Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC20MR, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC20MR-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.
SEBM037001 – Hydraulic Excavator PC20MR-2 Shop Manual.pdf
TEN00101-02 – Hydraulic Excavator GALEO PC20MR-2 Operation & Maintenance Manual.pdf
WEAM007000 – Hydraulic Excavator GALEO PC20MR-2 Operation & Maintenance Manual.pdf
Total Pages: 886 pages
File Format: PDF
Language: English
SEBM037001 – Hydraulic Excavator PC20MR-2 Shop Manual…2
COVER…2
CONTENTS…3
SAFETY…7
SAFETY NOTICE…7
FOREWORD…9
GENERAL…9
HOISTING INSTRUCTIONS…11
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER…12
COATING MATERIALS…14
STANDARD TIGHTENING TORQUE…16
ELECTRIC WIRE CODE…19
CONVERSION TABLE…20
UNITS…26
01 GENERAL…27
SPECIFICATION DIMENSION DRAWING…28
WORKING RANGE DRAWING…29
SPECIFICATIONS…30
WEIGHT TABLE…33
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…35
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…37
PTO…38
COOLING SYSTEM…40
POWER TRAIN…42
SWING CIRCLE…43
TRACK FRAME…44
IDLER CUSHION…45
IDLER…46
TRACK ROLLER…48
CARRIER ROLLER…49
SPROCKET…50
TRACK SHOE…51
HYDRAULIC COMPONENTS LAYOUT DRAWING…52
HYDRAULIC TANK…53
CENTER SWIVEL JOINT…54
TRAVEL MOTOR…55
HYDRAULIC CYLINDER…64
SOLENOID VALVE…67
MULTI-CONTROL VALVE (IF EQUIPPED)…70
HYDRAULIC PUMP…72
CONTROL VALVE…78
CLSS…91
OPERATION FOR EACH FUNCTION AND VALVE…94
SWING MOTOR…114
PPC VALVE…124
WORK EQUIPMENT…133
DIMENSIONS OF EACH PART OF WORK EQUIPMENT…136
FLOOR…139
ENGINE CONTROL…140
ELECTRIC CONTROL SYSTEM…142
COMPONENT PART OF SYSTEM…147
MONITOR SYSTEM…148
MONITOR PANEL…149
SENSORS…151
20 TESTING AND ADJUSTING…153
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…154
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…155
TESTING AND ADJUSTING…165
LIST OF TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS…166
MEASURING ENGINE SPEED…168
MEASUREMENT OF EXHAUST GAS COLOR…169
ADJUSTING VALVE CLEARANCE…170
MEASURING COMPRESSION PRESSURE…171
MEASURING ENGINE OIL PRESSURE…172
TESTING AND ADJUSTING FUEL INJECTION TIMING…173
BLEEDING AIR FROM FUEL CIRCUIT…175
TESTING AND ADJUSTING FAN BELT TENSION…176
ADJUSTING FUEL CONTROL LEVER LINKAGE…177
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS…178
TESTING AND ADJUSTING TRACK SHOE TENSION…179
TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT, TRAVEL, SWING, AND BLADE CIRCUITS…181
MEASURING CONTROL CIRCUIT BASIC PRESSURE…184
TESTING AND ADJUSTING PUMP LS DIFFERENTIAL PRESSURE…185
MEASURING SOLENOID VALVE OUTPUT PRESSURE…187
MEASURING PPC VALVE OUTPUT PRESSURE…189
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES…191
MEASURING SWING HOLDING BRAKE RELEASE PRESSURE…191
MEASURING OF OIL LEAKAGE FROM CYLINDER…193
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT…195
BLEEDING AIR FROM CYLINDER…195
PRESSURIZING HYDRAULIC TANK…196
HOW TO OPEN AND CLOSE (TILT) FLOOR…197
INSPECTION PROCEDURES FOR DIODE…199
TROUBLESHOOTING…201
POINTS TO REMEMBER WHEN TROUBLESHOOTING…202
SEQUENCE OF EVENTS IN TROUBLESHOOTING…203
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…204
CHECKS BEFORE TROUBLESHOOTING…212
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING…213
CONNECTORS LIST AND STEREOGRAM…216
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…224
T-ADAPTER-BOXES AND T-ADAPTER TABLE…247
TROUBLESHOOTING OF ELECTRICAL SYSTEM (EXCEPT MONITOR PANEL E-MODE)…251
BEFORE STARTING E-MODE TROUBLESHOOTING…252
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…254
E-1 ENGINE DOES NOT START…255
E-2 ENGINE DOES NOT STOP…261
E-3 WHEN SAFETY LOCK LEVER IS IN FREE POSITION, WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE SYSTEMS DO NOT WORK…263
E-4 WHEN SAFETY LOCK LEVER IS IN LOCK POSITION, WHOLE WORK EQUIPMENT, TRAVEL, SWING AND BLADE SYSTEMS WORK…266
E-5 WHEN MACHINE STARTS TRAVELING, TRAVEL ALARM DOES NOT SOUND…268
E-6 WHEN MACHINE STOPS TRAVELING, TRAVEL ALARM DOES NOT STOP SOUNDING…270
E-7 WINDSHIELD WIPER DOES NOT OPERATE [CAB SPECIFICATION]…272
E-8 WINDSHIELD WASHER DOES NOT OPERATE [CAB SPECIFICATION]…274
E-9 HEATER DOES NOT OPERATE…276
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)…279
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…280
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT, TRAVEL, SWING, AND BLADE IS LOW…281
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS…284
H-3 WHOLE WORK EQUIPMENT, TRAVEL SYSTEM, SWING SYSTEM, AND BLADE DO NOT WORK …285
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP…288
H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW…288
H-6 SPEED OR POWER OF BOOM IS LOW…289
H-7 SPEED OR POWER OF ARM IS LOW…290
H-8 SPEED OR POWER OF BUCKET IS LOW…291
H-9 SPEED OR POWER OF BOOM SWING IS LOW…292
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY…292
H-11 WORK EQUIPMENT HYDRAULIC DRIFT IS LARGE…293
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE…294
H-13 IN COMPOUND OPERATION OF WORK EQUIPMENT, SPEED OF PART LOADED MORE IS LOW…294
H-14 MACHINE DEVIATES DURING TRAVEL…295
H-15 TRAVEL SPEED OR TRAVEL POWER IS LOW…297
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW…297
H-17 TRAVEL SPEED DOES NOT CHANGE…298
H-18 TRAVEL MOTOR DOES NOT WORK (ONE SIDE ONLY)…298
H-19 SPEED OR POWER OF SWING IS LOW…299
H-20 MACHINE DOES NOT SWING…301
H-21 SWING ACCELERATION PERFORMANCE IS LOW…303
H-22 MACHINE OVERRUNS WHEN IT STOPS SWINGING…304
H-23 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING…305
H-24 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND…305
H-25 HYDRAULIC DRIFT OF SWING IS LARGE…306
H-26 SPEED OR POWER OF BLADE IS LOW…307
H-27 BLADE DOES NOT MOVE…308
H-28 HYDRAULIC DRIFT OF BLADE IS LARGE…308
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M MODE)…309
BEFORE STARTING M-MODE TROUBLESHOOTING…310
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…312
M-1 WHEN STARTING SWITCH IS TURNED ON, NO MONITOR/GAUGE OPERATES…314
M-2 WHEN STARTING SWITCH IS TURNED ON, SOME MONITORS/GAUGES DO NO OPERATE…316
M-3 CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING…318
M-4 WHILE ENGINE IS RUNNING, ENGINE OIL PRESSURE MONITOR FLASHES…320
M-5 WHILE ENGINE IS RUNNING, CHARGE LEVEL MONITOR FLASHES…322
M-6 PREHEATING SYSTEM DOES NOT OPERATE…324
M-7 COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY…327
M-8 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY…330
M-9 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING…332
M-10 TRAVEL SPEED SHIFTING SYSTEM DOES NOT OPERATE NORMALLY…333
M-11 MONITOR PANEL NIGHT LAMP AND WORKING LAMP DO NOT LIGHT UP…336
TROUBLESHOOTING OF ENGINE (S MODE)…341
TROUBLESHOOTING OF ENGINE (S-MODE)…342
30 DISASSEMBLY AND ASSEMBLY…349
HOW TO READ THIS MANUAL…350
PRECAUTIONS WHEN PERFORMING OPERATION…352
SPECIAL TOOL LIST…354
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY…356
REMOVAL AND INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY…358
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY…363
REMOVAL AND INSTALLATION TRACK SHOE ASSEMBLY…365
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…366
DISASSEMBLY AND ASSEMBLYOF RECOIL SPRING ASSEMBLY…368
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY…371
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY…372
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY…374
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY…376
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY…381
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY…382
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY…384
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY…386
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…387
DISASSEMBLY AND ASSEMBLY OF HDYRAULIC CYLINDER ASSEMBLY…391
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY…395
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)…396
90 OTHERS…405
HYDRAULIC CIRCUIT DIAGRAM…407
ELECTRICAL CIRCUIT DIAGRAM (1/2)…408
ELECTRICAL CIRCUIT DIAGRAM (2/2)…409
TEN00101-02 – Hydraulic Excavator GALEO PC20MR-2 Operation & Maintenance Manual…410
COVER…410
FOREWORD…411
FOREWORD…412
SAFETY INFORMATION…415
INTRODUCTION…417
DIRECTIONS OF MACHINE…417
PRODUCT INFORMATION…418
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…418
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…418
EPA NAMEPLATE…419
SERVICE METER LOCATION…419
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…420
CONTENTS…421
SAFETY…424
SAFETY INFORMATION…425
SAFETY LABELS…427
LOCATION OF SAFETY LABELS…427
SAFETY LABELS…428
SAFETY INFORMATION…433
SAFETY RULES…433
IF PROBLEMS ARE FOUND…433
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…433
FIRE EXTINGUISHER AND FIRST AID KIT…433
SAFETY EQUIPMENT…434
KEEP MACHINE CLEAN…434
KEEP OPERATOR'S COMPARTMENT CLEAN…434
LEAVING OPERATOR'S SEAT WITH LOCK…434
HANDRAILS AND STEPS…435
MOUNTING AND DISMOUNTING…435
NO PERSONS ON ATTACHMENTS…435
BURN PREVENTION…436
FIRE PREVENTION AND EXPLOSION PREVENTION…436
ACTION IF FIRE OCCURS…437
WINDSHIELD WASHER FLUID…437
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…438
CAUTIONS RELATED TO ROPS (ROLLOVER PROTECTION SYSTEM)…438
ATTACHMENT INSTALLATION…439
ATTACHMENT COMBINATIONS…439
CAB WINDOW GLASSES…439
UNAUTHORIZED MODIFICATIONS…439
SAFETY AT JOBSITE…439
WORKING ON LOOSE GROUND…439
DISTANCE TO HIGH VOLTAGE CABLES…440
ENSURE GOOD VISIBILITY…440
VENTILATION FOR ENCLOSED AREA…440
SIGNALMAN'S SIGNAL AND SIGNS…440
EMERGENCY EXIT FROM OPERATOR'S CAB…441
ASBESTOS DUST HAZARD PREVENTION…441
SAFETY MACHINE OPERATION…442
STARTING ENGINE…442
CHECKS BEFORE STARTING ENGINE…442
SAFETY RULES FOR STARTING ENGINE…443
STARTING ENGINE IN COLD WEATHER…443
OPERATION…444
CHECKS BEFORE OPERATION…444
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…444
SAFETY RULES FOR TRAVELING…445
TRAVELING ON SLOPES…446
OPERATIONS ON SLOPES…447
PROHIBITED OPERATIONS…447
OPERATIONS ON SNOW…449
PARKING MACHINE…449
TRANSPORTATION…450
LOADING AND UNLOADING…450
SHIPPING THE MACHINE…450
BATTERY…451
BATTERY HAZARD PREVENTION…451
STARTING ENGINE WITH BOOSTER CABLES…452
TOWING…453
SAFETY RULES FOR TOWING…453
LIFTING OBJECTS WITH BUCKET…454
SAFETY RULES FOR LIFTING OBJECTS…454
SAFETY MAINTENANCE INFORMATION…455
WARNING TAG…455
KEEP WORK PLACE CLEAN AND TIDY…455
APPOINT LEADER WHEN WORKING WITH OTHERS…455
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…456
CAUTIONS FOR OPENING (TILTING) FLOOR…457
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…458
PROPER TOOLS…458
PERSONNEL…458
ATTACHMENTS…459
WORK UNDER THE MACHINE…459
NOISE…459
WHEN USING HAMMER…459
WELDING WORKS…459
REMOVING BATTERY TERMINALS…460
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…460
DO NOT DISASSEMBLE RECOIL SPRINGS…460
SAFETY RULES FOR HIGH-PRESSURE OIL…460
SAFETY HANDLING HIGH-PRESSURE HOSES…461
WASTE MATERIALS…461
COMPRESSED AIR…461
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…461
OPERATION…462
MACHINE VIEW ILLUSTRATIONS…463
OVERALL MACHINE VIEW…463
CONTROLS AND GAUGES…464
DETAILED CONTROLS AND GAUGES…465
MONITORING SYSTEM…465
SWITCHES…473
CONTROL LEVERS AND PEDALS…477
WINDSHIELD…483
SLIDING DOOR…487
SLIDING WINDOW…487
EMERGENCY ESCAPE HAMMER…488
CAP WITH LOCK…489
ENGINE REAR COVER…490
COOLING COVER…490
FRONT RIGHT COVER…491
METHOD OF OPENING (TILTING) FLOOR…492
FUSE…497
BLOCK FUSE…498
OPERATION MANUAL STORAGE…498
TOOL BOX…498
GREASE GUN HOLDER…499
ASHTRAY…499
MACHINE OPERATIONS AND CONTROLS…500
BEFORE STARTING ENGINE…500
STARTING ENGINE…515
AFTER STARTING ENGINE…519
STOPPING THE ENGINE…522
MACHINE OPERATION…523
STEERING THE MACHINE…528
SWINGING…530
WORK EQUIPMENT CONTROLS AND OPERATIONS…531
PROHIBITED OPERATIONS…533
GENERAL OPERATION INFORMATION…535
TRAVELING ON SLOPES…537
ESCAPE FROM MUD…539
WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…540
BUCKET REPLACEMENT…542
PARKING MACHINE…543
MACHINE INSPECTION AFTER DAILY WORK…544
LOCKING…545
RUBBER SHOES (MACHINE WITH RUBBER SHOES ONLY)…546
TRANSPORTATION…551
TRANSPORTATION PROCEDURE…551
LOADING AND UNLOADING WITH TRAILER…552
LIFTING MACHINE…558
COLD WEATHER OPERATION…561
COLD WEATHER OPERATION INFORMATION…561
CAB HEATER IN COLD WEATHER…562
AFTER DAILY WORK COMPLETION…563
AFTER COLD WEATHER SEASON…563
LONG TERM STORAGE…564
BEFORE STORAGE…564
DURING STORAGE…564
AFTER STORAGE…564
TROUBLES AND ACTIONS…565
RUNNING OUT OF FUEL…565
PHENOMENA THAT ARE NOT FAILURES…565
TOWING THE MACHINE…566
SEVERE JOB CONDITION…566
DISCHARGED BATTERY…567
OTHER TROUBLE…571
MAINTENANCE…574
MAINTENANCE INFORMATION…575
OUTLINE OF SERVICE…577
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…577
ELECTRIC SYSTEM MAINTENANCE…580
HANDLING HYDRAULIC SYSTEM…580
WEAR PARTS…581
WEAR PARTS LIST…581
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…582
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN…584
TIGHTENING TORQUE SPECIFICATIONS…585
TIGHTENING TORQUE LIST…585
SAFETY CRITICAL PARTS…586
SAFETY CRITICAL PARTS LIST…586
MAINTENANCE SCHEDULE…587
MAINTENANCE SCHEDULE CHART…587
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…588
MAINTENANCE PROCEDURE…589
WHEN REQUIRED…589
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…589
CLEAN INSIDE OF COOLING SYSTEM…592
CHECK LEVEL OF BATTERY ELECTROLYTE…595
CLEAN FUEL FILTER ELEMENT (WITH WATER SEPARATOR)…597
DRAIN WATER AND SEDIMENT FROM FUEL TANK…597
CHECK AND ADJUST TRACK TENSION (MACHINE EQUIPPED WITH STEEL SHOE)…598
CHECK RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)…600
CHECK AND ADJUST RUBBER SHOE TENSION (MACHINE EQUIPPED WITH RUBBER SHOES)…602
REPLACE RUBBER SHOES (MACHINE EQUIPPED WITH RUBBER SHOES)…604
REPLACE BUCKET TEETH…607
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…610
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…611
BLEEDING AIR FROM HYDRAULIC SYSTEM…612
CHECK BEFORE STARTING…613
EVERY 500 HOURS MAINTENANCE…614
LUBRICATING…614
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…617
REPLACE FUEL FILTER ELEMENT (WITH WATER SEPARATOR)…618
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…619
REPLACE FUEL FEED PUMP PRE-FILTER…620
CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…620
CHECK AND ADJUST COOLING FAN BELT TENSION…621
EVERY 1000 HOURS MAINTENANCE…622
CHANGE OIL IN FINAL DRIVE CASE…622
REPLACE HYDRAULIC OIL FILTER ELEMENT…623
CHECK ENGINE VALVE CLEARANCE, ADJUST…624
EVERY 2000 HOURS MAINTENANCE…625
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…625
CHECK ALTERNATOR, STARTING MOTOR…627
SPECIFICATIONS…628
SPECIFICATIONS…629
ATTACHMENTS, OPTIONS…631
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…632
SAFETY FIRST…632
ATTACHMENT INSTALLATION…633
BUCKET WITH HOOK…634
PROHIBITED OPERATIONS…634
WINDSHIELD WASHER…635
WINDSHIELD WASHER OPERATION…635
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…635
MACHINE READY FOR ATTACHMENT…636
LOCATIONS…636
HYDRAULIC CIRCUIT…638
ATTACHMENT OPERATIONS…640
LONG TERM STORAGE…641
SPECIFICATIONS…641
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE…642
CONTROL PATTERN CHANGE PROCEDURE…642
MACHINE CONTROL PATTERNS…643
ATTACHMENT GUIDE…644
ATTACHMENT COMBINATIONS…644
RECOMMENDED ATTACHMENT OPERATIONS…645
HYDRAULIC BREAKER…645
INDEX…650
WEAM007000 – Hydraulic Excavator GALEO PC20MR-2 Operation & Maintenance Manual…653
1.1 FOREWORD…655
1.2 INFORMATION ON SAFETY…656
1.3 INTRODUCTION…658
1.3.1 INTENDED USES…658
1.3.2 IMPROPER OR UNAUTHORIZED USES…658
1.3.3 MAIN CHARACTERISTICS…658
1.3.4 RUNNING-IN…659
1.3.5 DIRECTIONS OF MACHINE…659
1.4 PRODUCT IDENTIFICATION…660
1.4.1 MACHINE SERIAL NUMBER…660
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)…660
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE…661
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER…661
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER…662
1.4.6 CAB SERIAL NUMBER…662
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS…663
TABLE OF CONTENTS…664
2.1 SAFETY, NOISE AND VIBRATION PLATES…672
2.1.1 POSITION OF THE SAFETY PLATES…672
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS…673
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB…678
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CANOPY…679
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED…679
2.2 GENERAL PRECAUTIONS…680
2.2.1 GENERAL SAFETY RULES…680
2.2.2 SAFETY DEVICES AND GUARDS…680
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS…680
2.2.4 UNAUTHORIZED MODIFICATIONS…681
2.2.5 LEAVING THE OPERATOR’S SEAT…681
2.2.6 GETTING ON AND OFF THE MACHINE…682
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL…683
2.2.8 PREVENTING BURNS…683
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER…684
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT…684
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT…685
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE…685
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT…685
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE…686
2.3.1 SAFETY ON THE WORK SITE…686
2.3.2 FIRE PREVENTION…686
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB…686
2.3.4 ROOM VENTILATION…687
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS…687
2.3.6 CLEANING THE WINDOWS – CHECKING THE WINDSHIELD WIPER BLADES…687
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING…688
2.4.1 STARTING THE ENGINE…688
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE…688
2.4.3 CHECKS FOR TRAVELLING IN REVERSE…689
2.4.4 MOVING THE MACHINE…689
2.4.5 MOVING ON SLOPES…690
2.4.6 WORKING ON SLOPES…691
2.4.7 UNAUTHORIZED OPERATIONS…691
2.4.8 PREVENTING ELECTROCUTION…693
2.4.9 VISIBILITY…693
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES…693
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT…694
2.4.12 WORKING ON LOOSE GROUND…694
2.4.13 PARKING THE MACHINE…694
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES…695
2.5.1 LOADING AND UNLOADING…695
2.5.2 TRANSPORT…695
2.6 BATTERY…696
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY…696
2.6.2 STARTING WITH BOOSTER CABLES…696
2.7 PRECAUTIONS FOR THE REMOVAL…697
2.8 PRECAUTIONS FOR MAINTENANCE…698
2.8.1 WARNING PLATES…698
2.8.2 TOOLS…698
2.8.3 PERSONNEL…698
2.8.4 EQUIPMENT…699
2.8.5 WORKING UNDER THE MACHINE…699
2.8.6 CLEANING THE MACHINE…699
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS…700
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY…700
2.8.9 STOP THE ENGINE BEFORE CARRY ING OUT ANY MAINTENANCE OPER ATION OR INSPECTION…700
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP…701
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR…701
2.8.12 USING LAMPS…701
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR…702
2.8.14 PRECAUTIONS CONCERNING THE STARTER…702
2.8.15 HANDLING HIGH-PRESSURE PIPES…702
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL…703
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERA TURES AND HIGH PRESSURE…703
2.8.18 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE TRACK TENSION…704
2.8.19 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT…704
2.8.20 HYDRAULIC ACCUMULATOR…704
2.8.21 COOLING FAN AND BELT…705
2.8.22 WASTE MATERIALS…705
2.8.23 COMPRESSED AIR…705
2.8.24 PRECAUTIONS FOR THE USE OF THE synthetic biodegrada ble oil type HEES…705
3.1 MACHINE VIEW ILLUSTRATIONS…708
3.1.1 OVERALL MACHINE VIEW…708
3.1.2 CONTROLS AND GAUGES…709
3.2 DETAILED CONTROLS AND GAUGES…710
3.2.1 MONITORING SYSTEM…710
3.2.1.1 EMERGENCY MONITORS…711
3.2.1.2 METER DISPLAY PORTION…713
3.2.1.3 PILOT LAMPS…715
3.2.1.4 MONITOR SWITCHES PORTION…716
3.2.2 SWITCHES…718
3.2.3 CONTROL LEVERS AND PEDALS…721
3.2.4 WINDSHIELD (Machines equipped with cab)…728
3.2.5 SLIDING DOOR (Machines equipped with cab)…732
3.2.6 SLIDING WINDOW (Machines equipped with cab)…732
3.2.7 EMERGENCY ESCAPE HAMMER (Machines equipped with cab)…733
3.2.8 CAPS AND COVERS WITH LOCK…734
3.2.9 ENGINE REAR COVER…735
3.2.10 COOLING COVER…736
3.2.11 TANK COVER…737
3.2.12 METHOD OF OPENING (TILTING) FLOOR…738
3.2.13 FUSE…742
3.2.14 BLOCK FUSE…742
3.2.15 OPERATION MANUAL STORAGE…743
3.2.16 TOOL BOX…743
3.2.17 GREASE GUN HOLDER…743
3.2.18 ASHTRAY (Machines equipped with cab)…743
3.3 MACHINE OPERATIONS AND CONTROLS…744
3.3.1 BEFORE STARTING ENGINE…744
3.3.1.1 WALK-AROUND CHECKS…744
3.3.1.2 CHECKS BEFORE STARTING…746
3.3.1.3 ADJUSTMENT…752
3.3.1.4 OPERATIONS BEFORE STARTING ENGINE…755
3.3.1.5 STARTING ENGINE…757
3.3.2 AFTER STARTING ENGINE…760
3.3.2.1 BREAKING-IN THE NEW MACHINE…760
3.3.2.2 WARMING-UP OPERATION…760
3.3.3 STOPPING THE ENGINE…762
3.3.4 MACHINE OPERATION…763
3.3.4.1 PREPARATIONS FOR MOVING THE MACHINE OFF…763
3.3.4.2 MOVING MACHINE FORWARD…763
3.3.4.3 MOVING MACHINE BACKWARD…765
3.3.4.4 STOPPING MACHINE…766
3.3.5 STEERING THE MACHINE…767
3.3.5.1 STEERING…767
3.3.6 SWINGING…769
3.3.7 WORK EQUIPMENT CONTROLS AND OPERATIONS…770
3.3.8 PROHIBITED OPERATIONS…772
3.3.9 GENERAL OPERATION INFORMATION…774
3.3.10 TRAVELING ON SLOPES…776
3.3.11 ESCAPE FROM MUD…778
3.3.12 WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR…779
3.3.13 CHANGING THE BUCKET…781
3.3.14 PARKING MACHINE…782
3.3.15 CHECK AFTER SHUT OFF ENGINE…783
3.3.16 MACHINE INSPECTION AFTER DAILY WORK…783
3.3.17 LOCKING…783
3.3.18 RUBBER SHOES (Machines equipped only with rubber shoes)…784
3.3.18.1 OPTIMAL USE OF THE RUBBER SHOES…784
3.3.18.2 RUBBER SHOE WARRANTY…784
3.3.18.3 USING THE RUBBER SHOES…784
3.4 TRANSPORTATION…788
3.4.1 TRANSPORTATION PROCEDURE…788
3.4.2 LOADING AND UNLOADING WITH TRAILER…788
3.4.3 LIFTING MACHINE…794
3.5 COLD WEATHER OPERATION…796
3.5.1 COLD WEATHER OPERATION INFORMATION…796
3.5.1.1 FUEL AND LUBRICANTS…796
3.5.1.2 COOLING SYSTEM COOLANT…796
3.5.1.3 BATTERY…797
3.5.2 CAB HEATER IN COLD WEATHER (Machines equipped with cab)…797
3.5.3 AFTER DAILY WORK COMPLETION…798
3.5.4 AFTER COLD WEATHER SEASON…798
3.6 LONG TERM STORAGE…799
3.6.1 BEFORE STORAGE…799
3.6.2 DURING STORAGE…799
3.6.3 AFTER STORAGE…799
3.7 TROUBLES AND ACTIONS…800
3.7.1 RUNNING OUT OF FUEL…800
3.7.2 PHENOMENA THAT ARE NOT FAILURES…800
3.7.3 TOWING THE MACHINE…800
3.7.4 SEVERE JOB CONDITION…801
3.7.5 DISCHARGED BATTERY…801
3.7.5.1 BATTERY REMOVAL AND INSTALLATION…802
3.7.5.2 BATTERY CHARGES…802
3.7.5.3 STARTING ENGINE WITH BOOSTER CABLES…803
3.7.6 OTHER TROUBLE…805
3.7.6.1 ELECTRICAL SYSTEM…805
3.7.6.2 CHASSIS…806
3.7.6.3 ENGINE…806
4.1 MAINTENANCE INFORMATION…810
4.2 LUBRICANTS, COOLANT AND FILTERS…813
4.2.1 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…813
4.2.1.1 OIL…813
4.2.1.2 FUEL…813
4.2.1.3 COOLING SYSTEM COOLANT…814
4.2.1.4 GREASE…814
4.2.1.5 CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)…815
4.2.1.6 OIL AND FUEL STORAGE…816
4.2.1.7 FILTERS…816
4.2.2 ELECTRIC SYSTEM MAINTENANCE…817
4.2.3 HANDLING HYDRAULIC SYSTEM…817
4.3 WEAR PARTS…818
4.3.1 WEAR PARTS LIST…818
4.4 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…819
4.4.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS…823
4.5 TIGHTENING TORQUE SPECIFICATIONS…824
4.5.1 TIGHTENING TORQUE LIST…824
4.6 LUBRICATION…825
4.6.1 LUBRICATION DIAGRAM…825
4.7 SAFETY CRITICAL PARTS…826
4.7.1 SAFETY CRITICAL PARTS LIST…826
4.8 MAINTENANCE SCHEDULE…827
4.8.1 MAINTENANCE SCHEDULE CHART…827
4.8.2 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…828
4.8.2.a CHANGING THE HYDRAULIC OIL FIL TER…828
4.8.2.b CHANGING THE HYDRAULIC OIL…828
4.9 MAINTENANCE PROCEDURE…829
4.9.1 WHEN REQUIRED…829
4.9.1.a CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…829
4.9.1.b CLEAN INSIDE OF COOLING SYSTEM…831
4.9.1.c CHECK LEVEL OF BATTERY ELECTROLYTE…834
4.9.1.d CLEANING THE FUEL FILTER (WITH WATER SEPARATOR)…836
4.9.1.e DRAIN WATER AND SEDIMENT FROM FUEL TANK…836
4.9.1.f CHECK AND ADJUST TRACK TENSION (Machines equipped with steel shoes)…837
4.9.1.g CHECKING THE RUBBER SHOES (Machines equipped with rubber shoes)…839
4.9.1.h CHECK AND ADJUST RUBBER SHOE TENSION (Machine equipped with rubber shoes)…841
4.9.1.i REPLACE RUBBER SHOES (Machine equipped with rubber shoes)…843
4.9.1.j CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (Machine equipped with cab)…845
4.9.1.k CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER (Machine equipped with cab)…846
4.9.1.l BLEEDING AIR FROM HYDRAULIC SYSTEM…846
4.9.2 CHECK BEFORE STARTING…847
4.9.3 EVERY 500 HOURS MAINTENANCE…848
4.9.3.a LUBRICATING…848
4.9.3.b CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…850
4.9.3.c CHANGING THE FUEL FILTER ELEMENT (WITH WATER SEPARATOR)…851
4.9.3.d CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…852
4.9.3.e REPLACE FEED PUMP PRE-FILTER…853
4.9.3.f CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS…853
4.9.3.g CHECK AND ADJUST COOLING FAN BELT TENSION…854
4.9.4 EVERY 1000 HOURS MAINTENANCE…855
4.9.4.a CHANGING THE HYDRAULIC OIL FILTER ELEMENT…855
4.9.4.b CHANGE OIL IN FINAL DRIVE CASE…856
4.9.4.c CHECK ENGINE VALVE CLEARANCE, ADJUST…856
4.9.5 EVERY 2000 HOURS MAINTENANCE…857
4.9.5.a CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…857
4.9.5.b CHECK ALTERNATOR, STARTING MOTOR…858
5.1 SPECIFICATIONS…860
5.2 LIFTING CAPACITIES…862
5.2.1 LIFTING CAPACITIES (WITH CANOPY)…862
5.2.2 LIFTING CAPACITIES (WITH CABIN)…865
6.1 ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…870
6.1.1 SAFETY FIRST…870
6.1.2 ATTACHMENT INSTALLATION…871
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT…872
6.1.3.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT…872
6.2 MACHINE READY FOR ATTACHMENT…873
6.2.1 LOCATIONS…873
6.2.2 HYDRAULIC CIRCUIT…875
6.2.2.1 ASSEMBLYING AND CONNECTING THE EQUIPMENT…875
6.2.2.2 MAINTENANCE…876
6.2.2.3 BLEEDING AIR…876
6.3 ATTACHMENT OPERATIONS…877
6.3.1 LONG TERM STORAGE…878
6.3.2 SPECIFICATIONS…878
6.4 ATTACHMENT GUIDE…879
6.4.1 ATTACHMENT COMBINATIONS…879
6.5 RECOMMENDED ATTACHMENT OPERATIONS…880
6.5.1 HYDRAULIC BREAKER…880
Komatsu Hydraulic Excavator PC20MR Repair Service Manuals