINDSHIELD WASHER OPERATION…2446
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…2446
MACHINE READY FOR ATTACHMENT…2447
LOCATIONS…2447
HYDRAULIC CIRCUIT…2449
ATTACHMENT OPERATIONS…2452
LONG TERM STORAGE…2453
SPECIFICATIONS…2454
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…2455
CONTROL PATTERN CHANGE PROCEDURE…2455
MACHINE CONTROL PATTERNS…2456
POWER ANGLE BLADE…2457
BLADE CONTROL LEVER…2457
WHEN REQUIRED…2458
EVERY 500 HOURS SERVICE…2458
WEAR PARTS LIST…2459
SPECIFICATIONS…2459
ATTACHMENT GUIDE…2460
ATTACHMENT COMBINATIONS…2460
RECOMMENDED ATTACHMENT OPERATIONS…2461
HYDRAULIC BREAKER…2461
HIGH-ALTITUDE SPECIFICATION MACHINE…2466
LOCATIONS…2467
MACHINE OPERATIONS AND CONTROLS…2468
STARTING ENGINE…2468
WEAR PARTS…2470
WEAR PARTS LIST…2470
MAINTENANCE PROCEDURE…2471
EVERY 2000 HOURS MAINTENANCE…2471
SPECIFICATIONS…2472
INDEX…2474
Komatsu Hydraulic Excavators PC27MRX, PC30MRX, PC35MRX, PC40MRX, PC45MRX Repair Service Manuals
