INSTANT DOWNLOAD
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC27MR, PC30MR, PC35MR, PC40MR, PC50MR, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC27MR-2, PC27MR-3, PC30MR-2, PC30MR-3, PC35MR-2, PC35MR-3, PC40MR-2, PC50MR-2 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.
SEAM060100T – Hydraulic Excavator GALEO PC35MR-2 Operation & Maintenance Manual.pdf
SEBM032411 – Hydraulic Excavator PC27MR-2, PC30MR-2, PC35MR-2, PC40MR-2, PC50MR-2 Shop Manual.pdf
SEN04063-07 – Hydraulic Excavator PC27MR-3, PC30MR-3, PC35MR-3 Shop Manual.pdf
TEN00099-01 – Hydraulic Excavator PC27MR-2, PC35MR-2 Operation & Maintenance Manual.pdf
TEN00115-00 – Hydraulic Excavator GALEO PC27ME-2, PC35MR-2 Operation & Maintenance Manual.pdf
TEN00115-01 – Hydraulic Excavator GALEO PC27MR-2, PC35MR-2 Operation & Maintenance Manual.pdf
TEN00194-00 – Hydraulic Excavator GALEO PC27MR-2, PC35MR-2 Operation & Maintenance Manual.pdf
TEN00284-03 – Hydraulic Excavator GALEO PC27MR-3, PC35MR-3 Operation & Maintenance Manual.pdf
TEN00378-03 – Hydraulic Excavator PC27MR-3, PC35MR-3 Operation & Maintenance Manual.pdf
TEN00507-01 – Hydraulic Excavator PC27MR-3, PC35MR-3 Operation & Maintenance Manual.pdf
TEN00552-01 – Hydraulic Excavator PC27MR-3, PC35MR-3 Operation & Maintenance Manual.pdf
WEAM006600 – Hydraulic Excavator PC30MR-2, PC35MR-2 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 4,021 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
SEAM060100T – Hydraulic Excavator GALEO PC35MR-2 Operation & Maintenance Manual…2
COVER…2
FOREWORD…3
FOREWORD…4
SAFETY INFORMATION…7
INTRODUCTION…9
DIRECTIONS OF MACHINE…9
PRODUCT INFORMATION…10
PRODUCT IDENTIFICATION NUMBER (PIN) MACHINE SERIAL NO. PLATE…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
SAFETY RULES…25
IF ABNORMALITIES ARE FOUND…25
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…25
FIRE EXTINGUISHER AND FIRST AID KIT…25
SAFETY EQUIPMENT…26
KEEP MACHINE CLEAN…26
KEEP OPERATOR'S COMPARTMENT CLEAN…26
LEAVING OPERATOR'S SEAT WITH LOCK…26
HANDRAILS AND STEPS…27
MOUNTING AND DISMOUNTING…27
NO PERSONS ON ATTACHMENTS…27
BURN PREVENTION…28
FIRE PREVENTION AND EXPLOSION PREVENTION…28
ACTION IF FIRE OCCURS…29
WINDSHIELD WASHER FLUID…29
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…30
CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM)…30
ATTACHMENT INSTALLATION…31
ATTACHMENT COMBINATIONS…31
CAB WINDOW GLASSES…31
UNAUTHORIZED MODIFICATIONS…31
SAFETY AT JOBSITE…31
WORKING ON LOOSE GROUND…31
DISTANCE TO HIGH VOLTAGE CABLES…32
ENSURE GOOD VISIBILITY…32
VENTILATION FOR ENCLOSED AREA…33
SIGNALMAN'S SIGNAL AND SIGNS…33
EMERGENCY EXIT FROM OPERATOR'S CAB…33
ASBESTOS DUST HAZARD PREVENTION…33
SAFETY MACHINE OPERATION…34
STARTING ENGINE…34
CHECKS BEFORE STARTING ENGINE…34
SAFETY RULES FOR STARTING ENGINE…35
STARTING ENGINE IN COLD WEATHER…35
OPERATION…36
CHECKS BEFORE OPERATION…36
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…36
SAFETY RULES FOR TRAVELING…37
TRAVELING ON SLOPES…38
OPERATIONS ON SLOPES…39
PROHIBITED OPERATIONS…39
OPERATIONS ON SNOW…41
PARKING MACHINE…41
TRANSPORTATION…42
LOADING AND UNLOADING…42
SHIPPING THE MACHINE…42
BATTERY…43
BATTERY HAZARD PREVENTION…43
STARTING ENGINE WITH BOOSTER CABLES…44
TOWING…45
SAFETY RULES FOR TOWING…45
LIFTING OBJECTS WITH BUCKET…46
SAFETY RULES FOR LIFTING OBJECTS…46
SAFETY MAINTENANCE INFORMATION…47
WARNING TAG…47
KEEP WORK PLACE CLEAN AND TIDY…47
APPOINT LEADER WHEN WORKING WITH OTHERS…47
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…48
CAUTIONS FOR OPENING (TILTING) FLOOR…49
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…50
PROPER TOOLS…50
PERSONNEL…50
ATTACHMENTS…51
WORK UNDER THE MACHINE…51
NOISE…51
WHEN USING HAMMER…51
WELDING WORKS…51
REMOVING BATTERY TERMINALS…52
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…52
DO NOT DISASSEMBLE RECOIL SPRINGS…52
SAFETY RULES FOR HIGH-PRESSURE OIL…52
SAFETY HANDLING HIGH-PRESSURE HOSES…53
WASTE MATERIALS…53
AIR CONDITIONER MAINTENANCE…53
COMPRESSED AIR…53
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…53
OPERATION…54
MACHINE VIEW ILLUSTRATIONS…55
OVERALL MACHINE VIEW…55
CONTROLS AND GAUGES…56
DETAILED CONTROLS AND GAUGES…57
MONITORING SYSTEM…57
SWITCHES…65
CONTROL LEVERS AND PEDALS…69
WINDSHIELD…75
SLIDING DOOR…79
SLIDING WINDOW…79
EMERGENCY ESCAPE HAMMER…80
COVER WITH LOCK…81
ENGINE REAR COVER…82
COOLING COVER…82
MUD COVER…83
METHOD OF OPENING (TILTING) FLOOR…84
FUSE…89
BLOCK FUSE…90
OPERATION MANUAL STORAGE…91
TOOL BOX…91
GREASE GUN HOLDER…91
ASHTRAY…91
MACHINE OPERATIONS AND CONTROLS…92
BEFORE STARTING ENGINE…92
STARTING ENGINE…106
AFTER STARTING ENGINE…109
STOPPING THE ENGINE…112
MACHINE OPERATION…113
STEERING THE MACHINE…118
SWINGING…120
WORK EQUIPMENT CONTROLS AND OPERATIONS…121
PROHIBITED OPERATIONS…123
GENERAL OPERATION INFORMATION…125
TRAVELING ON SLOPES…126
ESCAPE FROM MUD…128
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…129
BUCKET REPLACEMENT…131
PARKING MACHINE…132
MACHINE INSPECTION AFTER DAILY WORK…133
LOCKING…134
RUBBER SHOES AND ROAD LINERS…135
TRANSPORTATION…140
TRANSPORTATION PROCEDURE…140
LOADING AND UNLOADING WITH TRAILER…141
LIFTING MACHINE…147
COLD WEATHER OPERATION…150
COLD WEATHER OPERATION INFORMATION…150
CAB HEATER IN COLD WEATHER…151
AFTER DAILY WORK COMPLETION…152
AFTER COLD WEATHER SEASON…152
LONG TERM STORAGE…153
BEFORE STORAGE…153
DURING STORAGE…154
AFTER STORAGE…154
TROUBLES AND ACTIONS…155
RUNNING OUT OF FUEL…155
PHENOMENA THAT ARE NOT FAILURES…155
TOWING THE MACHINE…156
SEVERE JOB CONDITION…156
DISCHARGED BATTERY…157
OTHER TROUBLE…161
MAINTENANCE…164
MAINTENANCE INFORMATION…165
LUBRICANTS, COOLANT AND FILTERS…168
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…168
ELECTRIC SYSTEM MAINTENANCE…171
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…184
CHECK LEVEL OF BATTERY ELECTROLYTE…187
CLEAN WATER SEPARATOR ELEMENT…189
DRAIN WATER AND SEDIMENT FROM FUEL TANK…189
CHECK AND TIGHTEN TRACK SHOE BOLTS (MACHINE EQUIPPED WITH ROAD LINER)…190
CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH ROAD LINER, STEEL SHOE)…191
CHECK, RUBBER SHOES OR ROAD LINERS (MACHINE EQUIPPED WITH RUBBER SHOES, ROAD LINER)…193
CHECK AND ADJUST RUBBER SHOE TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)…195
REPLACE BUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)…197
REPLACE ROAD LINERS (MACHINE EQUIPPED WITH ROAD LINER)…199
REPLACE BUCKET TEETH…200
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…203
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…204
LUBRICATING…204
BLEEDING AIR FROM HYDRAULIC SYSTEM…205
CHECK BEFORE STARTING…207
EVERY 500 HOURS MAINTENANCE…208
LUBRICATING…208
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…211
REPLACE FUEL FILTER CARTRIDGE…212
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…214
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…215
CHECK AND ADJUST COOLING FAN BELT TENSION…216
EVERY 1000 HOURS MAINTENANCE…217
REPLACE HYDRAULIC OIL FILTER ELEMENT…217
CHANGE OIL IN FINAL DRIVE CASE…218
CHECK ENGINE VALVE CLEARANCE, ADJUST…218
EVERY 2000 HOURS MAINTENANCE…219
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…219
CHECK ALTERNATOR, STARTING MOTOR…221
SPECIFICATIONS…222
SPECIFICATIONS…223
ATTACHMENTS, OPTIONS…225
ATTACHMENTS AND OPTIONS-GENERAL INFORMATION…226
SAFETY FIRST…226
ATTACHMENT INSTALLATION…227
BUCKET WITH HOOK…228
PROHIBITED OPERATIONS…228
AIR CONDITIONER…229
CONTROL PANEL AND COMPONENTS…229
AIR CONDITIONER CONTROLS…230
AIR CONDITIONER MAINTENANCE…231
RADIO…235
CONTROL PANEL…235
CONTROLS OF RADIO…236
CARE FOR RADIO…238
WINDSHIELD WASHER…239
WINDSHIELD WASHER OPERATION…239
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…239
MACHINE READY FOR ATTACHMENT…240
LOCATIONS…240
HYDRAULIC CIRCUIT…242
ATTACHMENT OPERATIONS…244
LONG TERM STORAGE…245
SPECIFICATIONS…245
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…246
CONTROL PATTERN CHANGE PROCEDURE…246
MACHINE CONTROL PATTERNS…247
ATTACHMENT GUIDE…248
ATTACHMENT COMBINATIONS…248
RECOMMENDED ATTACHMENT OPERATIONS…249
HYDRAULIC BREAKER…249
INDEX…254
SEBM032411 – Hydraulic Excavator PC27MR-2, PC30MR-2, PC35MR-2, PC40MR-2, PC50MR-2 Shop Manual…257
COVER…257
CONTENTS…258
01 GENERAL…283
SPECIFICATION DIMENSION DRAWING…284
WORKING RANGE DRAWING…286
SPECIFICATIONS…288
WEIGHT TABLE…307
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…315
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…318
PTO…319
COOLING SYSTEM…320
POWER TRAIN…323
SWING CIRCLE…325
SWING MACHINERY…326
TRACK FRAME…330
IDLER CUSHION…332
IDLER…333
TRACK ROLLER…335
CARRIER ROLLER…337
SPROCKET…338
TRACK SHOE…339
HYDRAULIC COMPONENTS LAYOUT DRAWING…346
HYDRAULIC TANK…348
CENTER SWIVEL JOINT…351
TRAVEL MOTOR…354
HYDRAULIC CYLINDER…362
SOLENOID VALVE…369
MULTI-CONTROL VALVE…373
HYDRAULIC PUMP…374
CONTROL VALVE…392
CLSS…429
OPERATION FOR EACH FUNCTION AND VALVE…432
SWING MOTOR…474
PPC VALVE…486
WORK EQUIPMENT…494
DIMENSIONS OF EACH PART OF WORK EQUIPMENT…497
FLOOR…508
AIR CONDITIONER…510
ENGINE CONTROL…511
ELECTRIC CONTROL SYSTEM…513
COMPONENT PARTS OF SYSTEM…521
MONITOR SYSTEM…522
MONITOR PANEL…523
SENSORS…525
20 TESTING AND ADJUSTING…527
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…528
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…533
TESTING AND ADJUSTING…559
LIST OF TESTING,ADJUSTING, AND TROUBLESHOOTING TOOLS…560
MEASURING ENGINE SPEED…562
MEASUREMENT OF EXHAUST GAS COLOR…563
ADJUSTING VALVE CLEARANCE…564
MEASURING COMPRESSION PRESSURE…566
MEASURING ENGINE OIL PRESSURE…567
TESTING AND ADJUSTING FUEL INJECTION TIMING…568
TESTING AND ADJUSTING ALTERNATOR BELT TENSION…571
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…572
ADJUSTING FUEL CONTROL LEVER…573
TESTING AND ADJUSTING TRACK SHOE TENSION…574
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS…575
MEASURING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, BOOM SWING, SWING,AND BLADE CIRCUITS…576
MEASURING AND ADJUSTING LS DIFFERENTIAL PRESSURE…582
ADJUSTING PC VALVE…586
MEASURING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE REDUCED BY SELF PRESSURE)…587
MEASURING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE…588
MEASURING SOLENOID VALVE OUTPUT PRESSURE…590
MEASURING PPC VALVE OUTPUT PRESSURE…592
ADJUSTING PPC VALVE…596
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE…597
TESTING AND ADJUSTING TRAVEL DEVIATION…598
MEASUREMENT OF OIL LEAKAGE FROM WORK EQUIPMENT CYLINDER…600
BLEEDING AIR FROM EACH PART…602
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT…605
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK…605
PRESSURIZING HYDRAULIC TANK…606
HOW TO OPEN AND CLOSE (TILT) FLOOR…607
INSPECTION PROCEDURES FOR DIODE…611
TROUBLESHOOTING…612
POINTS TO REMEMBER WHEN TROUBLESHOOTING…613
SEQUENCE OF EVENTS IN TROUBLESHOOTING…614
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…615
CHECKS BEFORE TROUBLESHOOTING…623
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING…624
TYPES AND LOCATIONS OF CONNECTORS…627
CONNECTOR ARRANGEMENT DIAGRAM…633
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…641
T-ADAPTER-BOXES AND T-ADAPTER TABLE…664
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…667
BEFORE STARTING E-MODE TROUBLESHOOTING…668
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…669
E-1 ENGINE DOES NOT START…670
E-2 ENGINE DOES NOT STOP…678
E-3 WHEN WORK EQUIPMENT LOCK (PPC BASIC PRESSURE LOCK) LEVER IS SET IN LOCK POSITION, WORK EQUIPMENT STILL MOVES…682
E-4 WINDSHIELD WIPER DOES NOT OPERATE…686
E-5 WINDSHIELD WASHER DOES NOT OPERATE…688
E-6 TRAVEL ALARM DOES NOT SOUND…692
E-7 DEFECTIVE AIR CONDITIONER…696
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…704
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…705
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL,SWING,AND BLADE IS LOW…706
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS…710
H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT WORK…711
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP…715
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW…715
H-6 SPEED OR POWER OF BOOM IS LOW…716
H-7 SPEED OR POWER OF ARM IS LOW…717
H-8 SPEED OR POWER OF BUCKET IS LOW…718
H-9 SPEED OR POWER OF BOOM SWING IS LOW…719
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY…719
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE…720
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE…721
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW…721
H-14 MACHINE DEVIATES DURING TRAVEL…722
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW (WHILE WORK EQUIPMENT IS NORMAL)…724
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW…725
H-17 TRAVEL SPEED DOES NOT CHANGE…726
H-18 TRAVEL MOTOR DOES NOT WORK…727
H-19 SPEED OR POWER OF SWING IS LOW…729
H-20 MACHINE DOES NOT SWING…731
H-21 SWING ACCELERATION PERFORMANCE IS LOW…733
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING…735
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING…736
H-24 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING,IT MAKES LARGE SOUND…736
H-25 HYDRAULIC DRIFT OF SWING IS LARGE…737
H-26 SPEED OR POWER OF BLADE IS LOW…738
H-27 BLADE DOES NOT MOVE…739
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE…739
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M-MODE)…740
BEFORE STARTING M-MODE TROUBLESHOOTING…741
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…742
SYSTEM DIAGRAM RELATED TO MONITOR PANEL…743
M-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT OPERATE…745
M-2 WHEN STARTING SWITCH IS TURNED ON, SOME ITEMS DO NOT OPERATE…747
M-3 ALARM BUZZER IS ABNORMAL…748
M-4 ENGINE OIL PRESSURE CAUTION IS TURNED ON…750
M-5 CHARGE LEVEL CAUTION IS TURNED ON…751
M-6 PREHEATING SYSTEM DOES NOT OPERATE OR PREHEATER DOES NOT BECOME HOT…755
M-7 COOLANT TEMPERATURE GAUGE IS ABNORMAL…757
M-8 FUEL LEVEL GAUGE IS ABNORMAL…762
M-9 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING …766
M-10 2ND TRAVEL SPEED IS NOT SELECTED…768
M-11 WORKING LAMP DOES NOT LIGHT UP…773
TROUBLESHOOTING OF ENGINE (S-MODE)…776
METHOD OF USING TROUBLESHOOTING CHARTS…777
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…781
S-2 ENGINE DOES NOT START…783
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…786
S-4 ENGINE STOPS DURING OPERATIONS…787
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…788
S-6 ENGINE LACKS OUTPUT OR LACKS POWER…789
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…790
S-8 OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE…791
S-9 OIL BECOMES CONTAMINATED QUICKLY…792
S-10 FUEL CONSUMPTION IS EXCESSIVE…793
S-11 OIL IS IN COOLANT, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…794
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…795
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…796
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…797
S-15 ABNORMAL NOISE IS MADE…798
S-16 VIBRATION IS EXCESSIVE…799
30 DISASSEMBLY AND ASSEMBLY…800
HOW TO READ THIS MANUAL…801
PRECAUTIONS WHEN PERFORMING OPERATION…803
SPECIAL TOOL LIST…807
SKETCHES OF SPECIAL TOOLS…811
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY…812
REMOVAL AND INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY…814
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY…821
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY…828
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…829
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY…831
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY…834
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY…836
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY…837
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY…840
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY…842
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY…846
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY…847
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY…853
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY…855
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY…857
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…858
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…859
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY…863
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)…866
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY…874
90 OTHERS…875
HYDRAULIC CIRCUIT DIAGRAM PC27MR-2…876
HYDRAULIC CIRCUIT DIAGRAM PC30MR-2…877
HYDRAULIC CIRCUIT DIAGRAM PC35MR-2…878
HYDRAULIC CIRCUIT DIAGRAM PC40MR, 50MR-2…879
HYDRAULIC CIRCUIT DIAGRAM PC40MR, 50MR-2 (ADDITIONAL ATTACHMENT CIRCUIT) …880
ELECTRICAL CIRCUIT DIAGRAM PC27MR, 30MR-2 (1/2)…881
ELECTRICAL CIRCUIT DIAGRAM PC27MR, 30MR-2 (2/2)…882
ELECTRICAL CIRCUIT DIAGRAM PC35MR-2 (1/2)…883
ELECTRICAL CIRCUIT DIAGRAM PC35MR-2 (2/2)…884
ELECTRICAL CIRCUIT DIAGRAM PC40MR, 50MR-2 (1/2)…885
ELECTRICAL CIRCUIT DIAGRAM PC40MR, 50MR-2 (2/2)…886
SEN04063-07 – Hydraulic Excavator PC27MR-3, PC30MR-3, PC35MR-3 Shop Manual…887
COVER…887
00 Index and foreword…0
100 Index…888
Composition of shop manual…889
Table of contents…891
200 Foreword and general information…898
Safety notice…899
How to read the shop manual…904
Explanation of terms for maintenance standard…906
Handling of electric equipment and hydraulic component…908
Handling of connectors newly used for engines…917
How to read electric wire code…920
Precautions when carrying out operation…923
Method of disassembling and connecting push-pull type coupler…926
Standard tightening torque table…929
Conversion table…933
01 Specification…0
100 Specification and technical data…940
Specification dimension drawing…941
Working range drawing…942
Specifications…943
Weight table…953
Table of fuel, coolant and lubricants…957
10 Structure, function and maintenance standard…0
100 Engine and cooling system…960
PTO…961
Cooling system…963
200 Power train…966
Power train…967
Swing circle…969
Swing machinery…970
300 Undercarriage and frame…974
Track frame…975
Idler cushion…976
Idler…977
Track roller…979
Carrier roller…980
Sprocket…981
Track shoe…982
410 Hydraulic system, Part 1…988
Hydraulic components layout drawing…989
Hydraulic tank, filter…990
Center swivel joint…992
Travel motor…994
Hydraulic cylinder…1002
Solenoid valve…1007
Multi-control valve…1013
420 Hydraulic system, Part 2…1016
Hydraulic pump…1017
Control valve…1033
430 Hydraulic system, Part 3…1066
CLSS…1067
Operation for each function and valve…1071
Swing motor…1111
PPC valve…1116
500 Work equipment…1128
Work equipment…1129
Dimensions of each part of work equipment…1133
600 Cab and its attachments…1142
Floor…1143
Air conditioner…1144
700 Electrical system…1146
Engine control system…1147
Electric control system…1151
Auto-deceleration function…1161
Attachment proportional switch, breaker operation switch, work mode selection, flow control function…1165
KOMTRAX system…1175
Component parts of system…1178
Monitor system…1179
Sensors…1183
20 Standard value table…0
100 Standard service value table…1188
Standard service value table for engine related parts…1189
Standard service value table for chassis related parts…1191
30 Testing and adjusting…0
100 Testing and adjusting…1216
Tools for testing, adjusting, and troubleshooting…1218
Testing engine speed…1221
Testing exhaust gas color…1222
Testing and adjusting valve clearance…1223
Testing compression pressure…1224
Testing engine oil pressure…1225
Testing and adjusting fuel injection timing…1226
Testing and adjusting alternator belt tension…1230
Testing and adjusting air conditioner compressor belt tension…1231
Adjusting fuel control lever…1232
Testing clearance in swing circle bearings…1233
Testing and adjusting track shoe tension…1234
Testing and adjusting oil pressures in work equipment, travel, boom swing, swing, and blade circuits…1235
Testing and adjusting LS differential pressure…1240
Adjusting PC valve…1243
Testing and adjusting control pump circuit oil pressure…1244
Testing solenoid valve output pressure…1246
Testing PPC valve output pressure…1247
Adjusting PPC valve…1251
Testing swing holding brake release pressure…1252
Testing and adjusting travel deviation…1253
Testing oil leakage from work equipment cylinder…1255
Bleeding air from each part…1257
Releasing residual pressure from hydraulic circuit…1259
Releasing residual pressure from hydraulic tank…1260
Pressurizing hydraulic tank…1260
How to open and close (tilt) floor…1261
Inspection procedures for diode…1266
Function and flow of operator and service mode…1267
How to start operation of KOMTRAX terminal…1291
Lamp display of KOMTRAX terminal…1295
Removal and installation of KOMTRAX terminal…1298
Preparation work for troubleshooting of electrical system…1299
40 Troubleshooting…0
010 Failure code table and fuse locations…1302
User code and failure code list…1303
Fuse locations…1304
100 General information on troubleshooting…1310
Points to remember when troubleshooting…1311
Sequence of events in troubleshooting…1312
Checks before troubleshooting…1313
Classification and procedures of troubleshooting…1314
Information contained in troubleshooting table…1315
Connection table for connector pin numbers…1319
T- branch box and T- branch adapter table…1355
110 Troubleshooting by failure code…1360
Failure code [DBHRKR] Communication error between monitor panel and attachment switch controller…1363
Failure code [DBH1KK] Unswitched power supply error…1365
Failure code [DBH2KK] Solenoid power supply error…1367
Failure code [DBH5KP] 5V sensor power supply output 0 error…1369
Failure code [DBH6KP] 5V sensor power supply output 1 error…1370
Failure code [DDWLKA] Breaker switch error (Disconnection or short circuit)…1371
Failure code [DDWLKB] Breaker switch error (Hot short circuit)…1372
Failure code [DFB1KA] Attachment switch (main) error (Disconnection or ground fault)…1373
Failure code [DFB1KB] Attachment switch (main) error (Hot short circuit)…1375
Failure code [DFB3L8] Attachment switch (main-sub) voltage difference error…1376
Failure code [DK10KA] Fuel control dial potentiometer error (Disconnection or ground fault)…1377
Failure code [DK10KB] Fuel control dial potentiometer error (Hot short circuit)…1379
Failure code [DK58KA] Governor stroke sensor error (Disconnection or ground fault)…1381
Failure code [DK58KB] Governor stroke sensor error (Hot short circuit)…1383
Failure code [D1E0KZ] Motor power supply relay error (Disconnection or hot short circuit)…1385
Failure code [D1E0KB] Motor power supply relay error (Ground fault)…1387
Failure code [D1E1KZ] Motor drive relay (+) error (Disconnection or hot short circuit)…1389
Failure code [D1E1KB] Motor drive relay (+) error (Ground fault)…1391
Failure code [D1E2KZ] Motor drive relay (-) error (Disconnection or hot short circuit)…1393
Failure code [D1E2KB] Motor drive relay (-) error (Ground fault)…1395
Failure code [DY10MA] Fuel control motor operation error…1397
Failure code [D1E0KA] Fuel control motor power supply relay contact sticking (NC side)…1399
Failure code [D1E0KY] Fuel control motor power supply relay contact sticking (NO side)…1401
Failure code [DXEAKA] EPC valve (port A side) error (Disconnection)…1403
Failure code [DXEAKB] EPC valve (port B side) error (Ground fault)…1405
Failure code [DXEAKY] EPC valve (port A side) error (Hot short circuit)…1406
200 Troubleshooting of electrical system (E-mode)…1408
Before carrying out troubleshooting of electrical system…1409
E-1 Engine does not start…1411
E-2 Engine does not stop…1427
E-3 When starting switch is turned ON, any item does not operate…1431
E-4 When starting switch is turned ON, some items do not operate…1435
E-5 Alarm buzzer is abnormal…1436
E-6 Engine oil pressure caution is turned ON…1438
E-7 Charge level caution is turned ON…1439
E-8 Preheating system does not operate or preheater does not become hot1…1441
E-9 Coolant temperature gauge is abnormal…1443
E-10 Fuel level gauge is abnormal…1451
E-11 Service meter does not operate while engine is running…1459
E-12 2nd travel speed is not selected…1463
E-13 Working lamp does not light up…1467
E-14 When work equipment lock (PPC basic pressure lock) lever is set in LOCK, work equipment still moves…1471
E-15 Windshield wiper does not operate…1475
E-16 Windshield washer does not operate…1479
E-17 Defective air conditioner…1482
E-18 KOMTRAX system does not operate normally…1490
300 Troubleshooting of hydraulic and mechanical system (H-mode)…1494
Information contained in troubleshooting table…1496
H1 Speed or power of whole work equipment, travel, swing, and blade is low…1497
H-2 Engine speed lowers extremely or engine stalls…1501
H-3 Whole work equipment, travel system, swing system, and blade do not work…1502
H-4 Abnormal sound comes out from around hydraulic pump…1506
H-5 Fine control performance or response is low…1506
H-6 Speed or power of boom is low…1507
H-7 Speed or power of arm is low…1508
H-8 Speed or power of bucket is low…1509
H-9 Speed or power of boom swing is low…1510
H-10 Work equipment does not move singly…1510
H-11 Work equipment hydraulic drift is large…1511
H-12 Time lag of work equipment is large…1513
H-13 In compound operation of work equipment, speed of part loaded more is low…1513
H-14 Machine deviates during travel…1514
H-15 Travel speed or travel power is low (while work equipment is normal)…1516
H-16 Machine is not steered well or steering power is low…1517
H-17 Travel speed does not change…1518
H-18 Travel motor does not work…1519
H-19 Speed or power of swing is low…1521
H-20 Machine does not swing…1523
H-21 Swing acceleration performance is low…1525
H-22 Machine overruns when it stops swinging…1527
H-23 Large shock is made when machine stops swinging…1528
H-24 When upper structure stops swinging, it makes large sound…1528
H-25 Hydraulic drift of swing is large…1529
H-26 Speed or power of blade is low…1530
H-27 Blade does not move…1531
H-28 Hydraulic drift of blade is large…1532
400 Troubleshooting of engine (S-mode)…1534
Method of using troubleshooting charts…1536
S-1 Starting performance is poor…1539
S-2 Engine does not start…1540
S-3 Engine does not pick up smoothly…1543
S-4 Engine stops during operations…1544
S-5 Engine does not rotate smoothly…1545
S-6 Engine lacks output (or lacks power)…1546
S-7 Exhaust smoke is black (incomplete combustion)…1547
S-8 Oil consumption is excessive (or exhaust smoke is blue)…1548
S-9 Oil becomes contaminated quickly…1549
S-10 Fuel consumption is excessive…1550
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…1551
S-12 Oil pressure drops…1552
S-13 Oil level rises (Entry of coolant/fuel)…1553
S-14 Coolant temperature becomes too high (overheating)…1554
S-15 Abnormal noise is made…1555
S-16 Vibration is excessive…1556
50 Disassembly and assembly…0
100 General information on disassembly and assembly…1558
How to read this manual…1559
Coating materials list…1561
Special tool list…1564
Sketches of special tools…1568
200 Engine and cooling system…1570
Removal and installation of fuel injection pump assembly…1571
Removal and installation of radiator and hydraulic oil cooler assembly…1574
Removal and installation of engine and hydraulic pump assembly…1578
300 Power train…1582
Removal and installation of swing motor and swing machinery assembly…1583
Disassembly and assembly of swing motor and swing machinery assembly…1584
Removal and installation of swing circle assembly…1589
400 Undercarriage and frame…1592
Removal and installation of track shoe assembly…1593
Disassembly and assembly of idler assembly…1594
Disassembly and assembly of recoil spring assembly…1596
Disassembly and assembly of track roller assembly…1599
Disassembly and assembly of carrier roller assembly…1600
Removal and installation of revolving frame assembly…1601
500 Hydraulic system…1604
Removal and installation of center swivel joint assembly…1605
Disassembly and assembly of center swivel joint assembly…1607
Disassembly and assembly of control valve assembly…1609
Disassembly and assembly of hydraulic cylinder assembly…1610
600 Work equipment…1616
Removal and installation of work equipment assembly…1617
700 Cab and its attachments…1620
Removal and installation of operator’s cab glass (stuck glass)…1621
Removal and installation of front window assembly…1630
Removal and installation of floor frame assembly…1631
800 Electrical system…1636
Removal and installation of air conditioner unit assembly (If equipped)…1637
90 Diagrams and drawings…0
100 Hydraulic diagrams and drawings…1642
Hydraulic circuit diagram…1644
200 Electrical diagrams and drawings…1652
Electrical circuit diagram…1654
Connector list and stereogram…1662
TEN00099-01 – Hydraulic Excavator PC27MR-2, PC35MR-2 Operation & Maintenance Manual…1666
COVER…1666
FOREWORD…1667
FOREWORD…1668
SAFETY INFORMATION…1671
INTRODUCTION…1673
DIRECTIONS OF MACHINE…1673
PRODUCT INFORMATION…1674
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1674
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1674
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…1675
SERVICE METER LOCATION…1675
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1676
CONTENTS…1677
SAFETY…1680
SAFETY INFORMATION…1681
SAFETY LABELS…1683
LOCATION OF SAFETY LABELS…1683
SAFETY LABELS…1684
SAFETY INFORMATION…1689
SAFETY RULES…1689
IF PROBLEMS ARE FOUND…1689
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…1689
FIRE EXTINGUISHER AND FIRST AID KIT…1689
SAFETY EQUIPMENT…1690
KEEP MACHINE CLEAN…1690
KEEP OPERATOR'S COMPARTMENT CLEAN…1690
LEAVING OPERATOR'S SEAT WITH LOCK…1690
HANDRAILS AND STEPS…1691
MOUNTING AND DISMOUNTING…1691
NO PERSONS ON ATTACHMENTS…1691
BURN PREVENTION…1692
FIRE PREVENTION AND EXPLOSION PREVENTION…1692
ACTION IF FIRE OCCURS…1693
WINDSHIELD WASHER FLUID…1693
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…1694
CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM)…1694
ATTACHMENT INSTALLATION…1695
ATTACHMENT COMBINATIONS…1695
CAB WINDOW GLASSES…1695
UNAUTHORIZED MODIFICATIONS…1695
SAFETY AT JOBSITE…1695
WORKING ON LOOSE GROUND…1695
DISTANCE TO HIGH VOLTAGE CABLES…1696
ENSURE GOOD VISIBILITY…1696
VENTILATION FOR ENCLOSED AREA…1696
SIGNALMAN'S SIGNAL AND SIGNS…1697
EMERGENCY EXIT FROM OPERATOR'S CAB…1697
ASBESTOS DUST HAZARD PREVENTION…1697
SAFETY MACHINE OPERATION…1698
STARTING ENGINE…1698
CHECKS BEFORE STARTING ENGINE…1698
SAFETY RULES FOR STARTING ENGINE…1699
STARTING ENGINE IN COLD WEATHER…1699
OPERATION…1700
CHECKS BEFORE OPERATION…1700
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…1700
SAFETY RULES FOR TRAVELING…1701
TRAVELING ON SLOPES…1702
OPERATIONS ON SLOPES…1703
PROHIBITED OPERATIONS…1703
OPERATIONS ON SNOW…1705
PARKING MACHINE…1705
TRANSPORTATION…1706
LOADING AND UNLOADING…1706
SHIPPING THE MACHINE…1706
BATTERY…1707
BATTERY HAZARD PREVENTION…1707
STARTING ENGINE WITH BOOSTER CABLES…1708
TOWING…1709
SAFETY RULES FOR TOWING…1709
LIFTING OBJECTS WITH BUCKET…1710
SAFETY RULES FOR LIFTING OBJECTS…1710
SAFETY MAINTENANCE INFORMATION…1711
WARNING TAG…1711
KEEP WORK PLACE CLEAN AND TIDY…1711
APPOINT LEADER WHEN WORKING WITH OTHERS…1711
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…1712
CAUTIONS FOR OPENING (TILTING) FLOOR…1713
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…1714
PROPER TOOLS…1714
PERSONNEL…1714
ATTACHMENTS…1715
WORK UNDER THE MACHINE…1715
NOISE…1715
WHEN USING HAMMER…1715
WELDING WORKS…1715
REMOVING BATTERY TERMINALS…1716
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…1716
DO NOT DISASSEMBLE RECOIL SPRINGS…1716
SAFETY RULES FOR HIGH-PRESSURE OIL…1716
SAFETY HANDLING HIGH-PRESSURE HOSES…1717
WASTE MATERIALS…1717
AIR CONDITIONER MAINTENANCE…1717
COMPRESSED AIR…1717
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1717
OPERATION…1718
MACHINE VIEW ILLUSTRATIONS…1719
OVERALL MACHINE VIEW…1719
CONTROLS AND GAUGES…1720
DETAILED CONTROLS AND GAUGES…1721
MONITORING SYSTEM…1721
SWITCHES…1729
CONTROL LEVERS AND PEDALS…1733
WINDSHIELD…1739
SLIDING DOOR…1743
SLIDING WINDOW…1743
EMERGENCY ESCAPE HAMMER…1744
COVER WITH LOCK…1745
ENGINE REAR COVER…1746
COOLING COVER…1746
MUD COVER…1747
METHOD OF OPENING (TILTING) FLOOR…1748
FUSE…1753
BLOCK FUSE…1754
OPERATION MANUAL STORAGE…1755
TOOL BOX…1755
GREASE GUN HOLDER…1755
ASHTRAY…1755
MACHINE OPERATIONS AND CONTROLS…1756
BEFORE STARTING ENGINE…1756
STARTING ENGINE…1771
AFTER STARTING ENGINE…1775
STOPPING THE ENGINE…1778
MACHINE OPERATION…1779
STEERING THE MACHINE…1784
SWINGING…1786
WORK EQUIPMENT CONTROLS AND OPERATIONS…1787
PROHIBITED OPERATIONS…1789
GENERAL OPERATION INFORMATION…1791
TRAVELING ON SLOPES…1793
ESCAPE FROM MUD…1795
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…1796
BUCKET REPLACEMENT…1798
PARKING MACHINE…1799
MACHINE INSPECTION AFTER DAILY WORK…1800
LOCKING…1801
RUBBER SHOES AND ROAD LINERS…1802
TRANSPORTATION…1807
TRANSPORTATION PROCEDURE…1807
LOADING AND UNLOADING WITH TRAILER…1808
LIFTING MACHINE…1814
COLD WEATHER OPERATION…1817
COLD WEATHER OPERATION INFORMATION…1817
CAB HEATER COLD WEATHER…1818
AFTER DAILY WORK COMPLETION…1819
AFTER COLD WEATHER SEASON…1819
LONG TERM STORAGE…1820
BEFORE STORAGE…1820
DURING STORAGE…1821
AFTER STORAGE…1821
TROUBLES AND ACTIONS…1822
RUNNING OUT OF FUEL…1822
PHENOMENA THAT ARE NOT FAILURES…1822
TOWING THE MACHINE…1823
SEVERE JOB CONDITION…1823
DISCHARGED BATTERY…1824
OTHER TROUBLE…1828
MAINTENANCE…1831
MAINTENANCE INFORMATION…1832
OUTLINE OF SERVICE…1834
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1834
ELECTRIC SYSTEM MAINTENANCE…1837
HANDLING HYDRAULIC SYSTEM…1837
WEAR PARTS…1838
WEAR PARTS LIST…1838
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…1839
TIGHTENING TORQUE SPECIFICATIONS…1843
TIGHTENING TORQUE LIST…1843
SAFETY CRITICAL PARTS…1844
SAFETY CRITICAL PARTS LIST…1844
MAINTENANCE SCHEDULE…1845
MAINTENANCE SCHEDULE CHART…1845
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1846
MAINTENANCE PROCEDURE…1847
WHEN REQUIRED…1847
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…1847
CLEAN INSIDE OF COOLING SYSTEM…1850
CHECK LEVEL OF BATTERY ELECTROLYTE…1854
CLEAN WATER SEPARATOR ELEMENT…1856
DRAIN WATER AND SEDIMENT FROM FUEL TANK…1856
CHECK AND TIGHTEN TRACK SHOE BOLTS…1857
CHECK AND ADJUST TRACK TENSION …1858
CHECK,RUBBER SHOES OR ROAD LINERS …1860
CHECK AND ADJUST RUBBER SHOE TENSION …1862
REPLACE RUBBER SHOES …1864
REPLACE ROAD LINERS…1866
REPLACE BUCKET TEETH…1867
CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID…1870
CHECK,CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…1871
LUBRICATING…1871
BLEEDING AIR FROM HYDRAULIC SYSTEM…1872
CHECK BEFORE STARTING…1874
EVERY 500 HOURS MAINTENANCE…1875
LUBRICATING…1875
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…1878
REPLACE FUEL FILTER CARTRIDGE…1879
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…1881
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…1882
CHECK AND ADJUST COOLING FAN BELT TENSION…1883
EVERY 1000 HOURS MAINTENANCE…1884
REPLACE HYDRAULIC OIL FILTER ELEMENT…1884
CHANGE OIL IN FINAL DRIVE CASE…1885
CHECK ENGINE VALVE CLEARANCE,ADJUST…1885
EVERY 2000 HOURS MAINTENANCE…1886
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…1886
CHECK ALTERNATOR, STARTING MOTOR…1888
SPECIFICATIONS…1889
SPECIFICATIONS…1890
ATTACHMENTS, OPTIONS…1892
ATTACHMENTS AND OPTIONS-GENERAL INFORMATION…1893
SAFETY FIRST…1893
ATTACHMENT INSTALLATION…1894
BUCKET WITH HOOK…1895
PROHIBITED OPERATIONS…1895
AIR CONDITIONER…1896
CONTROL PANEL AND COMPONENTS …1896
AIR CONDITIONER CONTROLS…1897
AIR CONDITIONER MAINTENANCE…1898
WINDSHIELD WASHER…1902
WINDSHIELD WASHER OPERATION …1902
CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID…1902
MACHINE READY FOR ATTACHMENT…1903
LOCATIONS…1903
HYDRAULIC CIRCUIT…1905
ATTACHMENT OPERATIONS…1907
LONG TERM STORAGE…1908
SPECIFICATIONS…1908
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…1909
CONTROL PATTERN CHANGE PROCEDURE…1909
MACHINE CONTROL PATTERNS…1910
POWER ANGLE BLADE…1911
BLADE CONTROL LEVER…1911
WHEN REQUIRED…1912
EVERY 500 HOURS SERVICE…1912
WEAR PARTS LIST…1913
SPECIFICATIONS…1913
ATTACHMENT GUIDE…1914
ATTACHMENT COMBINATIONS…1914
RECOMMENDED ATTACHMENT OPERATIONS…1915
HYDRAULIC BREAKER…1915
INDEX…1920
TEN00115-00 – Hydraulic Excavator GALEO PC27ME-2, PC35MR-2 Operation & Maintenance Manual…1923
COVER…1923
FOREWORD…1924
FOREWORD…1925
SAFETY INFORMATION…1928
INTRODUCTION…1930
DIRECTIONS OF MACHINE…1930
PRODUCT INFORMATION…1931
PRODUCT IDENTIFICATION NUMBER(PIN)/MACHINE SERIAL NO.PLATE…1931
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1931
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…1932
SERVICE METER LOCATION…1932
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1933
CONTENTS…1934
SAFETY…1937
SAFETY INFORMATION…1938
SAFETY LABELS…1940
LOCATION OF SAFETY LABELS…1940
SAFETY LABELS…1941
SAFETY INFORMATION…1946
SAFETY RULES…1946
IF PROBLEMS ARE FOUND…1946
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…1946
FIRE EXTINGUISHER AND FIRST AID KIT…1946
SAFETY EQUIPMENT…1947
KEEP MACHINE CLEAN…1947
KEEP OPERATOR'S COMPARTMENT CLEAN…1947
LEAVING OPERATOR'S SEAT WITH LOCK…1947
HANDRAILS AND STEPS…1948
MOUNTING AND DISMOUNTING…1948
NO PERSONS ON ATTACHMENTS…1948
BURN PREVENTION…1949
FIRE PREVENTION AND EXPLOSION PREVENTION…1949
ACTION IF FIRE OCCURS…1950
WINDSHIELD WASHER FLUID…1950
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…1951
CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM)…1951
ATTACHMENT INSTALLATION…1952
ATTACHMENT COMBINATIONS…1952
CAB WINDOW GLASSES…1952
UNAUTHORIZED MODIFICATIONS…1952
SAFETY AT JOBSITE…1952
WORKING ON LOOSE GROUND…1952
DISTANCE TO HIGH VOLTAGE CABLES…1953
ENSURE GOOD VISIBILITY…1953
VENTILATION FOR ENCLOSED AREA…1953
SIGNALMAN'S SIGNAL AND SIGNS…1954
EMERGENCY EXIT FROM OPERATOR'S CAB…1954
ASBESTOS DUST HAZARD PREVENTION…1954
SAFETY MACHINE OPERATION…1955
STARTING ENGINE…1955
CHECKS BEFORE STARTING ENGINE…1955
SAFETY RULES FOR STARTING ENGINE…1956
STARTING ENGINE IN COLD WEATHER…1956
OPERATION…1957
CHECKS BEFORE OPERATION…1957
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…1957
SAFETY RULES FOR TRAVELING…1958
TRAVELING ON SLOPES…1959
OPERATIONS ON SLOPES…1960
PROHIBITED OPERATIONS…1960
OPERATIONS ON SNOW…1962
PARKING MACHINE…1962
TRANSPORTATION…1963
LOADING AND UNLOADING…1963
SHIPPING THE MACHINE…1963
BATTERY…1964
BATTERY HAZARD PREVENTION…1964
STARTING ENGINE WITH BOOSTER CABLES…1965
TOWING…1966
SAFETY RULES FOR TOWING…1966
LIFTING OBJECTS WITH BUCKET…1967
SAFETY RULES FOR LIFTING OBJECTS…1967
SAFETY MAINTENANCE INFORMATION…1968
WARNING TAG…1968
KEEP WORK PLACE CLEAN AND TIDY…1968
APPOINT LEADER WHEN WORKING WITH OTHERS…1968
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…1969
CAUTIONS FOR OPENING (TILTING) FLOOR…1970
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…1971
PROPER TOOLS…1971
PERSONNEL…1971
ATTACHMENTS…1972
WORK UNDER THE MACHINE…1972
NOISE…1972
WHEN USING HAMMER…1972
WELDING WORKS…1972
REMOVING BATTERY TERMINALS…1973
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…1973
DO NOT DISASSEMBLE RECOIL SPRINGS…1973
SAFETY RULES FOR HIGH-PRESSURE OIL…1973
SAFETY HANDLING HIGH-PRESSURE HOSES…1974
WASTE MATERIALS…1974
AIR CONDITIONER MAINTENANCE…1974
COMPRESSED AIR…1974
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1974
OPERATION…1975
MACHINE VIEW ILLUSTRATIONS…1976
OVERALL MACHINE VIEW…1976
CONTROLS AND GAUGES…1977
DETAILED CONTROLS AND GAUGES…1978
MONITORING SYSTEM…1978
SWITCHES…1986
CONTROL LEVERS AND PEDALS…1990
WINDSHIELD…1996
SLIDING DOOR…2000
SLIDING WINDOW…2000
EMERGENCY ESCAPE HAMMER…2001
COVER WITH LOCK…2002
ENGINE REAR COVER…2003
COOLING COVER…2003
MUD COVER…2004
METHOD OF OPENING (TILTING) FLOOR…2005
FUSE…2010
BLOCK FUSE…2011
OPERATION MANUAL STORAGE…2012
TOOL BOX…2012
GREASE GUN HOLDER…2012
ASHTRAY…2012
MACHINE OPERATIONS AND CONTROLS…2013
BEFORE STARTING ENGINE…2013
STARTING ENGINE…2028
AFTER STARTING ENGINE…2032
STOPPING THE ENGINE…2035
MACHINE OPERATION…2036
STEERING THE MACHINE…2041
SWINGING…2043
WORK EQUIPMENT CONTROLS AND OPERATIONS…2044
PROHIBITED OPERATIONS…2046
GENERAL OPERATION INFORMATION…2048
TRAVELING ON SLOPES…2050
ESCAPE FROM MUD…2052
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…2053
BUCKET REPLACEMENT…2055
PARKING MACHINE…2056
MACHINE INSPECTION AFTER DAILY WORK…2057
LOCKING…2058
RUBBER SHOES AND ROAD LINERS…2059
TRANSPORTATION…2064
TRANSPORTATION PROCEDURE…2064
LOADING AND UNLOADING WITH TRAILER…2065
LIFTING MACHINE…2071
COLD WEATHER OPERATION…2074
COLD WEATHER OPERATION INFORMATION…2074
CAB HEATER IN COLD WEATHER…2075
AFTER DAILY WORK COMPLETION…2076
AFTER COLD WEATHER SEASON…2076
LONG TERM STORAGE…2077
BEFORE STORAGE…2077
DURING STORAGE…2078
AFTER STORAGE…2078
TROUBLES AND ACTIONS…2079
RUNNING OUT OF FUEL…2079
PHENOMENA THAT ARE NOT FAILURES…2079
TOWING THE MACHINE…2080
SEVERE JOB CONDITION…2080
DISCHARGED BATTERY…2081
OTHER TROUBLE…2085
MAINTENANCE…2088
MAINTENANCE INFORMATION…2089
OUTLINE OF SERVICE…2091
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…2091
ELECTRIC SYSTEM MAINTENANCE…2094
HANDLING HYDRAULIC SYSTEM…2094
WEAR PARTS…2095
WEAR PARTS LIST…2095
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…2096
TIGHTENING TORQUE SPECIFICATIONS…2100
TIGHTENING TORQUE LIST…2100
SAFETY CRITICAL PARTS…2101
SAFETY CRITICAL PARTS LIST…2101
MAINTENANCE SCHEDULE…2102
MAINTENANCE SCHEDULE CHART…2102
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…2103
MAINTENANCE PROCEDURE…2104
WHEN REQUIRED…2104
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…2104
CLEAN INSIDE OF COOLING SYSTEM…2107
CHECK LEVEL OF BATTERY ELECTROLYTE…2111
CLEAN WATER SEPARATOR ELEMENT…2113
DRAIN WATER AND SEDIMENT FROM FUEL TANK…2113
CHECK AND TIGHTEN TRACK SHOE BOLTS (MACHINE EQUIPPED WITH ROAD LINER)…2114
CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH ROAD LINER,STEEL SHOE)…2115
CHECK,RUBBER SHOES OR ROAD LINERS(MACHINE EQUIPPED WITH RUBBER SHOES,ROAD LINER)…2117
CHECK AND ADJUST RUBBER SHOE TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)…2119
REPLACE RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)…2121
REPLACE ROAD LINERS(MACHINE EQUIPPED WITH ROAD LINER)…2123
REPLACE BUCKET TEETH…2124
CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID…2127
CHECK,CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…2128
LUBRICATING…2128
BLEEDING AIR FROM HYDRAULIC SYSTEM…2129
CHECK BEFORE STARTING…2131
EVERY 500 HOURS MAINTENANCE…2132
LUBRICATING…2132
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…2135
REPLACE FUEL FILTER CARTRIDGE…2136
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…2138
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…2139
CHECK AND ADJUST COOLING FAN BELT TENSION…2140
EVERY 1000 HOURS MAINTENANCE…2141
REPLACE HYDRAULIC OIL FILTER ELEMENT…2141
CHANGE OIL IN FINAL DRIVE CASE…2142
CHECK ENGINE VALVE CLEARANCE, ADJUST…2142
EVERY 2000 HOURS MAINTENANCE…2143
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…2143
CHECK ALTERNATOR, STARTING MOTOR…2145
SPECIFICATIONS…2146
SPECIFICATIONS…2147
ATTACHMENTS, OPTIONS…2149
ATTACHMENTS AND OPTIONS-GENERAL INFORMATION…2150
SAFETY FIRST…2150
ATTACHMENT INSTALLATION…2151
BUCKET WITH HOOK…2152
PROHIBITED OPERATIONS…2152
AIR CONDITIONER…2153
CONTROL PANEL AND COMPONENTS…2153
AIR CONDITIONER CONTROLS…2154
AIR CONDITIONER MAINTENANCE…2155
WINDSHIELD WASHER…2159
WINDSHIELD WASHER OPERATION…2159
CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID…2159
MACHINE READY FOR ATTACHMENT…2160
LOCATIONS…2160
HYDRAULIC CIRCUIT…2162
ATTACHMENT OPERATIONS…2164
LONG TERM STORAGE…2165
SPECIFICATIONS…2165
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…2166
CONTROL PATTERN CHANGE PROCEDURE…2166
MACHINE CONTROL PATTERNS…2167
POWER ANGLE BLADE…2168
BLADE CONTROL LEVER…2168
WHEN REQUIRED…2169
EVERY 500 HOURS SERVICE…2169
WEAR PARTS LIST…2170
SPECIFICATIONS…2170
ATTACHMENT GUIDE…2171
ATTACHMENT COMBINATIONS…2171
RECOMMENDED ATTACHMENT OPERATIONS…2172
HYDRAULIC BREAKER…2172
HIGH-ALTITUDE SPECIFICATION MACHINE…2177
LOCATIONS…2178
MAINTENANCE PROCEDURE…2179
EVERY 2000 HOURS MAINTENANCE…2179
SPECIFICATIONS…2180
INDEX…2181
TEN00115-01 – Hydraulic Excavator GALEO PC27MR-2, PC35MR-2 Operation & Maintenance Manual…2184
COVER…2184
FOREWORD…2185
FOREWORD…2186
SAFETY INFORMATION…2189
INTRODUCTION…2191
DIRECTIONS OF MACHINE…2191
PRODUCT INFORMATION…2192
PRODUCT IDENTIFICATION NUMBER(PIN)/MACHINE SERIAL NO.PLATE…2192
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…2192
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…2193
SERVICE METER LOCATION…2193
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…2194
CONTENTS…2195
SAFETY…2199
SAFETY INFORMATION…2200
SAFETY LABELS…2202
LOCATION OF SAFETY LABELS…2202
SAFETY LABELS…2203
SAFETY INFORMATION…2208
SAFETY RULES…2208
IF PROBLEMS ARE FOUND…2208
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…2208
FIRE EXTINGUISHER AND FIRST AID KIT…2208
SAFETY EQUIPMENT…2209
KEEP MACHINE CLEAN…2209
KEEP OPERATOR'S COMPARTMENT CLEAN…2209
LEAVING OPERATOR'S SEAT WITH LOCK…2209
HANDRAILS AND STEPS…2210
MOUNTING AND DISMOUNTING…2210
NO PERSONS ON ATTACHMENTS…2210
BURN PREVENTION…2211
FIRE PREVENTION AND EXPLOSION PREVENTION…2211
ACTION IF FIRE OCCURS…2212
WINDSHIELD WASHER FLUID…2212
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…2213
CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM)…2213
ATTACHMENT INSTALLATION…2214
ATTACHMENT COMBINATIONS…2214
CAB WINDOW GLASSES…2214
UNAUTHORIZED MODIFICATIONS…2214
SAFETY AT JOBSITE…2214
WORKING ON LOOSE GROUND…2214
DISTANCE TO HIGH VOLTAGE CABLES…2215
ENSURE GOOD VISIBILITY…2215
VENTILATION FOR ENCLOSED AREA…2215
SIGNALMAN'S SIGNAL AND SIGNS…2215
EMERGENCY EXIT FROM OPERATOR'S CAB…2216
ASBESTOS DUST HAZARD PREVENTION…2216
SAFETY MACHINE OPERATION…2217
STARTING ENGINE…2217
CHECKS BEFORE STARTING ENGINE…2217
SAFETY RULES FOR STARTING ENGINE…2218
STARTING ENGINE IN COLD WEATHER…2218
OPERATION…2219
CHECKS BEFORE OPERATION…2219
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…2219
SAFETY RULES FOR TRAVELING…2220
TRAVELING ON SLOPES…2221
OPERATIONS ON SLOPES…2222
PROHIBITED OPERATIONS…2222
OPERATIONS ON SNOW…2224
PARKING MACHINE…2224
TRANSPORTATION…2225
LOADING AND UNLOADING…2225
SHIPPING THE MACHINE…2225
BATTERY…2226
BATTERY HAZARD PREVENTION…2226
STARTING ENGINE WITH BOOSTER CABLES…2227
TOWING…2228
SAFETY RULES FOR TOWING…2228
LIFTING OBJECTS WITH BUCKET…2229
SAFETY RULES FOR LIFTING OBJECTS…2229
SAFETY MAINTENANCE INFORMATION…2230
WARNING TAG…2230
KEEP WORK PLACE CLEAN AND TIDY…2230
APPOINT LEADER WHEN WORKING WITH OTHERS…2230
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…2231
CAUTIONS FOR OPENING (TILTING) FLOOR…2232
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…2233
PROPER TOOLS…2233
PERSONNEL…2233
ATTACHMENTS…2234
WORK UNDER THE MACHINE…2234
NOISE…2234
WHEN USING HAMMER…2234
WELDING WORKS…2234
REMOVING BATTERY TERMINALS…2235
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…2235
DO NOT DISASSEMBLE RECOIL SPRINGS…2235
SAFETY RULES FOR HIGH-PRESSURE OIL…2235
SAFETY HANDLING HIGH-PRESSURE HOSES…2236
WASTE MATERIALS…2236
AIR CONDITIONER MAINTENANCE…2236
COMPRESSED AIR…2236
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…2236
OPERATION…2237
MACHINE VIEW ILLUSTRATIONS…2238
OVERALL MACHINE VIEW…2238
CONTROLS AND GAUGES…2239
DETAILED CONTROLS AND GAUGES…2240
MONITORING SYSTEM…2240
SWITCHES…2248
CONTROL LEVERS AND PEDALS…2252
WINDSHIELD…2258
SLIDING DOOR…2262
SLIDING WINDOW…2262
EMERGENCY ESCAPE HAMMER…2263
COVER WITH LOCK…2264
ENGINE REAR COVER…2265
COOLING COVER…2265
MUD COVER…2266
METHOD OF OPENING (TILTING) FLOOR…2267
FUSE…2272
BLOCK FUSE…2273
OPERATION MANUAL STORAGE…2274
TOOL BOX…2274
GREASE GUN HOLDER…2274
ASHTRAY…2274
MACHINE OPERATIONS AND CONTROLS…2275
BEFORE STARTING ENGINE…2275
STARTING ENGINE…2290
AFTER STARTING ENGINE…2294
STOPPING THE ENGINE…2297
MACHINE OPERATION…2298
STEERING THE MACHINE…2303
SWINGING…2305
WORK EQUIPMENT CONTROLS AND OPERATIONS…2306
PROHIBITED OPERATIONS…2308
GENERAL OPERATION INFORMATION…2310
TRAVELING ON SLOPES…2311
ESCAPE FROM MUD…2313
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…2314
BUCKET REPLACEMENT…2316
PARKING MACHINE…2317
MACHINE INSPECTION AFTER DAILY WORK…2318
LOCKING…2319
RUBBER SHOES AND ROAD LINERS…2320
TRANSPORTATION…2325
TRANSPORTATION PROCEDURE…2325
LOADING AND UNLOADING WITH TRAILER…2326
LIFTING MACHINE…2332
COLD WEATHER OPERATION…2335
COLD WEATHER OPERATION INFORMATION…2335
CAB HEATER IN COLD WEATHER…2336
AFTER DAILY WORK COMPLETION…2337
AFTER COLD WEATHER SEASON…2337
LONG TERM STORAGE…2338
BEFORE STORAGE…2338
DURING STORAGE…2339
AFTER STORAGE…2339
TROUBLES AND ACTIONS…2340
RUNNING OUT OF FUEL…2340
PHENOMENA THAT ARE NOT FAILURES…2340
TOWING THE MACHINE…2341
SEVERE JOB CONDITION…2341
DISCHARGED BATTERY…2342
OTHER TROUBLE…2346
MAINTENANCE…2349
MAINTENANCE INFORMATION…2350
OUTLINE OF SERVICE…2352
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…2352
ELECTRIC SYSTEM MAINTENANCE…2355
HANDLING HYDRAULIC SYSTEM…2355
WEAR PARTS…2356
WEAR PARTS LIST…2356
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…2357
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…2359
TIGHTENING TORQUE SPECIFICATIONS…2360
TIGHTENING TORQUE LIST…2360
SAFETY CRITICAL PARTS…2361
SAFETY CRITICAL PARTS LIST…2361
MAINTENANCE SCHEDULE…2362
MAINTENANCE SCHEDULE CHART…2362
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…2363
MAINTENANCE PROCEDURE…2364
WHEN REQUIRED…2364
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…2364
CLEAN INSIDE OF COOLING SYSTEM…2367
CHECK LEVEL OF BATTERY ELECTROLYTE…2371
CLEAN WATER SEPARATOR ELEMENT…2373
DRAIN WATER AND SEDIMENT FROM FUEL TANK…2373
CHECK AND TIGHTEN TRACK SHOE BOLTS (MACHINE EQUIPPED WITH ROAD LINER)…2374
CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH ROAD LINER, STEEL SHOE)…2375
CHECK,RUBBER SHOES OR ROAD LINERS (MACHINE EQUIPPED WITH RUBBER SHOES, ROAD LINER)…2377
CHECK AND ADJUST RUBBER SHOE TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)…2379
REPLACE RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)…2381
REPLACE ROAD LINERS (MACHINE EQUIPPED WITH ROAD LINER)…2383
REPLACE BUCKET TEETH…2384
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…2387
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…2388
LUBRICATING…2388
BLEEDING AIR FROM HYDRAULIC SYSTEM…2389
CHECK BEFORE STARTING…2391
EVERY 500 HOURS MAINTENANCE…2392
LUBRICATING…2392
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…2395
REPLACE FUEL FILTER CARTRIDGE…2396
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…2398
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…2399
CHECK AND ADJUST COOLING FAN BELT TENSION…2400
EVERY 1000 HOURS MAINTENANCE…2401
REPLACE HYDRAULIC OIL FILTER ELEMENT…2401
CHANGE OIL IN FINAL DRIVE CASE…2402
CHECK ENGINE VALVE CLEARANCE, ADJUST…2402
EVERY 2000 HOURS MAINTENANCE…2403
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…2403
CHECK ALTERNATOR, STARTING MOTOR…2405
SPECIFICATIONS…2406
SPECIFICATIONS…2407
ATTACHMENTS, OPTIONS…2409
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…2410
SAFETY FIRST…2410
ATTACHMENT INSTALLATION…2411
BUCKET WITH HOOK…2412
PROHIBITED OPERATIONS…2412
AIR CONDITIONER…2413
CONTROL PANEL AND COMPONENTS…2413
AIR CONDITIONER CONTROLS…2414
AIR CONDITIONER MAINTENANCE…2415
WINDSHIELD WASHER…2419
WINDSHIELD WASHER OPERATION…2419
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…2419
MACHINE READY FOR ATTACHMENT…2420
LOCATIONS…2420
HYDRAULIC CIRCUIT…2422
ATTACHMENT OPERATIONS…2424
LONG TERM STORAGE…2425
SPECIFICATIONS…2425
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…2426
CONTROL PATTERN CHANGE PROCEDURE…2426
MACHINE CONTROL PATTERNS…2427
POWER ANGLE BLADE…2428
BLADE CONTROL LEVER…2428
WHEN REQUIRED…2429
EVERY 500 HOURS SERVICE…2429
WEAR PARTS LIST…2430
SPECIFICATIONS…2430
ATTACHMENT GUIDE…2431
ATTACHMENT COMBINATIONS…2431
RECOMMENDED ATTACHMENT OPERATIONS…2432
HYDRAULIC BREAKER…2432
HIGH-ALTITUDE SPECIFICATION MACHINE…2437
LOCATIONS…2438
MAINTENANCE PROCEDURE…2439
EVERY 2000 HOURS MAINTENANCE…2439
SPECIFICATIONS…2440
INDEX…2441
TEN00194-00 – Hydraulic Excavator GALEO PC27MR-2, PC35MR-2 Operation & Maintenance Manual…2444
COVER…2444
FOREWORD…2445
FOREWORD…2446
SAFETY INFORMATION…2449
INTRODUCTION…2451
DIRECTIONS OF MACHINE…2451
PRODUCT INFORMATION…2452
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…2452
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…2452
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…2453
SERVICE METER LOCATION…2453
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…2454
CONTENTS…2455
SAFETY…2459
SAFETY INFORMATION…2460
SAFETY LABELS…2462
LOCATION OF SAFETY LABELS…2462
SAFETY LABELS…2463
SAFETY INFORMATION…2468
SAFETY RULES…2468
IF PROBLEMS ARE FOUND…2468
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…2468
FIRE EXTINGUISHER AND FIRST AID KIT…2468
SAFETY EQUIPMENT…2469
KEEP MACHINE CLEAN…2469
KEEP OPERATOR'S COMPARTMENT CLEAN…2469
LEAVING OPERATOR'S SEAT WITH LOCK…2469
HANDRAILS AND STEPS…2470
MOUNTING AND DISMOUNTING…2470
NO PERSONS ON ATTACHMENTS…2470
BURN PREVENTION…2471
FIRE PREVENTION AND EXPLOSION PREVENTION…2471
ACTION IF FIRE OCCURS…2472
WINDSHIELD WASHER FLUID…2472
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…2473
CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM)…2473
ATTACHMENT INSTALLATION…2474
ATTACHMENT COMBINATIONS…2474
CAB WINDOW GLASSES…2474
UNAUTHORIZED MODIFICATIONS…2474
SAFETY AT JOBSITE…2474
WORKING ON LOOSE GROUND…2474
DISTANCE TO HIGH VOLTAGE CABLES…2475
ENSURE GOOD VISIBILITY…2475
VENTILATION FOR ENCLOSED AREA…2475
SIGNALMAN'S SIGNAL AND SIGNS…2476
EMERGENCY EXIT FROM OPERATOR'S CAB…2476
ASBESTOS DUST HAZARD PREVENTION…2476
SAFETY MACHINE OPERATION…2477
STARTING ENGINE…2477
CHECKS BEFORE STARTING ENGINE…2477
SAFETY RULES FOR STARTING ENGINE…2478
STARTING ENGINE IN COLD WEATHER…2478
OPERATION…2479
CHECKS BEFORE OPERATION…2479
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…2479
SAFETY RULES FOR TRAVELING…2480
TRAVELING ON SLOPES…2481
OPERATIONS ON SLOPES…2482
PROHIBITED OPERATIONS…2482
OPERATIONS ON SNOW…2484
PARKING MACHINE…2484
TRANSPORTATION…2485
LOADING AND UNLOADING…2485
SHIPPING THE MACHINE…2485
BATTERY…2486
BATTERY HAZARD PREVENTION…2486
STARTING ENGINE WITH BOOSTER CABLES…2487
TOWING…2488
SAFETY RULES FOR TOWING…2488
LIFTING OBJECTS WITH BUCKET…2489
SAFETY RULES FOR LIFTING OBJECTS…2489
SAFETY MAINTENANCE INFORMATION…2490
WARNING TAG…2490
KEEP WORK PLACE CLEAN AND TIDY…2490
APPOINT LEADER WHEN WORKING WITH OTHERS…2490
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…2491
CAUTIONS FOR OPENING (TILTING) FLOOR…2492
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…2493
PROPER TOOLS…2493
PERSONNEL…2493
ATTACHMENTS…2494
WORK UNDER THE MACHINE…2494
NOISE…2494
WHEN USING HAMMER…2494
WELDING WORKS…2494
REMOVING BATTERY TERMINALS…2495
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…2495
DO NOT DISASSEMBLE RECOIL SPRINGS…2495
SAFETY RULES FOR HIGH-PRESSURE OIL…2495
SAFETY HANDLING HIGH-PRESSURE HOSES…2496
WASTE MATERIALS…2496
AIR CONDITIONER MAINTENANCE…2496
COMPRESSED AIR…2496
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…2496
OPERATION…2497
MACHINE VIEW ILLUSTRATIONS…2498
OVERALL MACHINE VIEW…2498
CONTROLS AND GAUGES…2499
DETAILED CONTROLS AND GAUGES…2500
MONITORING SYSTEM…2500
SWITCHES…2508
CONTROL LEVERS AND PEDALS…2512
WINDSHIELD…2518
SLIDING DOOR…2522
SLIDING WINDOW…2522
EMERGENCY ESCAPE HAMMER…2523
COVER WITH LOCK…2524
ENGINE REAR COVER…2525
COOLING COVER…2525
MUD COVER…2526
METHOD OF OPENING (TILTING) FLOOR…2527
FUSE…2533
BLOCK FUSE…2534
OPERATION MANUAL STORAGE…2535
TOOL BOX…2535
ASHTRAY…2535
MACHINE OPERATIONS AND CONTROLS…2536
BEFORE STARTING ENGINE…2536
STARTING ENGINE…2551
AFTER STARTING ENGINE…2555
STOPPING THE ENGINE…2558
MACHINE OPERATION…2559
STEERING THE MACHINE…2564
SWINGING…2566
WORK EQUIPMENT CONTROLS AND OPERATIONS…2567
PROHIBITED OPERATIONS…2569
GENERAL OPERATION INFORMATION…2571
TRAVELING ON SLOPES…2572
ESCAPE FROM MUD…2574
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…2575
BUCKET REPLACEMENT…2577
PARKING MACHINE…2578
MACHINE INSPECTION AFTER DAILY WORK…2579
LOCKING…2580
RUBBER SHOES AND ROAD LINERS…2581
TRANSPORTATION…2586
TRANSPORTATION PROCEDURE…2586
LOADING AND UNLOADING WITH TRAILER…2587
LIFTING MACHINE…2593
COLD WEATHER OPERATION…2596
COLD WEATHER OPERATION INFORMATION…2596
CAB HEATER IN COLD WEATHER…2597
AFTER DAILY WORK COMPLETION…2598
AFTER COLD WEATHER SEASON…2598
LONG TERM STORAGE…2599
BEFORE STORAGE…2599
DURING STORAGE…2600
AFTER STORAGE…2600
TROUBLES AND ACTIONS…2601
RUNNING OUT OF FUEL…2601
PHENOMENA THAT ARE NOT FAILURES…2601
TOWING THE MACHINE…2602
SEVERE JOB CONDITION…2602
DISCHARGED BATTERY…2603
OTHER TROUBLE…2607
MAINTENANCE…2611
MAINTENANCE INFORMATION…2612
OUTLINE OF SERVICE…2614
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…2614
ELECTRIC SYSTEM MAINTENANCE…2617
HANDLING HYDRAULIC SYSTEM…2617
WEAR PARTS…2618
WEAR PARTS LIST…2618
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…2619
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…2621
TIGHTENING TORQUE SPECIFICATIONS…2622
TIGHTENING TORQUE LIST…2622
SAFETY CRITICAL PARTS…2623
SAFETY CRITICAL PARTS LIST…2623
MAINTENANCE SCHEDULE…2624
MAINTENANCE SCHEDULE CHART…2624
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…2625
MAINTENANCE PROCEDURE…2626
WHEN REQUIRED…2626
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…2626
CLEAN INSIDE OF COOLING SYSTEM…2629
CHECK LEVEL OF BATTERY ELECTROLYTE…2633
CLEAN WATER SEPARATOR ELEMENT…2635
DRAIN WATER AND SEDIMENT FROM FUEL TANK…2635
CHECK AND TIGHTEN TRACK SHOE BOLTS (MACHINE EQUIPPED WITH ROAD LINER)…2636
CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH ROAD LINER, STEEL SHOE)…2637
CHECK, RUBBER SHOES OR ROAD LINERS (MACHINE EQUIPPED WITH RUBBER SHOES, ROAD LINER)…2639
CHECK AND ADJUST RUBBER SHOE TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)…2641
REPLACE RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)…2643
REPLACE ROAD LINERS (MACHINE EQUIPPED WITH ROAD LINER)…2645
REPLACE BUCKET TEETH…2646
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…2649
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…2650
LUBRICATING…2650
BLEEDING AIR FROM HYDRAULIC SYSTEM…2651
CHECK BEFORE STARTING…2653
EVERY 500 HOURS MAINTENANCE…2654
LUBRICATING…2654
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…2657
REPLACE FUEL FILTER CARTRIDGE…2658
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…2660
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…2661
CHECK AND ADJUST COOLING FAN BELT TENSION…2662
EVERY 1000 HOURS MAINTENANCE…2663
REPLACE HYDRAULIC OIL FILTER ELEMENT…2663
CHANGE OIL IN FINAL DRIVE CASE…2664
CHECK ENGINE VALVE CLEARANCE, ADJUST…2664
EVERY 2000 HOURS MAINTENANCE…2665
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…2665
CHECK ALTERNATOR, STARTING MOTOR…2667
SPECIFICATIONS…2669
SPECIFICATIONS…2670
ATTACHMENTS, OPTIONS…2673
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…2674
SAFETY FIRST…2674
ATTACHMENT INSTALLATION…2675
BUCKET WITH HOOK…2676
PROHIBITED OPERATIONS…2676
AIR CONDITIONER…2677
CONTROL PANEL AND COMPONENTS…2677
AIR CONDITIONER CONTROLS…2678
AIR CONDITIONER MAINTENANCE…2679
WINDSHIELD WASHER…2683
WINDSHIELD WASHER OPERATION…2683
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…2683
MACHINE READY FOR ATTACHMENT…2684
LOCATIONS…2684
HYDRAULIC CIRCUIT…2686
ATTACHMENT OPERATIONS…2688
LONG TERM STORAGE…2689
SPECIFICATIONS…2689
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…2690
CONTROL PATTERN CHANGE PROCEDURE…2690
MACHINE CONTROL PATTERNS…2691
POWER ANGLE BLADE…2692
BLADE CONTROL LEVER…2692
WHEN REQUIRED…2693
EVERY 500 HOURS SERVICE…2693
WEAR PARTS LIST…2694
SPECIFICATIONS…2694
ATTACHMENT GUIDE…2695
ATTACHMENT COMBINATIONS…2695
RECOMMENDED ATTACHMENT OPERATIONS…2696
HYDRAULIC BREAKER…2696
HIGH-ALTITUDE SPECIFICATION MACHINE…2701
LOCATIONS…2702
MAINTENANCE PROCEDURE…2703
EVERY 2000 HOURS MAINTENANCE…2703
SPECIFICATIONS…2704
INDEX…2705
TEN00284-03 – Hydraulic Excavator GALEO PC27MR-3, PC35MR-3 Operation & Maintenance Manual…2711
COVER…2711
FOREWORD…2712
FOREWORD…2713
SAFETY INFORMATION…2714
INTRODUCTION…2716
DIRECTIONS OF MACHINE…2716
PRODUCT INFORMATION…2717
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…2717
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…2717
EPA NAMEPLATE…2718
SERVICE METER LOCATION…2718
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…2719
CONTENTS…2720
SAFETY…2724
SAFETY…2725
SAFETY LABELS…2727
LOCATION OF SAFETY LABELS…2727
SAFETY LABELS…2728
GENERAL PRECAUTIONS…2733
SAFETY MACHINE OPERATION…2742
STARTING ENGINE…2742
OPERATION…2744
TRANSPORTATION…2750
BATTERY…2751
TOWING…2753
LIFTING OBJECTS WITH BUCKET…2754
SAFETY MAINTENANCE INFORMATION…2755
OPERATION…2764
MACHINE VIEW ILLUSTRATIONS…2765
OVERALL MACHINE VIEW…2765
CONTROLS AND GAUGES…2766
DETAILED CONTROLS AND GAUGES…2767
MONITORING SYSTEM…2767
SWITCHES…2773
CONTROL LEVERS AND PEDALS…2777
WINDSHIELD…2783
SLIDING DOOR…2787
SLIDING WINDOW…2787
EMERGENCY ESCAPE HAMMER…2788
COVER WITH LOCK…2789
ENGINE REAR COVER…2790
COOLING COVER…2790
MUD COVER…2791
METHOD OF OPENING (TILTING) FLOOR…2792
AUXILIARY ELECTRIC POWER…2798
FUSE…2798
BLOCK FUSE…2799
OPERATION MANUAL STORAGE…2800
TOOL BOX…2800
GREASE GUN HOLDER…2800
ASHTRAY…2800
HANDLING MACHINES EQUIPPED WITH KOMTRAX…2801
MACHINE OPERATIONS AND CONTROLS…2802
BEFORE STARTING ENGINE…2802
STARTING ENGINE…2818
AFTER STARTING ENGINE…2822
STOPPING THE ENGINE…2825
MACHINE OPERATION…2826
STEERING THE MACHINE…2831
SWINGING…2833
WORK EQUIPMENT CONTROLS AND OPERATIONS…2834
PROHIBITED OPERATIONS…2836
GENERAL OPERATION INFORMATION…2838
TRAVELING ON SLOPES…2840
ESCAPE FROM MUD…2842
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…2843
BUCKET REPLACEMENT…2845
PARKING MACHINE…2846
MACHINE INSPECTION AFTER DAILY WORK…2847
LOCKING…2848
RUBBER SHOES AND ROAD LINERS…2849
TRANSPORTATION…2854
TRANSPORTATION PROCEDURE…2854
LOADING AND UNLOADING WITH TRAILER…2855
LIFTING MACHINE…2861
COLD WEATHER OPERATION…2864
COLD WEATHER OPERATION INFORMATION…2864
CAB HEATER IN COLD WEATHER…2865
AFTER DAILY WORK COMPLETION…2866
AFTER COLD WEATHER SEASON…2866
LONG TERM STORAGE…2867
BEFORE STORAGE…2867
DURING STORAGE…2867
AFTER STORAGE…2867
TROUBLES AND ACTIONS…2869
RUNNING OUT OF FUEL…2869
PHENOMENA THAT ARE NOT FAILURES…2869
TOWING THE MACHINE…2870
SEVERE JOB CONDITION…2870
DISCHARGED BATTERY…2871
OTHER TROUBLE…2875
MAINTENANCE…2878
MAINTENANCE INFORMATION…2879
OUTLINE OF SERVICE…2881
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…2881
ELECTRIC SYSTEM MAINTENANCE…2885
HANDLING HYDRAULIC SYSTEM…2885
WEAR PARTS…2886
WEAR PARTS LIST…2886
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…2887
TIGHTENING TORQUE SPECIFICATIONS…2890
TIGHTENING TORQUE LIST…2890
SAFETY CRITICAL PARTS…2891
SAFETY CRITICAL PARTS LIST…2891
MAINTENANCE SCHEDULE…2892
MAINTENANCE SCHEDULE CHART…2892
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…2893
MAINTENANCE PROCEDURE…2894
WHEN REQUIRED…2894
CHECK BEFORE STARTING…2921
EVERY 500 HOURS MAINTENANCE…2922
EVERY 1000 HOURS MAINTENANCE…2930
EVERY 1500 HOURS MAINTENANCE…2933
EVERY 2000 HOURS MAINTENANCE…2934
SPECIFICATIONS…2940
SPECIFICATIONS…2941
ATTACHMENTS, OPTIONS …2944
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…2945
SAFETY FIRST…2945
ATTACHMENT INSTALLATION…2946
BUCKET WITH HOOK…2947
HOOK CONDITION…2947
PROHIBITED OPERATIONS…2947
AIR CONDITIONER…2948
CONTROL PANEL AND COMPONENTS…2948
AIR CONDITIONER CONTROLS…2949
PHENOMENA THAT ARE NOT FAILURES…2950
AIR CONDITIONER MAINTENANCE…2951
RADIO…2955
CONTROL PANEL…2955
CONTROLS OF RADIO…2956
CARE FOR RADIO…2958
WINDSHIELD WASHER…2959
WINDSHIELD WASHER OPERATION…2959
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…2959
MACHINE READY FOR ATTACHMENT…2960
LOCATIONS…2960
HYDRAULIC CIRCUIT…2962
ATTACHMENT OPERATIONS…2963
LONG TERM STORAGE…2964
SPECIFICATIONS…2965
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…2966
CONTROL PATTERN CHANGE PROCEDURE…2966
MACHINE CONTROL PATTERNS…2967
ATTACHMENT GUIDE…2968
ATTACHMENT COMBINATIONS…2968
RECOMMENDED ATTACHMENT OPERATIONS…2969
HYDRAULIC BREAKER…2969
INDEX…2974
TEN00378-03 – Hydraulic Excavator PC27MR-3, PC35MR-3 Operation & Maintenance Manual…2978
COVER…2978
FOREWORD…2979
FOREWORD…2980
SAFETY INFORMATION…2981
INTRODUCTION…2983
DIRECTIONS OF MACHINE…2983
PRODUCT INFORMATION…2984
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…2984
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…2984
EPA NAMEPLATE…2985
SERVICE METER LOCATION…2985
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…2986
CONTENTS…2987
SAFETY…2991
SAFETY…2992
SAFETY LABELS…2994
LOCATION OF SAFETY LABELS…2994
SAFETY LABELS…2995
GENERAL PRECAUTIONS…3000
SAFETY MACHINE OPERATION…3009
STARTING ENGINE…3009
OPERATION…3011
TRANSPORTATION…3017
BATTERY…3018
TOWING…3020
LIFTING OBJECTS WITH BUCKET…3021
SAFETY MAINTENANCE INFORMATION…3022
OPERATION…3031
MACHINE VIEW ILLUSTRATIONS…3032
OVERALL MACHINE VIEW…3032
CONTROLS AND GAUGES…3033
DETAILED CONTROLS AND GAUGES…3034
MONITORING SYSTEM…3034
SWITCHES…3040
CONTROL LEVERS AND PEDALS…3044
WINDSHIELD…3050
SLIDING DOOR…3053
SLIDING WINDOW…3053
EMERGENCY ESCAPE HAMMER…3054
COVER WITH LOCK…3055
ENGINE REAR COVER…3056
COOLING COVER…3056
MUD COVER…3057
METHOD OF OPENING (TILTING) FLOOR…3058
AUXILIARY ELECTRIC POWER…3064
FUSE…3064
BLOCK FUSE…3065
OPERATION MANUAL STORAGE…3066
TOOL BOX…3066
GREASE GUN HOLDER…3066
ASHTRAY…3066
HANDLING MACHINES EQUIPPED WITH KOMTRAX…3067
MACHINE OPERATIONS AND CONTROLS…3068
BEFORE STARTING ENGINE…3068
STARTING ENGINE…3084
AFTER STARTING ENGINE…3088
STOPPING THE ENGINE…3091
MACHINE OPERATION…3092
STEERING THE MACHINE…3097
SWINGING…3099
WORK EQUIPMENT CONTROLS AND OPERATIONS…3100
PROHIBITED OPERATIONS…3102
GENERAL OPERATION INFORMATION…3104
TRAVELING ON SLOPES…3106
ESCAPE FROM MUD…3108
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…3109
BUCKET REPLACEMENT…3111
PARKING MACHINE…3112
MACHINE INSPECTION AFTER DAILY WORK…3113
LOCKING…3114
RUBBER SHOES AND ROAD LINERS…3115
TRANSPORTATION…3120
TRANSPORTATION PROCEDURE…3120
LOADING AND UNLOADING WITH TRAILER…3121
LIFTING MACHINE…3127
COLD WEATHER OPERATION…3130
COLD WEATHER OPERATION INFORMATION…3130
CAB HEATER IN COLD WEATHER…3131
AFTER DAILY WORK COMPLETION…3132
AFTER COLD WEATHER SEASON…3132
LONG TERM STORAGE…3133
BEFORE STORAGE…3133
DURING STORAGE…3133
AFTER STORAGE…3133
TROUBLES AND ACTIONS…3135
RUNNING OUT OF FUEL…3135
PHENOMENA THAT ARE NOT FAILURES…3135
TOWING THE MACHINE…3136
SEVERE JOB CONDITION…3136
DISCHARGED BATTERY…3137
OTHER TROUBLE…3141
MAINTENANCE…3145
MAINTENANCE INFORMATION…3146
OUTLINE OF SERVICE…3148
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…3148
ELECTRIC SYSTEM MAINTENANCE…3152
HANDLING HYDRAULIC SYSTEM…3152
WEAR PARTS…3153
WEAR PARTS LIST…3153
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…3154
TIGHTENING TORQUE SPECIFICATIONS…3157
TIGHTENING TORQUE LIST…3157
SAFETY CRITICAL PARTS…3158
SAFETY CRITICAL PARTS LIST…3158
MAINTENANCE SCHEDULE…3159
MAINTENANCE SCHEDULE CHART…3159
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…3160
MAINTENANCE PROCEDURE…3161
WHEN REQUIRED…3161
CHECK BEFORE STARTING…3188
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…3188
EVERY 500 HOURS MAINTENANCE…3189
EVERY 1000 HOURS MAINTENANCE…3197
EVERY 1500 HOURS MAINTENANCE…3200
EVERY 2000 HOURS MAINTENANCE…3201
SPECIFICATIONS…3207
SPECIFICATIONS…3208
ATTACHMENTS, OPTIONS…3211
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…3212
SAFETY FIRST…3212
ATTACHMENT INSTALLATION…3213
BUCKET WITH HOOK…3214
HOOK CONDITION…3214
PROHIBITED OPERATIONS…3214
AIR CONDITIONER…3215
CONTROL PANEL AND COMPONENTS…3215
AIR CONDITIONER CONTROLS…3216
PHENOMENA THAT ARE NOT FAILURES…3217
AIR CONDITIONER MAINTENANCE…3218
RADIO…3222
CONTROL PANEL…3222
CONTROLS OF RADIO…3223
CARE FOR RADIO…3225
WINDSHIELD WASHER…3226
WINDSHIELD WASHER OPERATION…3226
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…3226
MACHINE READY FOR ATTACHMENT…3227
LOCATIONS…3227
HYDRAULIC CIRCUIT…3233
ATTACHMENT OPERATIONS…3235
LONG TERM STORAGE…3240
SPECIFICATIONS…3240
OTHER TROUBLE…3241
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…3243
CONTROL PATTERN CHANGE PROCEDURE…3243
MACHINE CONTROL PATTERNS…3244
ATTACHMENT GUIDE…3245
ATTACHMENT COMBINATIONS…3245
RECOMMENDED ATTACHMENT OPERATIONS…3246
HYDRAULIC BREAKER…3246
INDEX…3251
TEN00507-01 – Hydraulic Excavator PC27MR-3, PC35MR-3 Operation & Maintenance Manual…3255
COVER…3255
FOREWORD…3256
FOREWORD…3257
SAFETY INFORMATION…3258
INTRODUCTION…3260
DIRECTIONS OF MACHINE…3260
PROTECTIVE STRUCTURE…3260
PRODUCT INFORMATION…3261
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…3261
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…3261
EPA NAMEPLATE…3262
SERVICE METER LOCATION…3262
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…3263
CONTENTS…3264
SAFETY…3268
SAFETY…3269
SAFETY LABELS…3271
LOCATION OF SAFETY LABELS…3271
SAFETY LABELS…3272
GENERAL PRECAUTIONS…3277
SAFETY MACHINE OPERATION…3286
STARTING ENGINE…3286
OPERATION…3288
TRANSPORTATION…3294
BATTERY…3295
TOWING…3297
LIFTING OBJECTS WITH BUCKET…3298
SAFETY MAINTENANCE INFORMATION…3299
OPERATION…3308
MACHINE VIEW ILLUSTRATIONS…3309
OVERALL MACHINE VIEW…3309
CONTROLS AND GAUGES…3310
DETAILED CONTROLS AND GAUGES…3311
MONITORING SYSTEM…3311
SWITCHES…3317
CONTROL LEVERS AND PEDALS…3321
WINDSHIELD…3327
SLIDING DOOR…3330
SLIDING WINDOW…3330
EMERGENCY ESCAPE HAMMER…3331
COVER WITH LOCK…3332
ENGINE REAR COVER…3334
COOLING COVER…3334
MUD COVER…3335
METHOD OF OPENING (TILTING) FLOOR…3336
AUXILIARY ELECTRIC POWER…3342
FUSE…3342
BLOCK FUSE…3343
OPERATION MANUAL STORAGE…3344
TOOL BOX…3344
GREASE GUN HOLDER…3344
ASHTRAY…3344
HANDLING MACHINES EQUIPPED WITH KOMTRAX…3345
MACHINE OPERATIONS AND CONTROLS…3346
BEFORE STARTING ENGINE…3346
STARTING ENGINE…3362
AFTER STARTING ENGINE…3366
STOPPING THE ENGINE…3369
MACHINE OPERATION…3370
STEERING THE MACHINE…3375
SWINGING…3377
WORK EQUIPMENT CONTROLS AND OPERATIONS…3378
PROHIBITED OPERATIONS…3380
GENERAL OPERATION INFORMATION…3382
TRAVELING ON SLOPES…3384
ESCAPE FROM MUD…3386
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…3387
BUCKET REPLACEMENT…3389
PARKING MACHINE…3390
MACHINE INSPECTION AFTER DAILY WORK…3391
LOCKING…3392
RUBBER SHOES AND ROAD LINERS…3393
TRANSPORTATION…3398
TRANSPORTATION PROCEDURE…3398
LOADING AND UNLOADING WITH TRAILER…3399
LIFTING MACHINE…3405
COLD WEATHER OPERATION…3408
COLD WEATHER OPERATION INFORMATION…3408
CAB HEATER IN COLD WEATHER…3409
AFTER DAILY WORK COMPLETION…3410
AFTER COLD WEATHER SEASON…3410
LONG TERM STORAGE…3411
BEFORE STORAGE…3411
DURING STORAGE…3411
AFTER STORAGE…3412
TROUBLES AND ACTIONS…3413
RUNNING OUT OF FUEL…3413
PHENOMENA THAT ARE NOT FAILURES…3413
TOWING THE MACHINE…3414
SEVERE JOB CONDITION…3414
DISCHARGED BATTERY…3415
OTHER TROUBLE…3419
MAINTENANCE…3422
MAINTENANCE INFORMATION…3423
OUTLINE OF SERVICE…3425
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…3425
ELECTRIC SYSTEM MAINTENANCE…3428
HANDLING HYDRAULIC SYSTEM…3429
WEAR PARTS…3430
WEAR PARTS LIST…3430
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…3431
TIGHTENING TORQUE SPECIFICATIONS…3434
TIGHTENING TORQUE LIST…3434
SAFETY CRITICAL PARTS…3435
SAFETY CRITICAL PARTS LIST…3435
MAINTENANCE SCHEDULE…3436
MAINTENANCE SCHEDULE CHART…3436
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…3437
MAINTENANCE PROCEDURE…3438
WHEN REQUIRED…3438
CHECK BEFORE STARTING…3464
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…3464
EVERY 500 HOURS MAINTENANCE…3465
EVERY 1000 HOURS MAINTENANCE…3473
EVERY 1500 HOURS MAINTENANCE…3476
EVERY 2000 HOURS MAINTENANCE…3477
SPECIFICATIONS…3484
SPECIFICATIONS…3485
ATTACHMENTS, OPTIONS…3488
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…3489
SAFETY FIRST…3489
ATTACHMENT INSTALLATION…3490
BUCKET WITH HOOK…3491
HOOK CONDITION…3491
PROHIBITED OPERATIONS…3491
AIR CONDITIONER…3492
CONTROL PANEL AND COMPONENTS…3492
AIR CONDITIONER CONTROLS…3493
PHENOMENA THAT ARE NOT FAILURES…3494
AIR CONDITIONER MAINTENANCE…3495
RADIO…3499
CONTROL PANEL…3499
CONTROLS OF RADIO…3500
CARE FOR RADIO…3502
WINDSHIELD WASHER…3503
WINDSHIELD WASHER OPERATION…3503
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…3503
MACHINE READY FOR ATTACHMENT…3504
LOCATIONS…3504
HYDRAULIC CIRCUIT…3510
ATTACHMENT OPERATIONS…3512
LONG TERM STORAGE…3517
SPECIFICATIONS…3517
OTHER TROUBLE…3518
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…3520
CONTROL PATTERN CHANGE PROCEDURE…3520
MACHINE CONTROL PATTERNS…3521
ATTACHMENT GUIDE…3522
ATTACHMENT COMBINATIONS…3522
RECOMMENDED ATTACHMENT OPERATIONS…3523
HYDRAULIC BREAKER…3523
INDEX…3528
TEN00552-01 – Hydraulic Excavator PC27MR-3, PC35MR-3 Operation & Maintenance Manual…3534
COVER…3534
FOREWORD…3535
FOREWORD…3536
SAFETY INFORMATION…3537
INTRODUCTION…3539
DIRECTIONS OF MACHINE…3539
PROTECTIVE STRUCTURE…3539
PRODUCT INFORMATION…3540
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…3540
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…3540
EPA NAMEPLATE…3541
SERVICE METER LOCATION…3541
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…3542
CONTENTS…3543
SAFETY…3547
SAFETY…3548
SAFETY LABELS…3550
LOCATION OF SAFETY LABELS…3550
SAFETY LABELS…3551
GENERAL PRECAUTIONS…3556
SAFETY MACHINE OPERATION…3565
STARTING ENGINE…3565
OPERATION…3567
TRANSPORTATION…3573
BATTERY…3574
TOWING…3576
LIFTING OBJECTS WITH BUCKET…3577
SAFETY MAINTENANCE INFORMATION…3578
OPERATION…3587
MACHINE VIEW ILLUSTRATIONS…3588
OVERALL MACHINE VIEW…3588
CONTROLS AND GAUGES…3589
DETAILED CONTROLS AND GAUGES…3590
MONITORING SYSTEM…3590
SWITCHES…3596
CONTROL LEVERS AND PEDALS…3600
WINDSHIELD…3606
SLIDING DOOR…3609
SLIDING WINDOW…3609
EMERGENCY ESCAPE HAMMER…3610
COVER WITH LOCK…3611
ENGINE REAR COVER…3613
COOLING COVER…3613
MUD COVER…3614
METHOD OF OPENING (TILTING) FLOOR…3615
AUXILIARY ELECTRIC POWER…3621
FUSE…3621
BLOCK FUSE…3622
OPERATION MANUAL STORAGE…3623
TOOL BOX…3623
GREASE GUN HOLDER…3623
ASHTRAY…3623
HANDLING MACHINES EQUIPPED WITH KOMTRAX…3624
MACHINE OPERATIONS AND CONTROLS…3625
BEFORE STARTING ENGINE…3625
STARTING ENGINE…3641
AFTER STARTING ENGINE…3645
STOPPING THE ENGINE…3648
MACHINE OPERATION…3649
STEERING THE MACHINE…3654
SWINGING…3656
WORK EQUIPMENT CONTROLS AND OPERATIONS…3657
PROHIBITED OPERATIONS…3659
GENERAL OPERATION INFORMATION…3661
TRAVELING ON SLOPES…3663
ESCAPE FROM MUD…3665
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…3666
BUCKET REPLACEMENT…3668
PARKING MACHINE…3669
MACHINE INSPECTION AFTER DAILY WORK…3670
LOCKING…3671
RUBBER SHOES AND ROAD LINERS…3672
TRANSPORTATION…3677
TRANSPORTATION PROCEDURE…3677
LOADING AND UNLOADING WITH TRAILER…3678
LIFTING MACHINE…3684
COLD WEATHER OPERATION…3687
COLD WEATHER OPERATION INFORMATION…3687
CAB HEATER IN COLD WEATHER…3688
AFTER DAILY WORK COMPLETION…3689
AFTER COLD WEATHER SEASON…3689
LONG TERM STORAGE…3690
BEFORE STORAGE…3690
DURING STORAGE…3690
AFTER STORAGE…3690
TROUBLES AND ACTIONS…3692
RUNNING OUT OF FUEL…3692
PHENOMENA THAT ARE NOT FAILURES…3692
TOWING THE MACHINE…3693
SEVERE JOB CONDITION…3693
DISCHARGED BATTERY…3694
OTHER TROUBLE…3698
MAINTENANCE…3701
MAINTENANCE INFORMATION…3702
OUTLINE OF SERVICE…3704
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…3704
ELECTRIC SYSTEM MAINTENANCE…3707
HANDLING HYDRAULIC SYSTEM…3708
WEAR PARTS…3709
WEAR PARTS LIST…3709
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…3710
TIGHTENING TORQUE SPECIFICATIONS…3713
TIGHTENING TORQUE LIST…3713
SAFETY CRITICAL PARTS…3714
SAFETY CRITICAL PARTS LIST…3714
MAINTENANCE SCHEDULE…3715
MAINTENANCE SCHEDULE CHART…3715
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…3716
MAINTENANCE PROCEDURE…3717
WHEN REQUIRED…3717
CHECK BEFORE STARTING…3743
EXPLANATION OF SYMBOLS FOR LUBRICATION STANDARD TABLE…3743
EVERY 500 HOURS MAINTENANCE…3744
EVERY 1000 HOURS MAINTENANCE…3752
EVERY 1500 HOURS MAINTENANCE…3755
EVERY 2000 HOURS MAINTENANCE…3756
SPECIFICATIONS…3763
SPECIFICATIONS…3764
ATTACHMENTS, OPTIONS…3767
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…3768
SAFETY FIRST…3768
ATTACHMENT INSTALLATION…3769
BUCKET WITH HOOK…3770
HOOK CONDITION…3770
PROHIBITED OPERATIONS…3770
AIR CONDITIONER…3771
CONTROL PANEL AND COMPONENTS…3771
AIR CONDITIONER CONTROLS…3772
PHENOMENA THAT ARE NOT FAILURES…3773
AIR CONDITIONER MAINTENANCE…3774
RADIO…3778
CONTROL PANEL…3778
CONTROLS OF RADIO…3779
CARE FOR RADIO…3781
WINDSHIELD WASHER…3782
WINDSHIELD WASHER OPERATION…3782
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…3782
MACHINE READY FOR ATTACHMENT…3783
LOCATIONS…3783
HYDRAULIC CIRCUIT…3789
ATTACHMENT OPERATIONS…3791
LONG TERM STORAGE…3796
SPECIFICATIONS…3796
OTHER TROUBLE…3797
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…3799
CONTROL PATTERN CHANGE PROCEDURE…3799
MACHINE CONTROL PATTERNS…3800
ATTACHMENT GUIDE…3801
ATTACHMENT COMBINATIONS…3801
RECOMMENDED ATTACHMENT OPERATIONS…3802
HYDRAULIC BREAKER…3802
INDEX…3807
WEAM006600 – Hydraulic Excavator PC30MR-2, PC35MR-2 Operation & Maintenance Manual…3811
1.1 FOREWORD…3813
1.2 INFORMATION ON SAFETY…3814
1.3 INTRODUCTION…3816
1.3.1 INTENDED USES…3816
1.3.2 IMPROPER OR UNAUTHORIZED USES…3816
1.3.3 MAIN CHARACTERISTICS…3816
1.3.4 RUNNING-IN…3817
1.4 PRODUCT IDENTIFICATION…3818
1.4.1 MACHINE SERIAL NUMBER…3818
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)…3818
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE…3819
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER…3819
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER…3820
1.4.6 CAB SERIAL NUMBER…3820
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS…3821
TABLE OF CONTENTS…3822
2.1 SAFETY, NOISE AND VIBRATION PLATES…3830
2.1.1 POSITION OF THE SAFETY PLATES…3830
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS…3831
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB…3836
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY…3837
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED…3837
2.2 GENERAL PRECAUTIONS…3838
2.2.1 GENERAL SAFETY RULES…3838
2.2.2 SAFETY DEVICES AND GUARDS…3838
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS…3838
2.2.4 UNAUTHORIZED MODIFICATIONS…3839
2.2.5 LEAVING THE OPERATOR’S SEAT…3839
2.2.6 GETTING ON AND OFF THE MACHINE…3840
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL…3840
2.2.8 PREVENTING BURNS…3841
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER…3841
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT…3841
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT…3842
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE…3842
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT…3842
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE…3843
2.3.1 SAFETY ON THE WORK SITE…3843
2.3.2 FIRE PREVENTION…3843
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB…3843
2.3.4 ROOM VENTILATION…3844
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS…3844
2.3.6 CLEANING THE WINDOWS – CHECKING THE WINDSHIELD WIPER BLADES…3844
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING…3845
2.4.1 STARTING THE ENGINE…3845
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE…3845
2.4.3 CHECKS FOR TRAVELLING IN REVERSE…3846
2.4.4 MOVING THE MACHINE…3846
2.4.5 MOVING ON SLOPES…3847
2.4.6 WORKING ON SLOPES…3848
2.4.7 UNAUTHORIZED OPERATIONS…3848
2.4.8 PREVENTING ELECTROCUTION…3850
2.4.9 VISIBILITY…3850
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES…3850
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT…3851
2.4.12 WORKING ON LOOSE GROUND…3851
2.4.13 PARKING THE MACHINE…3851
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES…3852
2.5.1 LOADING AND UNLOADING…3852
2.5.2 TRANSPORT…3852
2.6 BATTERY…3853
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY…3853
2.6.2 STARTING WITH BOOSTER CABLES…3853
2.7 PRECAUTIONS FOR THE REMOVAL…3854
2.8 PRECAUTIONS FOR MAINTENANCE…3855
2.8.1 WARNING PLATES…3855
2.8.2 TOOLS…3855
2.8.3 PERSONNEL…3855
2.8.4 EQUIPMENT…3856
2.8.5 WORKING UNDER THE MACHINE…3856
2.8.6 CLEANING THE MACHINE…3856
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS…3857
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY…3857
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION…3857
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP…3858
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR…3858
2.8.12 USING LAMPS…3858
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR…3859
2.8.14 PRECAUTIONS CONCERNING THE STARTER…3859
2.8.15 HANDLING HIGH-PRESSURE PIPES…3859
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL…3860
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE…3860
2.8.18 COOLING FAN AND BELT…3860
2.8.19 WASTE MATERIALS…3861
2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES…3861
3.1 MACHINE VIEW ILLUSTRATIONS…3864
3.1.1 OVERALL MACHINE VIEW…3864
3.1.2 CONTROLS AND GAUGES…3865
3.2 DETAILED CONTROLS AND GAUGES…3866
3.2.1 MONITORING SYSTEM…3866
3.2.1.1 EMERGENCY MONITORS…3867
3.2.1.2 METER DISPLAY PORTION…3869
3.2.1.3 PILOT LAMPS…3871
3.2.1.4 MONITOR SWITCHES PORTION…3872
3.2.2 SWITCHES…3874
3.2.3 CONTROL LEVERS AND PEDALS…3877
3.2.4 WINDSHIELD (Machines equipped with cab)…3883
3.2.5 SLIDING DOOR (Machines equipped with cab)…3887
3.2.6 SLIDING WINDOW (Machines equipped with cab)…3887
3.2.7 EMERGENCY ESCAPE HAMMER (Machines equipped with cab)…3888
3.2.8 COVER WITH LOCK…3889
3.2.9 ENGINE REAR COVER…3890
3.2.10 COOLING COVER…3891
3.2.11 MUD COVER…3892
3.2.12 METHOD OF OPENING (TILTING) FLOOR…3893
3.2.13 FUSE…3898
3.2.14 BLOCK FUSE…3898
3.2.15 OPERATION MANUAL STORAGE…3899
3.2.16 TOOL BOX…3899
3.2.17 GREASE GUN HOLDER…3899
3.2.18 ASHTRAY (Machines equipped with cab)…3899
3.3 MACHINE OPERATIONS AND CONTROLS…3900
3.3.1 BEFORE STARTING ENGINE…3900
3.3.1.1 WALK-AROUND CHECKS…3900
3.3.1.2 CHECKS BEFORE STARTING…3902
3.3.1.3 ADJUSTMENT…3908
3.3.1.4 OPERATIONS BEFORE STARTING ENGINE…3911
3.3.1.5 STARTING ENGINE…3913
3.3.2 AFTER STARTING ENGINE…3916
3.3.2.1 BREAKING-IN THE NEW MACHINE…3916
3.3.2.2 WARMING-UP OPERATION…3916
3.3.3 STOPPING THE ENGINE…3918
3.3.4 MACHINE OPERATION…3919
3.3.4.1 PREPARATIONS FOR MOVING THE MACHINE OFF…3919
3.3.4.2 MOVING MACHINE FORWARD…3919
3.3.4.3 MOVING MACHINE BACKWARD…3921
3.3.4.4 STOPPING MACHINE…3922
3.3.5 STEERING THE MACHINE…3923
3.3.5.1 STEERING…3923
3.3.6 SWINGING…3925
3.3.7 WORK EQUIPMENT CONTROLS AND OPERATIONS…3926
3.3.8 PROHIBITED OPERATIONS…3928
3.3.9 GENERAL OPERATION INFORMATION…3930
3.3.10 TRAVELING ON SLOPES…3932
3.3.11 ESCAPE FROM MUD…3934
3.3.12 WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…3935
3.3.13 CHANGING THE BUCKET…3937
3.3.14 PARKING MACHINE…3938
3.3.15 CHECK AFTER SHUT OFF ENGINE…3939
3.3.16 MACHINE INSPECTION AFTER DAILY WORK…3939
3.3.17 LOCKING…3939
3.3.18 RUBBER SHOES AND ROAD LINERS (Machine equipped with rubber shoe or road liner)…3940
3.3.18.1 RUBBER SHOES AND ROAD LINERS INFORMATION…3940
3.3.18.2 WARRANTY FOR RUBBER SHOES AND ROAD LINERS…3940
3.3.18.3 USING RUBBER SHOES AND ROAD LINERS…3940
3.4 TRANSPORTATION…3944
3.4.1 TRANSPORTATION PROCEDURE…3944
3.4.2 LOADING AND UNLOADING WITH TRAILER…3944
3.4.3 LIFTING MACHINE…3950
3.5 COLD WEATHER OPERATION…3952
3.5.1 COLD WEATHER OPERATION INFORMATION…3952
3.5.1.1 FUEL AND LUBRICANTS…3952
3.5.1.2 COOLING SYSTEM COOLANT…3952
3.5.1.3 BATTERY…3953
3.5.2 CAB HEATER IN COLD WEATHER (Machines equipped with cab)…3953
3.5.3 AFTER DAILY WORK COMPLETION…3954
3.5.4 AFTER COLD WEATHER SEASON…3954
3.6 LONG TERM STORAGE…3955
3.6.1 BEFORE STORAGE…3955
3.6.2 DURING STORAGE…3955
3.6.3 AFTER STORAGE…3955
3.7 TROUBLES AND ACTIONS…3956
3.7.1 RUNNING OUT OF FUEL…3956
3.7.2 PHENOMENA THAT ARE NOT FAILURES…3956
3.7.3 TOWING THE MACHINE…3956
3.7.4 SEVERE JOB CONDITION…3957
3.7.5 DISCHARGED BATTERY…3957
3.7.5.1 BATTERY REMOVAL AND INSTALLATION…3958
3.7.5.2 BATTERY CHARGES…3958
3.7.5.3 STARTING ENGINE WITH BOOSTER CABLES…3959
3.7.6 OTHER TROUBLE…3961
3.7.6.1 ELECTRICAL SYSTEM…3961
3.7.6.2 CHASSIS…3962
3.7.6.3 ENGINE…3962
4.1 MAINTENANCE INFORMATION…3966
4.2 LUBRICANTS, COOLANT AND FILTERS…3969
4.2.1 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…3969
4.2.1.1 OIL…3969
4.2.1.2 FUEL…3969
4.2.1.3 COOLING SYSTEM COOLANT…3970
4.2.1.4 GREASE…3970
4.2.1.5 CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)…3971
4.2.1.6 OIL AND FUEL STORAGE…3972
4.2.1.7 FILTERS…3972
4.2.2 ELECTRIC SYSTEM MAINTENANCE…3973
4.2.3 HANDLING HYDRAULIC SYSTEM…3973
4.3 WEAR PARTS…3974
4.3.1 WEAR PARTS LIST…3974
4.4 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…3975
4.4.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS…3979
4.5 TIGHTENING TORQUE SPECIFICATIONS…3980
4.5.1 TIGHTENING TORQUE LIST…3980
4.6 LUBRICATION…3981
4.6.1 LUBRICATION DIAGRAM…3981
4.7 SAFETY CRITICAL PARTS…3982
4.7.1 SAFETY CRITICAL PARTS LIST…3982
4.8 MAINTENANCE SCHEDULE…3983
4.8.1 MAINTENANCE SCHEDULE CHART…3983
4.8.2 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…3984
4.9 MAINTENANCE PROCEDURE…3985
4.9.1 WHEN REQUIRED…3985
4.9.1.a CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…3985
4.9.1.b CLEAN INSIDE OF COOLING SYSTEM…3987
4.9.1.c CHECK LEVEL OF BATTERY ELECTROLYTE…3989
4.9.1.d CLEAN WATER SEPARATOR ELEMENT…3991
4.9.1.e DRAIN WATER AND SEDIMENT FROM FUEL TANK…3991
4.9.1.f CHECK AND TIGHTEN TRACK SHOE BOLTS (Machine equipped with road liner, steel shoe)…3992
4.9.1.g CHECK AND ADJUST TRACK TENSION (Machine equipped with road liner, steel shoe)…3992
4.9.1.h CHECK, RUBBER SHOES OR ROAD LINERS (Machine equipped with rubber shoes, road liner)…3994
4.9.1.i CHECK AND ADJUST RUBBER SHOE TENSION (Machine equipped with rubber shoes)…3996
4.9.1.j REPLACE RUBBER SHOES (Machine equipped with rubber shoes)…3998
4.9.1.k REPLACE ROAD LINERS (Machine equipped with road liner)…4000
4.9.1.l CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (Machine equipped with cab)…4000
4.9.1.m CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER (Machine equipped with cab)…4001
4.9.1.n LUBRICATING…4001
4.9.1.o BLEEDING AIR FROM HYDRAULIC SYSTEM…4002
4.9.2 CHECK BEFORE STARTING…4003
4.9.3 EVERY 500 HOURS MAINTENANCE…4004
4.9.3.a LUBRICATING…4004
4.9.3.b CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…4006
4.9.3.c REPLACE FUEL FILTER CARTRIDGE…4007
4.9.3.d CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…4008
4.9.3.e CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…4008
4.9.3.f CHECK AND ADJUST COOLING FAN BELT TENSION…4009
4.9.4 EVERY 1000 HOURS MAINTENANCE…4010
4.9.4.a REPLACE HYDRAULIC OIL FILTER ELEMENT…4010
4.9.4.b CHANGE OIL IN FINAL DRIVE CASE…4012
4.9.4.c CHECK ENGINE VALVE CLEARANCE, ADJUST…4012
4.9.5 EVERY 2000 HOURS MAINTENANCE…4013
4.9.5.a CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…4013
4.9.5.b CHECK ALTERNATOR, STARTING MOTOR…4014
5.1 SPECIFICATIONS…4016
5.2 LIFTING CAPACITIES…4018
5.2.1 LIFTING CAPACITIES PC30MR-2 (WITH CANOPY)…4018
5.2.2 LIFTING CAPACITIES PC30MR-2 (WITH CABIN)…4021
5.2.3 LIFTING CAPACITIES PC35MR-2 (WITH CANOPY)…4024
5.2.4 LIFTING CAPACITIES PC35MR-2 (WITH CABIN)…4027
6.1 ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…4032
6.1.1 SAFETY FIRST…4032
6.1.2 ATTACHMENT INSTALLATION…4033
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT…4034
6.1.3.1 FOR MODEL PC30MR-2 ONLY…4034
6.1.3.2 FOR MODEL PC35MR-2 ONLY…4034
6.2 MACHINE READY FOR ATTACHMENT…4035
6.2.1 LOCATIONS…4035
6.2.2 HYDRAULIC CIRCUIT…4037
6.2.2.1 ASSEMBLYING AND CONNECTING THE EQUIPMENT…4037
6.2.2.2 MAINTENANCE…4038
6.2.2.3 BLEEDING AIR…4038
6.3 ATTACHMENT OPERATIONS…4039
6.3.1 LONG TERM STORAGE…4040
6.3.2 SPECIFICATIONS…4040
6.4 ATTACHMENT GUIDE…4041
6.4.1 ATTACHMENT COMBINATIONS…4041
6.5 RECOMMENDED ATTACHMENT OPERATIONS…4042
6.5.1 HYDRAULIC BREAKER…4042
Komatsu Hydraulic Excavator PC27MR, PC30MR, PC35MR, PC40MR, PC50MR Repair Service Manuals
INSTANT DOWNLOAD
