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Komatsu Galeo PC27MR-2, Operation & Maintence Manual

The Komatsu Galeo PC27MR-2 is a compact hydraulic excavator designed for exceptional performance and efficiency on construction sites. Ensure smooth operation and proper maintenance by downloading the free Operation & Maintenance Manual from manualshive.com. This comprehensive manual provides essential information to maximize the machine's lifespan and productivity.

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SAFETY 

SAFETY INFORMATION

SAFETY INFORMATION

SAFETY RULES

Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may
be severly impaired putting yourself and everyone else on your jobsite in danger.
When working with another operator or with a person on worksite traffic duty, be sure that all personnel
understand all hand signals that are to be used.

IF PROBLEMS ARE FOUND

If you find any problems in the machine during operation or maintenance (noise, vibration, smell, incorrect gauges,
smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person in charge
and  have  the necessary action taken. Do not operate the machine until the problem has been corrected.

WORKING WEAR AND PERSONAL PROTECTIVE ITEMS

Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other
protruding parts.
If you have long hair and it hangs out from your hard hat, there
is a hazard that it may get caught up in the machine, so tie your
hair up and be careful not to let it get caught.
Always wear a hard hat and safety shoes.  If the nature of the
work requires it, wear safety glasses, mask, gloves, ear plugs,
and safety belt when operating or maintaining the machine.
Check that all protective equipment functions properly before
using it.

FIRE EXTINGUISHER AND FIRST AID KIT

Always follow the precautions below to prepare for action if any injury or fire should occur.

Be sure that fire extinguishers have been provided and read the
labels to ensure that you know how to use them in emergencies.
Carry out periodic inspection and maintenance to ensure that
the fire extinguisher can always be used.
Provide a first aid kit in the storage point.   Carry out periodic
checks and add to the contents if necessary.

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Summary of Contents for Galeo PC27MR-2

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Page 3: ...hem fully Keep this manual in the storage location for the operation and maintenance manual given below and have all personnel read it periodically If this manual has been lost or has become dirty and cannot be read request a replacement manual immediately from Komatsu or your Komatsu distributor If you sell the machine be sure to give this manual to the new owners together with the machine Komats...

Page 4: ... FOREWORD FOREWORD 1 3 ...

Page 5: ... FOREWORD FOREWORD 1 4 ...

Page 6: ...ituation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury This word is used also to alert against unsafe practices that may cause property damage Example of safety message using signal word WARNING When standing up from the operator s seat always place the lock lever in the LOCK posi...

Page 7: ...d inside a triangle and the method of avoiding the hazardous condition is shown inside a circle Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance Therefore the safety messages in this manual and on the machine may not include all possible safety precautions If any proceduresor actions not specifically recommendedor allowed in this manual a...

Page 8: ...oading work Demolition work See the section WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR PAGE 3 79 for further details DIRECTIONS OF MACHINE In this manual the terms front rear left and right refer to the travel direction as seen from the operator s seat when the operator s seat is facing the front and the sprocket is at the rear of the machine 1 7 ...

Page 9: ...please inform your Komatsu distributor of the following items PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERIAL NO PLATE On the left front of the frame The design of the nameplate differs according to the territory ENGINE SERIAL NUMBER PLATE AND ITS LOCATION This is fixed to the water separator bracket 1 8 ...

Page 10: ...CT INFORMATION EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION This is fixed on top of the water separator bracket EPA Environmental Protection Agency U S A SERVICE METER LOCATION On top of the machine monitor 1 9 ...

Page 11: ... FOREWORD PRODUCT INFORMATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Distributor name Address Service Personnel Phone Fax 1 10 ...

Page 12: ...TY MACHINE OPERATION 2 19 STARTING ENGINE 2 19 OPERATION 2 21 TRANSPORTATION 2 27 BATTERY 2 28 TOWING 2 30 LIFTING OBJECTS WITH BUCKET 2 31 SAFETY MAINTENANCE INFORMATION 2 32 OPERATION 3 1 MACHINE VIEW ILLUSTRATIONS 3 2 OVERALL MACHINE VIEW 3 2 CONTROLS AND GAUGES 3 3 DETAILED CONTROLS AND GAUGES 3 4 MONITORING SYSTEM 3 4 SWITCHES 3 12 CONTROL LEVERS AND PEDALS 3 16 WINDSHIELD 3 22 SLIDING DOOR 3...

Page 13: ...MACHINE 3 97 COLD WEATHER OPERATION 3 100 COLD WEATHER OPERATION INFORMATION 3 100 CAB HEATER IN COLD WEATHER 3 101 AFTER DAILY WORK COMPLETION 3 102 AFTER COLD WEATHER SEASON 3 102 LONG TERM STORAGE 3 103 BEFORE STORAGE 3 103 DURING STORAGE 3 104 AFTER STORAGE 3 104 TROUBLES AND ACTIONS 3 105 RUNNING OUT OF FUEL 3 105 PHENOMENA THAT ARE NOT FAILURES 3 105 TOWING THE MACHINE 3 106 SEVERE JOB CONDI...

Page 14: ...6 6 AIR CONDITIONER MAINTENANCE 6 7 WINDSHIELD WASHER 6 11 WINDSHIELD WASHER OPERATION 6 11 CHECK WINDOW WASHER FLUID LEVEL ADD FLUID 6 11 MACHINE READY FOR ATTACHMENT 6 12 LOCATIONS 6 12 HYDRAULIC CIRCUIT 6 14 ATTACHMENT OPERATIONS 6 16 LONG TERM STORAGE 6 17 SPECIFICATIONS 6 17 CHANGING MACHINE CONTROL PATTERN IF PATTERN CHANGE VALVE EQUIPPED 6 18 CONTROL PATTERN CHANGE PROCEDURE 6 18 MACHINE CO...

Page 15: ... 2 1 ...

Page 16: ...rsons on Attachments 2 12 Burn Prevention 2 13 Fire Prevention and Explosion Prevention 2 13 Action if Fire Occurs 2 14 Windshield Washer Fluid 2 14 Falling Objects Flying Objects and Intruding Objects Prevention 2 15 Cautions Related to ROPS Rollover Protection System 2 15 Attachment Installation 2 16 Attachment Combinations 2 16 Cab Window Glasses 2 16 Unauthorized Modifications 2 16 Safety at J...

Page 17: ... LIFTING OBJECTS WITH BUCKET 2 31 Safety Rules for Lifting Objects 2 31 SAFETY MAINTENANCE INFORMATION 2 32 Warning Tag 2 32 Keep Work Place Clean and Tidy 2 32 Appoint Leader when Working with Others 2 32 Stop Engine Before Carrying Out Maintenance 2 33 Cautions for Opening Tilting Floor 2 34 Two Workers for Maintenance when Engine is Running 2 35 Proper Tools 2 35 Personnel 2 35 Attachments 2 36...

Page 18: ...ce and always keep them clean When cleaning them do not use organic solvents or gasoline These may cause the labels to peel off There are also other labels in addition to the warning signs and safety labels Handle those labels in the same way If the labels are damaged lost or cannot be read properly replace them with new ones For details of the part numbers for the labels see this manual or the ac...

Page 19: ... SAFETY SAFETY LABELS SAFETY LABELS 1 Caution before operating or maintaining machine 09651 03001 2 Caution for before operation 22L 98 22160 3 Warning for leaving operator s seat 09654 03001 2 5 ...

Page 20: ... SAFETY SAFETY LABELS SAFETY SAFETY LABELS 4 Warnings for high voltage 09801 03001 5 Caution for operating pattern 22J 98 1A631 6 Caution for high temperature coolant 20M 98 83250 2 6 ...

Page 21: ... LABELS 7 Caution for high temperature hydraulic oil 22L 98 22240 8 Caution for handling electric wires 09808 03000 9 Caution for check and adjust track tention 09657 03003 10 Caution when opening while engine is running 09667 03001 2 7 ...

Page 22: ... to enter range of swing 20M 98 73130 12 Caution for stowage 09803 03000 Machines equipped with cab 13 Caution when changing operating pattern 22L 98 22311 14 Caution for lock pin when opening floor 22L 98 22390 15 Caution when closing floor 22L 98 22410 2 8 ...

Page 23: ...AFETY LABELS SAFETY SAFETY LABELS 16 Caution for handling battery 09664 30002 17 Caution for handling ROPS 22L 98 22321 18 Caution with high temperature parts 09817 A0753 High altitude specification machine 2 9 ...

Page 24: ...ntil the problem has been corrected WORKING WEAR AND PERSONAL PROTECTIVE ITEMS Do not wear loose clothing and accessories There is a hazard that they may catch on control levers or other protruding parts If you have long hair and it hangs out from your hard hat there is a hazard that it may get caught up in the machine so tie your hair up and be careful not to let it get caught Always wear a hard ...

Page 25: ...ate the pedal with mud or oil affixed to your shoes your foot may slip and this may cause a serious accident Do not leave parts or tools lying around the operator s compartment Do not stick suction pads to the window glass Suction pads act as a lens and may cause fire Do not use cellular telephones inside the operator s compartment when driving or operating the machine Never bring any dangerous ob...

Page 26: ...limb on the engine hood or covers where there are no non slip pads Before getting on or off the machine check the handrails and steps including the track shoe If there is any oil grease or mud on the handrails or steps including the track shoe wipe it off immediately Always keep these parts clean Repair any damage and tighten any loose bolts Do not get on or off the machine while holding tools in ...

Page 27: ... oil antifreeze and window washer liquid are particularly flammable and can be hazardous To prevent fire always observe the following Do not smoke or use any flame near fuel or oil Stop the engine before refueling Do not leave the machine while adding fuel or oil Tighten all fuel and oil caps securely Do not spill fuel on overheated surfaces or on parts of the electrical system Use well ventilated...

Page 28: ...raulic line Check that all the hose and tube clamps guards and cushions are securely fixed in position If they are loose they may vibrate during operation and rub against other parts This may lead to damage to the hoses and cause high pressure oil to spurt out leading to fire damage or serious injury Explosion caused by lighting equipment When checking fuel oil battery electrolyte window washer fl...

Page 29: ...ing to the operating conditions on the jobsite Always contact your Komatsu distributor for advice CAUTIONS RELATED TO ROPS ROLLOVER PROTECTION SYSTEM ROPS is a structure designed to protect an operator who is wearing a seatbelt if the machine should roll over It supports the weight of the machine when it rolls over and also absorbs the impact energy If ROPS is modified its strength may be reduced ...

Page 30: ...carrying out operations near combustible materials such as thatched roofs dry leaves or dry grass there is a hazard of fire so be careful when operating Check the terrain and condition of the ground at the worksite and determine the safest method of operation Do not carry out operations at places where there is a hazard of landslides or falling rocks If water lines gas lines or high voltage electr...

Page 31: ... the seat and be careful not to touch the chassis with any exposed part of your body Use a signalman to give warning if the machine approaches too close to the electric cables When carrying out operations near high voltage cables do not let anyone come close to the machine If the machine should come too close or touch the electric cable to prevent electric shock the operator should not leave the o...

Page 32: ... frame first and be careful not to cut yourself on the glass Be careful also not to slip on the broken pieces of glass on the ground ASBESTOS DUST HAZARD PREVENTION Asbestos dust in the air can cause lung cancer if it is inhaled There is danger of inhaling asbestos when working on jobsites handling demolition work or work handling industrial waste Always observe the following Spray water to keep d...

Page 33: ...ps and check that they light up correctly Check the coolant level fuel level and oil level in engine oil pan check for clogging of the air cleaner and check for damage to the electric wiring Adjust the operator s seat to a position where it is easy to carry out operations and check that there is no damage or wear to the seat belt or mounting clamps Check the operation of the instruments and gauges...

Page 34: ... seated Do not attempt to start the engine by short circuiting the engine starting circuit Such an act may cause a serious bodily injury or fire When starting the engine sound the horn as a warning Do not allow anyone apart from the operator to ride on the machine STARTING ENGINE IN COLD WEATHER Carry out the warming up operation thoroughly If the machine is not thoroughly warmed up before the con...

Page 35: ...s at the front of the operator s cab the machine makes a movement reverse to the control lever movement for example forward becomes reverse and left becomes right Be careful to avoid such a reverse movement of the machine Before travelling check again that there is no one in the surrounding area and that there are no obstacles Before travelling sound the horn to warn people in the area Always oper...

Page 36: ...er obstacles which make the machine tilt strongly to one side When traveling or carrying out operations always keep a safe distance from people structures or other machines to avoid coming into contact with them When passing over bridges or structures check first that the structure is strong enough to support the weight of the machine When traveling on public roads check first with the relevant au...

Page 37: ... check the firmness of the ground under the front of the machine when traveling When traveling up a steep slope extend the work equipment to the front to improve the balance keep the work equipment approximately 20 to 30 cm 8 to 12 in above the ground and travel at low speed When traveling downhill lower the engine speed keep the travel lever close to the neutral position and travel at low speed W...

Page 38: ...ere is a hazard that the machine may lose its balance and turn over when the swing or work equipment are operated This may lead to serious injury or property damage so always provide a stable place when carrying out these operations and operate carefully Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded This operation is dangerous and may cause the...

Page 39: ...t use the impact force of the work equipment for breaking work There is a hazard of damage to the work equipment or a hazard of serious personal injury being caused by flying pieces of broken materials or of the machine tipping over due to reaction from the impact Generally speaking the machine is more liable to overturn when the work equipment is at the side than when it is at the front or rear W...

Page 40: ...e is a hazard of the machine tipping over or hitting covered objects so always carry out operations carefully PARKING MACHINE Park the machine on firm level ground Select a place where there is no hazard of falling rocks or landslides or of flooding if the land is low Lower the work equipment and blade completely to the ground When leaving the machine set lock lever 1 to the LOCK position L then s...

Page 41: ...w speed and operate the machine slowly when loading or unloading Never correct your steering on the ramps If necessary drive off the ramps correct the direction then enter the ramps again When on the ramps do not operate any lever except for the travel lever The center of gravity of the machine will change suddenly at the joint between the ramps and the track or trailer and there is danger of the ...

Page 42: ... sparks will be generated always do as follows Do not let tools or other metal objects make any contact between the battery terminals Do not leave tools or other metal objects on top of the battery Always disconnect the negative terminal ground side first when removing the battery when installing the battery connect the positive terminal first and connect the ground last Tighten the battery termin...

Page 43: ...hine There is a hazard that the machine will move when the power is connected Be sure to connect the positive cable first when installing the booster cables Disconnect the negative cable ground side first when removing them When removing the booster cables be careful not to let the booster cable clips touch each other or to let the clips touch the machine Always wear safety goggles and rubber glov...

Page 44: ... rope For towing see TOWING THE MACHINE PAGE 3 106 Always wear leather gloves when handling wire rope Fix the wire rope to the track frame During the towing operation never stand between the towing machine and the machine being towed Never tow a machine on a slope Never use a wire rope which has cut strands A reduced diameter B or kinks C There is danger that the rope may break during the towing o...

Page 45: ...ing load For details of the maximum lifting load permitted for this machine see BUCKET WITH HOOK PAGE 6 4 It is dangerous if the load hits any worker or structure Always check carefully that the surrounding area is safe before swinging or turning the machine Do not start swing or stop the machine suddenly There is a hazard that the lifted load will swing Do not pull the load to the side or in towa...

Page 46: ... others start the engine or touch or operate the work equipment control lever while you are performing service or maintenance you could suffer serious injury or property damage KEEP WORK PLACE CLEAN AND TIDY Park the machine on firm level ground Select a place where there is no hazard of falling rocks or landslides or of flooding if the land is low Lower the work equipment and blade completely to ...

Page 47: ...ks or landslides or of flooding if the land is low Lower the work equipment and blade completely to the ground Place the work equipment control lever to the neutral position set lock lever 1 to LOCK position L then stop the engine REMARK For machines equipped with a cab there is only a lock lever on the left Put blocks under the track to prevent the machine from moving 2 33 ...

Page 48: ...o not open the floor when the machine is on a slope or when there is strong wind This may lead to serious personal injury Never open the floor when the engine is running or when the door on the cab specification machine is open or when the lock lever is at the FREE position This is extremely dangerous Immediately after the engine is stopped the parts and oil are at a high temperature and will caus...

Page 49: ...t When carrying out operations near the fan fan belt or other rotating parts there is a hazard of being caught in the parts so be careful not to come close Do not touch any control levers If any control lever must be operated give a signal to the other workers to warn them to move to a safe place Never drop or insert tools or other objects into the fan or fan belt Parts may break or be sent flying...

Page 50: ...r the machine NOISE When carrying out maintenance of the engine and you are exposed to noise for long periods of time wear ear covers or ear plugs while working If the noise from the machine is too loud it may cause temporary or permanent hearing problems WHEN USING HAMMER When using a hammer pins may fly out or metal particles may be scattered This may lead to serious injury Always do as follows ...

Page 51: ...er for the idler If it is disassembled by mistake the spring will fly out and cause serious injury When it becomes necessary to disassemble it ask your Komatsu distributor to do the work SAFETY RULES FOR HIGH PRESSURE OIL The hydraulic system is always under internal pressure When inspecting or replacing piping or hoses always check that the pressure in the hydraulic circuit has been released If t...

Page 52: ...ters and batteries AIR CONDITIONER MAINTENANCE If air conditioner refrigerant gets into your eyes it may cause blindness if it touches your skin it may cause frostbite Never touch refrigerant COMPRESSED AIR When carrying out cleaning with compressed air there is a hazard of serious injury caused by flying particles When using compressed air to clean elements or the radiator always wear safety gogg...

Page 53: ... 3 1 ...

Page 54: ...NE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW 1 2 3 4 5 6 Bucket Bucket cylinder Arm Arm cylinder Boom Boom cylinder 7 8 9 10 11 12 Track shoe Sprocket Track frame Idler Blade cylinder Blade 3 2 ...

Page 55: ...wing lock cover Horn switch Right work equipment control lever Lock lever right canopy specification machine Blade control lever Machine monitor 13 14 15 16 17 18 19 20 21 22 23 24 Fuel control lever Starting switch Floor lock cancel lever Service meter Engine coolant temperature gauge Fuel gauge Engine pre heating monitor Charge level monitor Engine oil pressure monitor Travel speed boost monitor...

Page 56: ...vices needed for operating the machine To perform suitable operations correctly and safely it is important to completely understand methods of operating the equipment and the meanings of the displays MONITORING SYSTEM A B Emergency monitors Meter display portion C D Pilot lamps Monitor switches portion 3 4 ...

Page 57: ...ormal location on the monitor will lights up and the buzzer will sound Carry out the necessary repairs immediately 1 Engine oil pressure monitor 2 Charge level monitor Engine Oil Pressure Monitor This monitor 1 flashes and the buzzer sounds if the engine and lubricating oil pressure goes below the specified level If the monitor flashes stop the engineand carry out inspection For details see OTHER ...

Page 58: ...hen the engine is running this monitor 2 flashes and the buzzer sounds If the monitor flashes stop the engine and check the V belt tension If any problem is found see OTHER TROUBLE PAGE 3 111 REMARK While the starting switch is ON the lamp will remain lit and will go off once the engine is started 3 6 ...

Page 59: ...the engine at low idle and wait until pilot lamp C goes out and the indicator goes down to range A Fuel Gauge This meter 2 shows the fuel level in the fuel tank F indicates that the tank is full E indicates that the fuel level is low If the fuel level goes below 4 5 liters 1 19 US gal the indicator enters red range A and at the same time pilot lamp B flashes If the indicator enters red range A or ...

Page 60: ...t the machine has been operated Use this display to manage the specified service intervals If the engine is running the service meter advances even if the machine is not being operated The meter advances 0 1 for every 1 10 hours 6 minutes of engine operation regardless of the engine speed 3 8 ...

Page 61: ... the buzzer sounds and the monitor goes out Travel Speed Boost Monitor This monitor 2 lights up when the speed range selector switch is at high speed When the speed range is low speed the monitor goes out REMARK When traveling at high speed if the machine travels on soft ground or up a slope and the load increases the travel is automatically switched to low speed travel but the travel speed boost ...

Page 62: ...ES Monitor Switches Portion 1 Lamp switch 2 Travel speed selector switch Lamp Switch Use this switch 1 to turn on the headlamps and the lamp inside the machine monitor Each time the switch is pressed it is switched between ON and OFF 3 10 ...

Page 63: ... switch 2 to switch the travel speed to low speed or high speed Each time the switch is pressed it is switched between low speed and high speed When the machine is traveling at high speed the travel speed boost monitor lights up REMARK When the engine is started the travel speed is automatically set to low speed When traveling at high speed if the machine travels on soft ground or up a slope and t...

Page 64: ...arting switch Horn switch Lamp switch Travel speed selector switch Cab heater switch Machines equipped with cab 6 7 8 Windshield wiper switch Machines equipped with cab Room lamp switch Machines equipped with cab Cigarette lighter Machines equipped with cab 3 12 ...

Page 65: ...ngine in cold weather turn the key to this position When the key is set to the HEAT position the engine pre heating monitor lights up Keep the key at this position until the engine pre heating monitor goes out When the engine pre heating monitor goes out release the key When the key is released it will return to the OFF position so turn it immediately to START and start the engine Horn Switch Pres...

Page 66: ...r This is also used as the window washer switch The switch is operated as follows Wiper only When the switch is set to position B the wiper is actuated Position A Wiper stopped Position B Wiper actuated Wiper and window washer When the wiper is working and the switch is kept pushed to position B washer fluid is sprayed out When the switch is released it returns and only the wiper operates REMARK B...

Page 67: ...sed to turn on the room lamp Position A Lights off Position B Lights up Cigarette Lighter Machines equipped with cab This lighter 8 is used to light cigarettes When the cigarette lighter is pushed in it will return to its original position after a few seconds so take it out to light your cigarette 3 15 ...

Page 68: ... 3 4 Lock lever Machine equipped with cab left side only Left work equipment control lever Right work equipment control lever Fuel control lever 5 6 7 8 9 Blade control lever Travel levers with pedals Swing lock cover Boom swing control pedal Floor lock cancel lever 3 16 ...

Page 69: ... up it is set to LOCK position L This lock lever is a hydraulic lock type so even when it is at LOCK position L the control levers and pedals move but the work equipment and and the machine do not move REMARK If the lock lever on either the left or right is not at LOCK position L the engine will not start Check that the lock lever is at LOCK position L before operating the starting switch If the e...

Page 70: ...te that matches the movement of the machine The place to attach the operating plate is on the right side of the operator s cab A Machine equipped with canopy B Machine equipped with cab This left work equipmentcontrol lever 2 is used to operate the arm and upper structure Swing operation a Swing to right b Swing to left Arm operation c Arm IN d Arm OUT N Neutral The upper structure and arm are hel...

Page 71: ...ed and output a Low idle Push the lever fully b High idle Pull the lever fully Blade Control Lever NOTICE When digging operations using the blade are continued for more than one hour pay careful attention to the rise in the coolant temperature This lever 5 is used to control the blade a Lower b Raise 3 19 ...

Page 72: ... care when traveling or steering the machine using the pedal When getting in or out of the operator s compartment there is danger that your toes may catch on the travel pedal so always fold back the pedal so that it cannot be operated This lever 6 is used to change the direction of travel This indicates operation of the pedal a FORWARD This lever is pushed forward The pedal is angled forward b REV...

Page 73: ...eutral Boom is stopped and held in this position Floor Lock Cancel Lever WARNING Always observe the warning and caution items when opening or closing the floor If the operation is carried out mistakenly it may lead to serious personal injury Do not open or close the floor on slopes Do not open or close the floor when there is a strong wind When opening or closing the floor pull this lever 9 to FRE...

Page 74: ...e front window hold the grip securely with both hands pull up and do not let go until the automatic lock catch is locked When closing the front window hold the handle with your both hands and close it firmly It is possible to stow pull up the front window in the roof of the operator s compartment The front window bottom can be removed and stored at the rear inside the cab Opening 1 Stop the machin...

Page 75: ...left and right knobs A and pull the front window up diagonally 5 When it will move no further to the rear push up knobs A to lock securely When pushing up check that lock lever B moves in lock release direction F then returns in the lock direction L Push up knobs A to lock securely 3 23 ...

Page 76: ... the front and pull knobs A down to release the lock 4 Grip left and right knobs A and slowly lower the front window diagonally to the front 5 When the bottom of the window reaches the top of the bottom window push left and right knobs A to the front and push against left and right stoppers C to engage the lock When pushing to the front check that lock lever B moves in lock release direction F the...

Page 77: ...ow 2 After removing the lower window stow it in left and right brackets B at the rear of the operator s cab Installing Lower Windshield With the front window open install the bottom part of the front window 1 Open the front window then hold grip A pull up and remove the bottom window 2 Install the lower window and push it down securely 3 25 ...

Page 78: ...1 and knob 2 Be careful not to get your hands caught between the front pillar or center pillar If there is anyone inside the cab call out to that person before opening or closing the door NOTICE Always clean the step at the entrance to the cab and take action to prevent snow or mud from accumulating If snow accumulates it may freeze and make it impossible to open the door Door Lock When closing th...

Page 79: ... to injure yourself on the flying pieces of broken glass To prevent injury remove the broken pieces of glass remaining in the frame before escaping through the window Be careful also not to slip on the broken pieces of glass In case it becomes impossible to open the door a hammer 1 to be used for escape from the cab is installed When escaping break the window glass with hammer 1 3 27 ...

Page 80: ...erted the key may break In Case of Tool Box and Cab Door When Opening 1 Insert the key into the key slot 2 Turn the key counterclockwise and pull the cover or doorknob to open When Locking 1 Close the cover and insert the key into the key slot 2 Turn the key clockwise and take the key out In Case of Engine Rear Cover and Dirt Cover When Opening 1 Insert the key into the key slot 2 Turn the key clo...

Page 81: ... opening knob 2 of the cover and open engine rear cover 3 3 Pull engine rear cover 3 and open it fully Cover 3 is secured in position by rod 4 4 When closing engine rear cover 3 lift up rod 4 and close cover 3 slightly When the rod comes out from the groove close the cover Push cover 3 in to lock it 5 Lock the cover COOLING COVER CAUTION When carrying out inspection and maintenance of the cooling ...

Page 82: ...tenance inside the cover always open the cover fully and check that it is secured in position by the support lever NOTICE Always keep the hood locked except when opening it Check the direction of the key slot in the opening knob to check that it is locked 1 Release lock 1 of the cover For details of the method of opening and closing the cover with the lock see In Case of Engine Rear Cover and Dirt...

Page 83: ... the lock when the floor is opened stop the operation and ask your Komatsu distributor to carry out repairs Do not remove the canopy There is danger that the floor may suddenly come up Do not remove the floor mounting bolts 1 There is danger that the floor may suddenly come up Before starting the opening tilting operation of the floor read the precautions related to safety and maintenance in CAUTI...

Page 84: ...ing the cover with the lock see In Case of Engine Rear Cover and Dirt Cover PAGE 3 28 6 Remove bolts 3 M10 x 3 then remove triangular cover 4 7 Open engine rear cover 5 fully and secure it in position For details of the method of opening and closing the cover with the lock see In Case of Engine Rear Cover and Dirt Cover PAGE 3 28 8 Loosen floor tilt lock bolts 6 M14 x 6 Bolts 6 have a structure th...

Page 85: ... opening or closing the floor do not let any part of your body enter the area under the floor REMARK The floor opening operation is assisted by a gas cylinder so when the ambient temperature is low the operating effort increases 11 After the floor rises push knob 9 up until lock pin 10 fits in the lock groove 12 of lock plate 11 When lock pin 10 moves to lock groove 12 the 1st stage lock is comple...

Page 86: ...in the direction of the arrow to the rear while holding knob 9 with your right hand and pulling it down in the direction of the arrow approx 45 NOTICE Lower slowly and check that there is no damage or catching of the wiring or piping When opening or closing the floor do not let any part of your body enter the area under the floor 3 Open engine rear cover 5 fully and secure it in position For detai...

Page 87: ...ERATION DETAILED CONTROLS AND GAUGES 7 Close dirt cover 2 For details of the method of opening and closing the cover with the lock see In Case of Engine Rear Cover and Dirt Cover PAGE 3 28 This completes the operation for closing the floor 3 35 ...

Page 88: ...other of the same capacity Fuse Capacities and Circuit Names No Fuse capacity Name of circuit Canopy specification Cab specification 1 30A Engine stop solenoid 2 10A PPC solenoid horn fuel pump safety relay 3 10A Monitor panel buzzer speed boost solenoid 4 10A If equipped 5 10A 20A Heater travel alarm buzzer air conditioner Cab specification 6 20A Room lamp radio windshield wiper window washer 7 1...

Page 89: ...nd check or replace the fuse This is at the top surface of the battery For details of the method of opening and closing the cover on the right side of the machine see COOLING COVER PAGE 3 29 REMARK A block fuse is a large fuse wire installed to the circuit where a large capacity current is flowing It acts in the same way as a normal fuse to protect the electrical equipment and wiring from burning ...

Page 90: ...ys keep the cover locked Store the tools in this box GREASE GUN HOLDER WARNING Immediately after the engine is stopped the parts are at a high temperature and will cause burns Wait for the temperature to go down before starting the operation This is on top of the fuel tank When not using the grease gun fit it in this holder Close the grease gun handle and stow the grease gun with the handle on the...

Page 91: ...ng every day before starting engine for the day s work 1 Check for damage wear play in work equipment cylinders linkage and hoses Check that there are no cracks excessive wear or play in the work equipment cylinders linkage or hoses If any problem is found repair it 2 Remove dirt and dust from around engine battery and radiator Check that there is no dirt or dust accumulated around the engine or r...

Page 92: ... tilt lock bolts Open the engine rear cover and check that 6 floor tilt lock bolts 1 are tightened properly If any bolts are loose tighten them If there is any up and down play in the floor plate or if clearance A is too large normal approx 5 mm 0 197 in lock bolts 1 may be broken or loose so check lock bolts 1 If any problem is found always carry out repairs yourself or ask your Komatsu distribut...

Page 93: ...ant is at a high temperature and the radiator is under high internal pressure If the cap is removed to check the coolant level in this condition there is a hazard of burns Wait for the temperature to go down then turn the cap slowly to release the pressure before removing it 1 Open the engine rear cover and cooling cover For details see COOLING COVER PAGE 3 29 2 Check that the coolant level is bet...

Page 94: ...ACHINE OPERATIONS AND CONTROLS PC35MR 3 After adding coolant tighten the cap securely 4 If the sub tank is empty check for leakage of water then check the radiator coolant level Add coolant to the radiator if necessary then add coolant to the sub tank 3 42 ...

Page 95: ...fore checking 1 Open the engine rear cover 2 Remove dipstick G and wipe the oil off with a cloth 3 Fully insert dipstick G into filler pipe F then remove it 4 The oil level should be between the H and L marks on dipstick G If the oil level is below the L mark add oil through oil filler F 5 If the oil is above the H mark remove the undercover under the machine drain the excess oil from drain plug P...

Page 96: ...r fuel 1 Insert the key in starting switch 1 and turn in to the ON position to light up the monitor 2 Check the fuel level with fuel gauge 2 If the fuel level is low open the dirt cover and add fuel through fuel filler port F while checking level gauge G Fuel capacity 44 liters 11 62 US gal 3 After adding fuel tighten the cap securely NOTICE If breather hole 3 in the cab is clogged the pressure in...

Page 97: ...details see COOLING COVER PAGE 3 29 3 Confirm that the oil level is between the H and L marks of sight gauge G NOTICE Do not add oil above the H line This will damage the hydraulic circuit or cause the oil to spurt out If oil has been added above the H level stop the upper structure so that the drain plug P under the hydraulic tank will be between both tracks and stop the engine and wait for the h...

Page 98: ...sely affect the equipment Check Dust Indicator 1 Open the engine rear cover and cooling cover For details see COOLING COVER PAGE 3 29 2 Check that the red piston has not appeared in the transparent portion of dust indicator 1 PC27MR PC35MR 3 If the red piston has appeared clean or replace the element immediately For details of the method of cleaning the element see CHECK CLEAN AND REPLACE AIR CLEA...

Page 99: ...mediately perform repairs or contact your Komatsu distributor for repairs Keep the top surface of the battery clean and check the breather hole in the battery cap If it is clogged with dirt or dust wash the battery cap to clean the breather hole Check for damage to the fuse that a fuse of the specified capacity is being used that there are no signs of any disconnection breakage or short circuit in...

Page 100: ...out deep digging operations slide the seat to the front to improve the view below the front of the machine B Adjusting reclining Pull up lever 2 and set the backrest to a position that is comfortable for operation then release the lever Sit with your back against the seat backrest when adjusting If your back is not against the backrest the backrest may suddenly move forward C Adjusting suspension ...

Page 101: ...ERATION MACHINE OPERATIONS AND CONTROLS Rearview Mirrors Adjust the angle so that the area behind the operator s compartment can be seen clearly Machine equipped with canopy Machine equipped with cab 3 49 ...

Page 102: ...s and retighten them if necessary The tightening torque for the mounting bolt is 24 5 4 9 N m 2 5 0 5 kgf m 18 1 3 6 lbft If the belt surface is scratched or frayed or if the fittings are broken or deformed replace the seat belt unit Fastening and Removing 1 Adjust the seat so that the operator still feels that there is sufficient knee room when fully depressing the pedal while seated with the ope...

Page 103: ...NE OPERATIONS AND CONTROLS Seat Belt Adjustment Shortening Pull the free end of the belt on either the buckle body or tongue side Lengthening Pull the belt while holding it at a right angle to the buckle or tongue 3 51 ...

Page 104: ...r stopped 1 Check that lock lever 1 is at the LOCK position L REMARK If the lock lever 1 is not at LOCK position L the engine will not start Machine equipped with canopy REMARK If the lock lever 1 on either the left or right is not at LOCK position L the engine will not start Machine equipped with cab REMARK For machines equipped with a cab there is only a lock lever on the left 2 Check the positi...

Page 105: ...evel caution lamp 7 Travel speed boost monitor 8 If a monitor or gauge does not light up or the buzzer does not sound there is probably a blown fuse or disconnection in the monitor so contact your Komatsu distributor for repairs After approx 3 seconds only the following monitors stay lighted up The other monitors go out Charge level monitor 4 Engine oil pressure monitor 5 2 Press lamp switch 9 and...

Page 106: ...c When starting the engine in confined spaces be particularly careful to ensure good ventilation NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds If the engine will not start wait for at least 2 minutes before trying to start the engine again 1 Check to make sure that lock lever 1 is at the LOCK position L If lock lever 1 is in the FREE position F the engine wil...

Page 107: ...ngine by short circuiting the engine starting circuit Such an act may cause a serious bodily injury or fire Check that there are no persons or obstacles in the surrounding area then sound the horn and start the engine Never use starting aid fluids as they may cause explosions Exhaust gas is toxic When starting the engine in confined spaces be particularly careful to ensure good ventilation NOTICE ...

Page 108: ...ed position position B 3 Hold the key in starting switch 3 at the HEAT position and check that the buzzer sounds and engine pre heating monitor 4 lights up and that engine pre heating monitor 4 flashes after that After approx 18 seconds the buzzer sounds and engine pre heating monitor 4 goes out to indicate that the pre heating is completed REMARK The monitor and gauge also light up when the key i...

Page 109: ...OPERATION MACHINE OPERATIONS AND CONTROLS OPERATION MACHINE OPERATIONS AND CONTROLS 5 When the engine starts release the key in starting switch 3 The key will return automatically to the ON position 3 57 ...

Page 110: ...her than the standard one ISO pattern refer to the chapter of ATTACHMENTS AND OPTIONS in this manual Breaking in the New Machine CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment However operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life Be sure to break in the machine for the initial 1...

Page 111: ... do not immediately start operations First perform the following operations and checks 1 Pull fuel control lever 1 from low idle position A to midway position B between full speed and low idle to raise the engine speed to a mid range speed then run under no load for approx 5 minutes REMARK When the ambient temperature is below 0 C 32 F keep the fuel control lever close to the 1 4 position when car...

Page 112: ...ect range Engine oil pressure monitor 6 Monitor is off Charge level monitor 7 Monitor is off 5 Check for abnormal exhaust gas color noise or vibration If any problem is found contact your Komatsu distributor 6 Set lock lever 2 to the LOCK position L then check that the machine does not move even when the levers and pedals are operated 1 The work equipment and swing do not move when the left and ri...

Page 113: ...not stop the engine abruptly except in an emergency If the engine has overheated do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually and then stop it 1 Run the engine at low idle for about 5 minutes to cool down gradually 2 Turn the key of starting switch 1 to the OFF position to stop the engine 3 Remove the key from starting switch 1 3 61 ...

Page 114: ...the travel levers is reversed When moving off check that the area around the machine is safe and sound the horn before moving Clear all personnal from the machine and the area Clear all obstracles from the path of the machine Check that the travel alarm works properly Preparations for Moving the Machine 1 Pull fuel control lever 1 to mid range speed position B and raise the engine speed 3 62 ...

Page 115: ...s at the rear of the machine Push the both travel levers 3 forward slowly to move the machine off When the sprocket A is at the front of the machine Pull the both travel levers 3 backward slowly to move the machine off 4 Switch the travel speed as follows When the travel speed selector switch 4 is pressed the travel speed can be switched between high speed and low speed Each time the switch is pre...

Page 116: ...y switched to low speed travel so there is no need to operate the switch The travel speed boost monitor displays stays lighted up When the load is reduced the travel system returns to high speed travel 5 Check that the travel alarm sounds If the alarm does not sounds please contact your Komatsu distributor for repairs Moving Machine Backward 1 Set lock lever 2 to the FREE position then raise the w...

Page 117: ...is traveling at high speed travel speed boost monitor 5 lights up For details of the travel speed values see SPECIFICATIONS PAGE 5 2 REMARK When the engine is started the travel speed is automatically set to low speed When traveling at high speed if the machine travels on soft ground or up a slope and the load increases the travel is automatically switched to low speed travel so there is no need t...

Page 118: ... MACHINE OPERATIONS AND CONTROLS Stopping Machine WARNING Avoid stopping suddenly Give yourself ample room when stopping 1 Put the left and right travel levers 1 in the NEUTRAL position then stop the machine 3 66 ...

Page 119: ...ission to low speed and the machine travels slowly When the load decreases it automatically returns the transmission to high speed travel Use the travel levers to change direction Avoid sudden changes of direction as much as possible Especially when performing counter rotation spin turn stop the machine before turning Operate two travel levers 1 as follows Steering the Machine when Stopped When tu...

Page 120: ...n to the left REMARK When turning to the right operate the right travel lever in the same way Counter rotation Turn Spin Turn When using counter rotation spin turn to turn left pull the left travel lever back and push the right travel lever forward REMARK When using counter rotation spin turn to turn right pull the right travel lever back and push the left travel lever forward 3 68 ...

Page 121: ...ent control lever 1 to the N position The swing holding brake will be applied REMARK When using the swing on a slope run the engine at low idle and operate the swing lever extremely slowly Be particularly careful to avoid sudden movement when the bucket is loaded When the bucket is loaded and the left work equipment control lever is operated the swing holding brake is released so the upper structu...

Page 122: ...te the work equipment Note that when the levers are released they return to the HOLD position and the work equipment is held in that position Arm control Move the left work equipment control lever to the front or rear to operate the arm Swing control Move the left work equipment control lever to the left or right to swing the upper structure Boom control Move the right work equipment control lever...

Page 123: ...Move the right work equipment control lever to the left or right to operate the bucket Boom swing operation The boom swing operation can be carried out with the boom swing control pedal Blade control Move the lever on the right side of the operator s seat to the front or rear to operate the blade 3 71 ...

Page 124: ...into the ground and use the travel force to carry out excavation This will damage the machine or work equipment Prohibition of Operations Using Hydraulic Cylinders to Stroke Ends When operating the cylinder do not operate it to the end of its stroke Always leave a small margin If the cylinder is operated to the end of its stroke force will be brought to bear on the cylinder and this may cause dama...

Page 125: ...e life of the machine Operations Using Machine Dropping Force It is prohibited to carry out digging operations using the dropping force of the machine When excavating hard rock bed use some other method to break the rock into small pieces before excavating This avoids damage to the machine and also is more economical Support Blade on Both Sides When using the blade as an outrigger never suport the...

Page 126: ...duce the travel speed keep the work equipment close to the ground and try to travel so that the center of the track passes over the obstacle Folding in Work Equipment When folding in the work equipment to the travel or transportation posture be careful not to let the bucket hit the blade Avoid Hitting Blade Be careful not to hit the blade against rocks or boulders This will cause premature damage ...

Page 127: ...and water will be thrown up by the radiator fan This may cause the fan to break Be extremely careful when driving the machine out of water Do not immerse the machine in water by more than the permissible depth under center of carrier roller 1 In addition for parts that have been immersed in water for a long time pump in grease until the old grease comes out from the bearings Around the bucket pins...

Page 128: ... to a flat place to perform these operations It may be longer but it will ensure safety Always operate or travel in such a way that it is possible to stop safely at any time if the machine slips or becomes unstable When traveling uphill if the shoes slip or it is impossible to travel uphill using only the force of the tracks do not use the pulling force of the arm to help the machine travel uphill...

Page 129: ...on lower the bucket to the ground stop the machine then start the engine again Cab Doors on Slope If the engine stops when the machine is on a slope never use the left work equipment control lever to carry out swing operations The upper structure will swing under its own weight Do not open or close the sliding door cab specifications on slopes when traveling or operating The operating effort may c...

Page 130: ...h the ground Never push with the teeth The angle between the boom and arm should be 90 to 110 When only one side is stuck in mud use the bucket to raise the track then lay boards or logs and drive the machine out Tracks on Both Sides Stuck If the track on both sides are in mud and the machine slips and cannot move use the procedure given above to lay logs or timber dig the bucket into the ground a...

Page 131: ...m is from a 45 angle away from the machine to a 30 angle toward the machine There may be some differences depending on the digging depth not try to keep within the above range rather than operating to the end of the cylinder stroke Ditching Work Ditching work can be performed efficiently by attaching a bucket which matches the digging operation and then setting the tracks parallel to the line of t...

Page 132: ...OLS Smoothing Work When refilling after excavation and when smoothing the ground surface use the blade Side Ditching Work The machine can be used for side ditching in a confined worksite by combining the swing and boom swing operations 3 80 ...

Page 133: ...oes not get on them Dust seals are fitted at both ends of the bushings be careful not to damage them Stop the machine on a firm and flat surface and do the work When performing joint work appoint a lead and follow that person s instructions and signals 1 Place the bucket in contact with a flat surface then pull out pins A and B REMARK When removing the pins place the bucket so that it is in light ...

Page 134: ...t into the ground surface to stop the machine from moving If the control levers are touched by accident the work equipment or machine may move suddenly and this may lead to a serious accident Before standing up from the operator s seat always set the lock lever securely to the LOCK position Set the blade on the downhill side and lower it to the ground 1 Put the left and right travel levers 1 in th...

Page 135: ...NSPECTION AFTER DAILY WORK Before Stop Engine Check the engine coolant temperature 1 engine oil pressure 2 and fuel level 3 on the machine monitor After Stop Engine 1 Walk around the machine and check the work equipment machine exterior and undercarriage also check for any leakage of oil or coolant If any problems are found repair them 2 Fill the fuel tank 3 Check the engine compartment for paper ...

Page 136: ... s cab door machines equipped with cab Always close the windows 2 Engine rear cover 3 Dirt cover 4 Operation and Maintenance Manual toolbox cover For details of locking see Opening and Closing Covers with Lock PAGE 3 28 REMARK Use the starting switch key to lock and unlock all these places 3 84 ...

Page 137: ...er shoes and road liners offer various advantages However their weak point is lack of strength Therefore it is important to understand the advantages of rubber shoes and road liners and to follow the precautions regarding handling and prohibited work This will extend the life of the rubbershoes and road liners and will enable the machine to display the advantages of rubber shoes and road liners to...

Page 138: ...g points when carrying out work Avoid carrying out counterrotation turns on concrete surfaces There is danger that the concrete surface will scrape off the rubber from the shoe Avoid making sudden changes in direction This may cause premature wear or damage to the rubber shoes and road liners Avoid operating the steering when traveling over places where there is a big difference in height When tra...

Page 139: ...s always travel at right angles to the object 2 When traveling in reverse up a slope do not turn when moving from flat ground onto the slope If it is necessary to turn on slopes be sure to turn gradually 3 Avoid traveling along the edge of slopes or on rough ground with the track on one side raised with the machine tilting at an angle of more than approx 10 and with the track on the other side on ...

Page 140: ...e if the machine travels in reverse a gap is formed between the track roller idler and rubber shoe When turning in a condition where the rubber shoe cannot move to the side because of the object it is passing over or because of some other object When the rubber shoe has moved out of alignment and the idler or track roller are not aligned with the core If the machine travels in reverse in this cond...

Page 141: ... OPERATION MACHINE OPERATIONS AND CONTROLS OPERATION MACHINE OPERATIONS AND CONTROLS If the machine is turned in this condition the rubber shoe will come off 3 89 ...

Page 142: ...safety TRANSPORTATION PROCEDURE As a basic rule transport the machine by trailer Select the trailer to match the weight and dimensions given in SPECIFICATIONS PAGE 5 2 Note that the value for the weight and transportation dimensions given in SPECIFICATIONS may differ according to the type of shoe or type of arm or other attachments 3 90 ...

Page 143: ...se oil or other substances stuck to the ramps Never change the direction of travel when the machine is on the ramps There is danger that the machine may tip over Return the machine to the road surface or the trailer platform then change the direction of travel It is dangerous to use the work equipment for the loading or unloading operation Never operate any lever other than the travel lever on the...

Page 144: ...locks under the tires to ensure that the trailer does not move Make the slope of the ramps a maximum of 15 3 Set fuel control lever to the low idle position A 4 Check that the travel speed boost monitor is off If the monitor is on the speed is set to high speed travel so press the travel speed selector switch The monitor goes out and the speed is shifted to low speed travel 3 92 ...

Page 145: ...aight line with the ramps and that the centerline of the machine matches that of the trailer Align the direction of travel with the ramps and travel slowly Lower the work equipment as far as possible without causing interference When on the ramps operate only the travel lever Do not operate any other lever 7 Stop the machine at the specified place then swing the upper structure slowly 180 8 Load t...

Page 146: ...s with the lock lever REMARK For machines equipped with a cab there is only a lock lever on the left 5 Lock the sliding door cab specification and covers with locks See Opening and Closing Covers with Lock PAGE 3 28 NOTICE Do not use the hole at the back of the track frame for towing or lifting the machine 6 Place blocks under both ends of the tracks to prevent the machine from moving during trans...

Page 147: ...ve Make the slope of the ramps a maximum of 15 3 Remove the chains and wire ropes fastening the machine 4 Start the engine Warm the engine up fully 5 Check that the travel speed boost monitor is off If the monitor is on the speed is set to high speed travel so press the travel speed selector switch The monitor goes out and the speed is shifted to low speed travel 6 Set the lock lever to the FREE p...

Page 148: ...ever on the left 7 Set fuel control lever to the low idle position A 8 Raise the blade 9 Raise the work equipment align the direction of travel with the ramp and travel slowly Lower the work equipment as far as possible without causing interference When on the ramps operate only the travel lever Do not operate any other lever or pedal 3 96 ...

Page 149: ...b It is prohibited to use the transportation holes in the track frame to lift the machine This will damage the track frame NOTICE For the details on the machine weight see the section of SPECIFICATIONS PAGE 5 2 The lifting procedure applies to machines with standard specifications The method of lifting differs according to the attachments and options actually installed In such cases please contact...

Page 150: ... then get off the machine For cab specification machines close the cab door and front glass securely 7 Install shackles to the lifting holes 2 places on both ends of the blade then install the wire ropes 8 Install a shackle to the lifting hole 1 place in the bracket on the boom then fit the wire rope NOTICE Be sure to use all three lifting holes Do not lift the machine with the boom or the upper s...

Page 151: ...N OPERATION TRANSPORTATION 9 Set the lifting angle of the wire rope to 30 to 40 then lift the machine slowly 10 After the machine comes off the ground check the hook condition and the lifting posture and then lift slowly 3 99 ...

Page 152: ...o not bring any flame close Do not smoke when handling antifreeze NOTICE Never use methanol ethanol or propanol based antifreeze Never use any water leakage prevention agent or any antifreeze containing such an agent Do not mix different types of antifreeze For details of the antifreeze mixture when changing the coolant see CLEAN INSIDE OF COOLING SYSTEM PAGE 4 20 Use a Permanent Antifreeze ethyle...

Page 153: ...possible to 100 Insulate it against cold temperature to ensure the machine can be started easily the next morning REMARK Measure the specific gravity and calculate the charging rate from the following conversion table Electrolyte Temperature C Charging Rate 20 0 10 20 100 1 28 1 29 1 30 1 31 90 1 26 1 27 1 28 1 29 80 1 24 1 25 1 26 1 27 75 1 23 1 24 1 25 1 26 As the battery capacity drastically dr...

Page 154: ...boards The boards prevent the tracks from freezing to the ground and allow the machine to be moved the next morning Open the drain valve and drain any water collected in the fuel system to prevent it from freezing After operation in water or mud remove water from undercarriage as described below to extend undercarriage service life 1 Swing 90 with engine at low idle and bring the work equipment to...

Page 155: ... the machine with a sheet Completely fill the fuel tank This prevents moisture from collecting Lubricate and change the oil before storage Coat the exposed portion of the hydraulic cylinder piston rod with grease Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately Lock each control lever and pedal with the lock lever and swing lock co...

Page 156: ... of the air conditionercompressor Always run the engine at low idle when doing this In addition check the refrigerant level twice a year AFTER STORAGE NOTICE If the machine has been stored without carrying out the monthly rust prevention operation consult your Komatsu distributor before using it When using the machine after long term storage do as follows before using it Wipe off the grease from t...

Page 157: ...sition and the work equipment is lowered under no load from a high position the arm speed will drop momentarily when the arm is more or less at the vertical position When the bucket control lever is operated to the CURL position and the work equipment is lowered under no load from a high position the bucket speed will drop momentarily when the bucket teeth are more or less at the horizontal positi...

Page 158: ...f the track frame as shown in the diagram on the right before carrying out towing Places pieces of wood between the wire ropes and the body to prevent the wire ropes from damaging the body SEVERE JOB CONDITION When digging in water if the water gets on to the work equipment mounting pins add grease to bucket links A B C D and E for each operation When carrying out heavy duty digging and deep diggi...

Page 159: ...clothes or on your skin immediately wash it off with a large amount of water If it gets in your eyes wash it out with fresh water and consult a doctor When handling batteries always wear protective goggles and rubber gloves When removing the battery first disconnect the cable from the ground normally the negative terminal When installing install the positive terminal first If a tool touches the po...

Page 160: ...nd the instruction manual accompanying the charger and do as follows Flammable hydrogen gas is generated when the battery is charged so remove the battery from the chassis take it to a well ventilated place and remove the battery caps before charging it Tighten the battery caps securely If any battery cap is damaged replace it immediately Set the voltage of the charger to match the voltage of the ...

Page 161: ...oster cable exercise good care so that the booster cable clips may not contact each other or they contact the chassis NOTICE The size of the booster cable and clip should be suitable for the battery size The battery of the normal machine must be the same capacity as that of the engine to be started Check the cables and clips for damage or corrosion Make sure that the cables and clips are firmly co...

Page 162: ... of the problem machine to the START position and start the engine If the engine doesn t start at first try again after 2 minutes or so Booster Cable Disconnection After the engine has started disconnect booster cables in the reverse order in which they were connected 1 Remove one clip of booster cable B from the engine block of the problem machine 2 Remove the other clip of booster cable B from t...

Page 163: ...sufficient battery charge Defective starting motor Charge Replace Starting motor disengages before engine starts Defective wiring Insufficient battery charge Check repair Charge Engine pre heating monitor does not light up Defective wiring Defective monitor Check repair Replace Oil pressure monitor does not light up when engine is stopped starting switch at ON position Defective monitor Defective ...

Page 164: ...ystem see WHEN REQUIRED Clean or repair see EVERY 500 HOURS SERVICE Replace themostat Tighten cap or replace packing Replace sensor Engine coolant temperature gauge indicator is in red range at same time pilot lamp flashes and buzzer sounds Even when engine is run for a long time engine coolant temperature gauge indicator does not enter correct range Defective thermostat Monitor defective Replace ...

Page 165: ...ace nozzles See defective compression above Combustion noise occasionally makes bresthing sound Defective nozzle Replace nozzle Abnornal noise generated combustion or mechanical Low grade fuel being used Overheating Damage inside muffler Excessive valve clearnce Change to specified fuel See engine coolant temperature gauge indicator is in red range as above Replace muffler Adjust valve clearance 3...

Page 166: ... 4 1 ...

Page 167: ...r machine is equipped with a fuel strainer do not remove it while fueling Welding Instructions Turn off the engine starting switch Do not apply more than 200 V continuously Connect grounding cable within 1 m 3 3 ft of the area to be welded If grounding cable is connected near instruments connectors etc the instruments may malfunction If a seal or bearing happens to come between the part being weld...

Page 168: ...hen removing parts at locations where there are O rings or gasket seals clean the mounting surface and replace with new parts When doing this be careful not to forget to assemble the O rings and gaskets When installing the hoses do not twist or bend them into loops with a small radius This will cause damage to the hose and drastically reduce its service life Checks After Inspection and Maintenance...

Page 169: ...ll prevent the moisture from condensing and mixing with the fuel The fuel pump is a precision instrument and if fuel containing water or dirt is used it cannot work properly Be extremely careful not to let impurities get in when storing or adding fuel Always use the fuel specified in the Operation and Maintenance Manual Fuel may congeal depending on the temperature when it is used particularly in ...

Page 170: ...ts of the machine This then makes it possible to ensure prevention of failures and reduction in downtime Komatsu s long years of experience and rich supply of accumulated data make it possible to accurately determine the condition of your machine This enables us to locate the problems and to recommend suitable and timely repair methods The oil clinic charges the customer only the actual costs and ...

Page 171: ...r take other measures to protect them To prevent any change in quality during long term storage be sure to use in the order of first in first out use the oldest oil or fuel first Filters Filters are extremely important safety parts They prevent impurities in the fuel and air circuits from entering important equipment and causing problems Replace all filters periodically For details see the Operati...

Page 172: ...and immediately after operations During operations it is also under high pressure so be careful of the following points when carrying out inspection and maintenance of hydraulic related equipment Stop the machine on level ground lower the bucket completely to the ground and set so that there is no pressure on the cylinder circuits Always stop the engine Immediately after the engine is stopped the ...

Page 173: ...r of the machine serial number and check for the latest part number when ordering parts WEAR PARTS LIST The parts in parentheses are to be replaced at the same time Item Part No Part Name Q ty Replacement frequentcy Engine oil filter YM129150 35152 Cartridge 1 EVERY 500 HOURS Fuel filter YM119802 55800 Cartridge 1 EVERY 500 HOURS Hydraulic filter 22L 60 22120 Element 1 EVERY 1000 HOURS Water separ...

Page 174: ... good exhaust gas characteristics For this reason it requires high precision for the parts and good lubrication If kerosene or other fuel with low lubricating ability is used there will be a big drop in durability Engine oil pan Final drive case each Hydraulic system Fuel tank Cooling system PC27MR PC35MR PC27MR PC35MR Specified capacity Liters 5 7 7 7 0 6 40 45 44 3 3 US gal 1 51 2 03 0 16 10 57 ...

Page 175: ...C reduce the engine oil change interval to half There is no problem if single grade oil is mixed with multigrade oil SAE10W 30 15W 40 but be sure to add single grade oil that matches the temperature range in the table We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications Specified capacity Total amount of oi...

Page 176: ...EP Hypogear EP Energrease LS EP2 Antifreeze 6 CALTEX RPM delo 400 RPM delo 450 Universal thuban Universal thuban EP Marfak all purpose 2 Ultra duty grease 2 AF engine coolant 7 CASTROL Turbomax RX super CRD EP EPX Hypoy Hypoy B Hypoy C MS3 Spheerol EPL2 Anti freeze 8 CHEVRON Delo 400 Universal gear Ultra duty grease 2 9 CONOCO Fleet motor oil Universal gear lubricant Super sta grease 10 ELF Multip...

Page 177: ...hite bearing grease Anti freeze and summer coolant 15 PETROFIN A FINA kappa TD FINA potonic N FINA potonic NE FINA marson EPL2 FINA tamidor 16 SHELL Rimura X Spirax EP Spirax heavy duty Albania EP grease 17 SUN Sunoco GL5 gear oil Sunoco ultra prestige 2EP Sun prestige 742 Sunoco antifreeze and summer coolant 18 TEXACO Ursa super plus Ursa premium Multigear Multifak EP2 Starplex 2 Coda 2055 starte...

Page 178: ... 7 5 10 0 12 5 15 5 19 5 8 7 10 8 20 3 25 3 43 4 54 2 72 3 90 4 112 1 141 16 18 20 22 24 24 27 30 32 36 260 360 510 688 883 26 5 37 52 3 70 3 90 191 7 267 6 378 3 508 5 651 235 285 320 400 455 565 610 765 785 980 23 5 29 5 33 0 41 0 46 5 58 0 62 5 78 0 80 0 100 0 170 0 213 4 238 7 296 6 336 3 419 5 452 1 564 2 578 6 723 3 27 30 33 36 39 41 46 50 55 60 1295 1720 2210 2750 3280 132 5 175 0 225 0 280...

Page 179: ...clamps show deterioration like deformation or crack replace such a defective clamp with a new one together with a defective hose Also carry out the following checks with hydraulic hoses which need not be replaced periodically Tighten a loosened clamp again or replace a defective hose as such problem requires When replacing the hoses always replace the O rings gaskets and other such parts at the sa...

Page 180: ... liner 4 30 CHECK AND ADJUST RUBBER SHOE TENSION Machine equipped with rubber shoes 4 32 REPLACE RUBBER SHOES Machine equipped with rubber shoes 4 34 REPLACE ROAD LINERS Machine equipped with road liner 4 36 REPLACE BUCKET TEETH 4 37 CHECK WINDOW WASHER FLUID LEVEL ADD FLUID 4 40 CHECK CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER 4 41 LUBRICATING 4 41 BLEEDING AIR FROM HYDRAULIC SYSTEM 4 42 ...

Page 181: ...r than for normal bucket digging operations so set the maintenance intervals as follows Replace hydraulic filter element On a new machine replace the element after the first 100 to 150 hours then carry out further replacement of the element according to the table on the right Change oil in hydraulic tank Change the oil according to the table on the right 4 16 ...

Page 182: ...around and cause serious injury Always use protective glasses dust mask and other protective equipment Checking 1 Open the engine rear cover and cooling cover For details see COOLING COVER PAGE 3 29 2 If the dust indicator 1 shows red clean the air cleaner element NOTICE Do not clean the air cleaner element before the red piston in dust indicator 1 appears If the air cleaner element is cleaned fre...

Page 183: ...e 4 Clean the inside of the air cleaner body dust cap 3 and vacuator valve 5 5 Direct dry compressed air Max 0 69 MPa 7 kgf cm2 99 4 PSI from the inside of the outer element along its folds Then direct the compressed air from the outside along the folds and again from the inside 1 Replace the element which has been cleaned 5 times repeatedly or used throughout a year 2 Replace element when the dus...

Page 184: ...gainst something Do not use an element whose folds or gasket or seal are damaged Wrap unused element and store them in a dry place 7 Remove the cloth or adhesive tape used to cover the air connector inside the air cleaner body 8 Install cleaned element 4 or a new element 9 Set dust cup 3 with the arrow pointing up then set it to the air cleaner body and secure it with clip 2 10 Press the button of...

Page 185: ...ange the coolant according to the table below Antifreeze coolant Interval of cleaning inside of cooling system and changing antifreeze coolant Komatsu supercoolant AF NAC Every two years or every 4000 hours whichever comes first Permanent type antifreeze All season type Every year autumn or every 2000 hours whichever comes first Permanent type antifreeze shall meet the requirements of ASTM D3306 0...

Page 186: ...o be particularly careful to keep it away from flame Super coolant is toxic When removing the drain plug be careful not to get coolant on yourself If it gets into your eyes wash your eyes immediately with ample water then consult a doctor for treatment Always use Komatsu genuine super coolant AF NAC for the coolant Use tap water to dilute the coolant If river water or well water or simple water su...

Page 187: ...at low idle speed After the coolant temperature rises above 90 C 194 F run the engine for about 10 minutes 7 Stop the engine then open drain valve 2 and remove drain plug 3 to drain the water 8 Close drain valve 2 Wind seal tapes onto drain plug 3 then tighten it 9 Decide the proportions of antifreeze and water according to the table for the mixing rate of water and antifreeze 10 To remove air in ...

Page 188: ... MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE MAINTENANCE PROCEDURE PC35MR 12 Stop the engine About 3 minutes later supply city water up to the water filler then close radiator cap 4 23 ...

Page 189: ...he morning to prevent the electrolyte from freezing Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below When Checking Electrolyte Level from Side of Battery If it is possible to check the electrolyte level from the side of the battery check as follows 1 Open the engine rear cover and cooling cover For details see COOLING COVER PAGE 3 29 2 ...

Page 190: ...e add distilled water so that the level reaches the bottom of the sleeve UPPER LEVEL line without fail Use the diagram below for reference and check if the electrolyte reaches the bottom of the sleeve 3 After adding distilled water tighten cap 1 securely REMARK If distilled water is added to above the bottom of the sleeve use a syringe to lower the level to the bottom of the sleeve Neutralize the ...

Page 191: ...stall to the filter holder and tighten ring 4 Tightening torque 14 7 to 19 6 N m 1 5 to 2 0 kgf m 10 8 to 14 5 lbft 8 Set handle 1 of the water separator to OPEN position B 9 After washing the water separator bleed the air For details of the procedure for bleeding the air see Air Bleeding PAGE 4 50 DRAIN WATER AND SEDIMENT FROM FUEL TANK NOTICE Never use trichlene for washing the inside of the tan...

Page 192: ... loose bolts immediately Tightening Tighten to a tightening torque of 127 to 142 N m 13 to 14 5 kgf m 94 to 104 9 lbft then check that the nut and shoe are in close contact with the link contact surface Order for Tightening Tighten the bolts in the order shown in the diagram on the right After tightening check that the nut and shoe are in close contact with the link mating surface 4 27 ...

Page 193: ...ne 2 Choose wooden block 3 that will reach from idler 1 to carrier roller 2 then place it on top of the track 3 Measure the maximum deflection between the top surface of the track and the bottom surface of the wooden block Standard deflection Deflection a should be 5 to 15 mm 0 197 to 0 6 in If the track tension is not at the standard value adjust it in the following manner Adjustment WARNING Ther...

Page 194: ...r replaced Please contact your Komatsu distributor for repairs Loosening Track Tension WARNING It is extremely dangerous to release the grease by any method except the procedure given below If track tension is not relieved by this procedure contact your Komatsu distributor for repairs 1 Loosen plug 1 gradually to release the grease 2 When loosening plug 1 turn it a maximum of one turn 3 If the gre...

Page 195: ...r Komatsu distributor for repairs or replacement Lug Height If lug height a is reduced by wear the drawbar pull will drop If a is less than 5 mm 0 2 in replace with a new part If the lug wears and the steel cord inside the shoe is exposed for two links or more replace with a new part Machine equipped with rubber shoes Rubber Shoe Steel Code Cuts If more than half of the steel cord layer on one sid...

Page 196: ... only elongation of the rubber shoe but also damage to the grease cylinder Rubber Shoe Cracks If the cracks between the rubber shoe lugs increase to a size of approx 60 mm 2 36 in the rubber shoe must be repaired Even if the crack is small and short if the steel cord can be seen inside carry out repairs immediately If the length is less than 30 mm 1 18 in or the depth of the crack is less than 10 ...

Page 197: ...ied out when the rubber shoe is loose the track will come off and it will cause premature wear of the core Checking 1 Run the engine at low idle move the machine forward a distance equal to the length of track on ground then stop the machine 2 Choose wooden block 3 that will reach from idler 1 to carrier roller 2 then place it on top of the track 3 Measure the maximum deflection between the top su...

Page 198: ...sk your Komatsu distributor for replacement Loosening Track Tension WARNING It is extremely dangerous to release the grease by any method except the procedure given below If the track tension is not relieved by this procedure please contact your Komatsu distributor 1 Loosen plug 1 gradually to release the grease 2 When loosening plug 1 turn it a maximum of one turn 3 If the grease does not come ou...

Page 199: ...ion is correct run the engine at low idle move the machine forward a distance equal to the length of track on ground then stop the machine NOTICE It is possible to change from the rubber shoe to the road liner and steel shoe However it is necessary to remove the idler guard and to carry out adjustment so always contact your Komatsu distributor to have the replacement carried out Prepare a grease g...

Page 200: ... rubber shoe rotate the sprocket in reverse so that the steel pipes make the rubber shoe come up from the idler then to the side to remove Rubber Shoes Installation 1 Raise the chassis with the boom and arm When doing this operate the levers slowly 2 Mesh the rubber shoe with the sprocket and fit it over the idler 3 Rotate the sprocket in reverse then push in the rubber shoe and stop the rotation ...

Page 201: ...etails see CHECK AND ADJUST RUBBER SHOE TENSION PAGE 4 32 7 Check that the track tension is correct and that the rubber shoe is correctly meshed on the sprocket and idler then lower the machine to the ground REPLACE ROAD LINERS Machine equipped with road liner When replacing all the road liner for the machine please contact your Komatsu distributor to have the replacement carried out When replacin...

Page 202: ...a cab there is only a lock lever on the left Replace the bucket teeth before the adapter starts to wear 1 To make it possible to knock out the pin of tooth 1 set the bottom surface of the bucket on a block check that the work equipment is in a stable condition then set the lock lever to the LOCK position L Set so that the bottom face of the bucket is horizontal 2 Use a hammer and drift to knock ou...

Page 203: ...adapter 4 If there is mud affixed to it or if there are protrusions the teeth will not enter the adapter properly and there will not be proper contact at the mating portion 7 Fit tooth 1 to adapter 4 and confirm that when the pointer is pressed strongly the rear face of the hole for the pin of the teeth is at the same level as the rear face of the hole for the pin of the adapter If the rear face o...

Page 204: ...e 2 Lightly hit lock pin 2 in the reverse direction from which it was hit in 3 Lightly hit the tip of the point from above and below and hit its sides from right and left 4 Confirm that rubber pin lock 3 and lock pin 2 are set as shown in the figure The life of the teeth can be lengthened and the frequency of its replacement can be reduced by turning it upside down so that it will wear evenly Repl...

Page 205: ...let any dust get in PC27MR PC35MR Mixture Ratio of Pure Washer Fluid and Water The proportion differs according to the ambient temperature so dilute the washer fluid with water to the following proportions before adding Area season Proportions Freezing temperature Normal Washer fluid 1 3 water 2 3 10 C 14 F Winter in cold area Washer fluid 1 2 water 1 2 20 C 4 F Winter in extremely cold area Pure ...

Page 206: ... 2 Use a cloth to wipe off any dirt from rail 1 Greasing NOTICE Do not use high viscosity oil for the lubricant Use grease only 1 Spray rail 1 and roller 2 thoroughly with lubricant 2 After spraying with lubricant slide the door and check that the door opens and closes smoothly If the movement is not smooth contact your Komatsu distributor for repair LUBRICATING Boom swing cylinder foot pin 1 plac...

Page 207: ...1 M10 x 3 then remove triangular cover 2 2 Remove the oil filler cap from the hydraulic oil tank 3 Loosen air bleed plug 3 and check that oil oozes out from the bleeder plug completion of air bleeding PC27MR PC35MR 4 After completion of the air bleeding operation tighten the air bleed plug 5 Tighten the oil filler cap of the hydraylic oil tank 6 Install the cover 2 Start the engine For details see...

Page 208: ...inder 4 to 5 times to the end of its stroke to completely remove the air 4 Bleeding air from attachment when installed NOTICE If the method of bleeding the air from the attachment itself is specified by the manufacturer bleed the air according to the specified procedure After completing the air bleeding operation stop the engine and leave the machine for 5 minutes before starting operations This w...

Page 209: ...ee Checks Before Starting PAGE 3 41 in the OPERATION section Check coolant level add coolant Check oil level in engine oil pan add oil Check fuel level add fuel Check oil level in hydraulic tank add oil Check dust indicator Check water separator Check electric wiring Check function of horn 4 44 ...

Page 210: ...irst 100 hours on new machines where the parts are settling in carry out greasing every 10 hours Prepare a grease gun 1 Using a grease pump pump in grease through the grease fittings shown by arrows 2 After greasing wipe off any old grease that was pushed out 1 Swing pinion 1 place 2 Swing circle 1 place When lubricating the swing circle and swing pinion turn the chassis little by little to change...

Page 211: ...ng posture shown on the right diagram lower the work equipment to the ground then stop the engine 2 Using a grease pump pump in grease through the grease fittings shown by arrows 3 After greasing wipe off any old grease that was pushed out 1 Bucket Link connecting pins 1 place 2 Arm Bucket connection pin 1 place 3 Arm Link coupling pin 1 place 4 Bucket cylinder rod end 1 place 5 Link coupling pin ...

Page 212: ...NCE PROCEDURE MAINTENANCE MAINTENANCE PROCEDURE 13 Boom cylinder rod end 1 place 14 Arm cylinder foot pin 1 place 15 Arm cylinder rod end 1 place 16 Boom Arm connecting pins 1 place 17 Bucket cylinder foot pin 1 place 4 47 ...

Page 213: ...elf and drain the oil 3 Check the drained oil and if there are excessive metal particles or foreign material please contact your Komatsu distributor 4 Install drain plug P 5 Install the undercover 6 Open the engine rear cover 7 Using a filter wrench turn filter cartridge 1 counterclockwise to remove it 8 Clean the filter holder coat the new filter cartridge packing and threaded portion with clean ...

Page 214: ...h turn filter cartridge 2 counterclockwise to remove it If any fuel spills wipe it up immediately with a cloth 5 Clean the filter holder fill the new filter cartridge with fuel then coat the packing surface with fuel and install to the filter holder 6 When installing turn to the right to tighten until the packing surface contacts the seal surface of the filter holder then use a filter wrench to ti...

Page 215: ...r 3 turns 4 When no more bubbles come out with the fuel from air bleed bolt 2 tighten air bleed bolt 2 5 Turn the starting switch to the ON position hold it there for 10 to 15 seconds then return it to the OFF position Air bleeding is carried out automatically by the automatic air bleed device REMARK When the machine has run out of fuel carry out the same procedure to bleed the air 4 50 ...

Page 216: ...nside the case the oil or plug may fly out Loosen the plug slowly to release the pressure Prepare a container to catch drained oil Prepare a hexagon wrench 1 Set so that plug G is at the top with plug G and plug P perpendicular to the ground 2 Set the container to catch oil under plug P 3 Remove plug G with a hexagonal wrench Oil level shouldbe near the bottom of the plug hole G 4 If the oil level...

Page 217: ...n use the compressed air keep a distance from air nozzle to prevents damage to the fins To prevent damage to the fins apply compressed air from and appropriate distance Damaged fins may cause water leakage or overheating In a dusty site check the fins daily irrespective of the maintenance interval 1 Open the engine rear cover and cooling cover For details see COOLING COVER PAGE 3 29 2 Use compress...

Page 218: ...arting the operation Prepare a pinch bar Prepare a wooden block 1 When opening tilting the floor see When Opening tilt open PAGE 3 31 for details 2 Insert a bar between alternator 1 and the cylinder block to fix alternator 1 in position When fixing alternator 1 in position insert a wooden block between the bar and alternator 1 to prevent any damage to the alternator 3 Loosen alternator adjustment ...

Page 219: ...etails of the method of opening and closing the cover with the lock see In Case of Engine Rear Cover and Dirt Cover PAGE 3 28 2 Remove grease gun 9 then remove bolt 12 and take off grease gun holder 10 3 Remove bolt 13 then remove divider plate 11 4 Loosen bolt 2 then remove plate 3 to the front 5 Remove the cap from oil filler F and release the internal pressure 6 Remove bolts 4 then remove cover...

Page 220: ...mmediately after the engine is stopped and may cause serious burns Wait for the temperature to go down before starting the operation If there is still pressure remaining inside the case the oil or plug may fly out Loosen the plug slowly to release the pressure Prepare a container to catch drained oil Prepare a hexagon wrench 1 Set so that plug G is at the top with plug G and plug P perpendicular t...

Page 221: ...nance Immediately after the engine is stopped the parts and oil are at a high temperature and will cause burns Wait for the temperature to go down before starting the operation When removing the oil filler cap oil may spurt out so turn it slowly to release the internal pressure before removing it Container to catch drained oil Min 20 liters 5 28 US gal capacity Refill capacity 20 liters 5 28 US ga...

Page 222: ... Loosen hose clamp 4 remove hose 5 then remove bolt 6 and take out strainer 7 11 Remove any dirt stuck to strainer 7 then wash it in clean diesel oil or flushing oil If strainer 7 is damaged replace it with a new one 12 Secure strainer 7 with bolt 6 then install hose 5 and secure it in position with hose clamp 4 13 After completing the adjustment close the floor For details see When Closing tilt c...

Page 223: ...E CHECK ALTERNATOR STARTING MOTOR The brush may be worn or the bearing may have run out of grease Contact your Komatsu distributor for inspection or repair If the engine is started frequently carry out inspection every 1000 hours 4 58 ...

Page 224: ... 5 1 ...

Page 225: ...19 26 2 600 21 7 29 1 2 400 A Overall length mm ft in 4 320 14 2 4 850 15 11 B Overall height mm ft in 2 530 8 4 C Overall width mm ft in 1 550 5 1 1 740 5 9 D Track width mm ft in 300 11 8 E Radius of upper structure Canopy specified mm ft in 775 2 7 950 3 1 Cab specified 775 2 7 950 3 1 F Length of track mm ft in 1 950 6 5 2 105 6 11 G Tumbler center distance mm ft in 1 485 4 10 1 650 5 5 Min gr...

Page 226: ... 14 9 5 010 16 5 D Max vertical wall depth mm ft in 2 185 7 2 2 720 8 11 E Max dumping height Canopy specified mm ft in 3 230 10 7 3 530 11 7 Cab specified mm ft in 3 230 10 7 3 530 11 7 F Minimum swing radius of work equipment mm ft in 1 910 6 3 2 080 6 10 Minimum swing radius of work equipment at boom swing mm ft in 1 510 4 11 1 590 5 3 G Max reach at ground level mm ft in 4 550 14 11 5 225 17 2...

Page 227: ... 6 1 ...

Page 228: ... When an attachment is installed the swing range and center of gravity of the machine are different and the machine may move in an unexpected way Be sure that you understand the condition of the machine properly Before starting operations set up a fence around the machine to prevent people from entering Never operate the machine when there are people near the machine To prevent serious accidents c...

Page 229: ...stance from operating to stop the swing to the point where the swing stops completely so there is danger of mistaking the distance and hitting other objects Allow a margin to the stopping point when operating In addition the hydraulic drift the gradual downward movement caused by the weight of the work equipment when the work equipment is stopped in a raised condition will also increase If the cor...

Page 230: ...o damage to the hook stopper and hook mount If any problem is found please contact your Komatsu distributor Never travel the machine while lifting a load Depending on the operating posture there is danger that the wire or pulley may come off from the hook To avoid these parts from coming off pay careful attention to the angle of the hook In addition do not allow any person to come under or in the ...

Page 231: ...ent Temperature Control Switch This switch 1 continuously adjusts the temperature between high and low The more the switch is turned to the left the lower the temperature becomes the more the switch is turned to the right the higher the temperature becomes Air Flow Selector Switch This switch 2 adjusts air flow in three steps Position 3 High Position 2 Intermediate Position 1 Low Position 0 OFF 6 ...

Page 232: ... change the direction of the airflow by rotating or reversing the louvers of each vent 5 AIR CONDITIONER CONTROLS Cooling If you smoke when the cooler is on the smoke may start to hurt your eyes so carry out ventilation and cooling for a short time to remove the smoke When running the air conditioner for a long time carry out ventilation and cooling together once an hour Cooling with Care When the...

Page 233: ...ansparent No refrigerant REMARK When there are bubbles the refrigerant gas level is low so contact your Komatsu distributors to have refrigerant added If the air conditioner is run with the refrigerant gas level low it will cause damage to the compressor Off Season Checks Even during the off season operate the air conditioner for 3 to 5 minutes once a month to maintain the oil film at all parts of...

Page 234: ...ey 1 1 Open the engine rear cover and loosen locknut 3 2 Adjust with adjustment nut 2 so that the deflection of the belt is 10 to 15 mm 0 4 to 0 6 in approx 58 8 N approx 6 kgf 3 Tighten nut 3 to hold idle pulley in position 4 Check for damage to the pulleys and wear of the V groove and V belt Be particularly careful to check that the V belt is not in contact with the bottom of the V groove 5 Repl...

Page 235: ...amage to the fins Especially for the aftercooler blow the air from 300 mm 11 8 in or more and at a 45 degree angle To prevent damage to the fins apply compressed air from an appropriate distance Damaged fins may cause water leakage or overheating On dusty sites check the fins daily regardless of the maintenance interval 1 Blow off mud dust or leaves clogging the condenser fins using compressed air...

Page 236: ... the filter dry it thoroughly before using it REMARK If the clogging of the filter cannot be removed by blowing it with compressed air or washing in water replace the filter with a new one 4 Install cover 2 in position Clean Air Conditioner RECIRC Filter WARNING If compressed air is used there is danger that dirt may fly and cause personal injury Always wear protective glasses dust mask and other ...

Page 237: ...EL ADD FLUID If air is mixed in the windshield washer fluid check the fluid level of washer fluid tank in the engine compartment If it is too low supply the same kind of washer fluid as automobiles use At this time take care that dust does not enter the tank Washer Fluid Dilution Ratio The proportion differs according to the ambient temperature so dilute the washer fluid with water to the followin...

Page 238: ...g products are used for the quick coupler Arm left side hole end STUCCHI F FIRG12A BSP Arm right side shaft end PC27MR STUCCHI APM13 1 2 BSP PC35MR STUCCHI APM15 3 4 BSP When removing the attachment install this coupler 1 to cap A When installing the attachment remove cap A clean all the dirt from coupler 1 then connect the piping The following products are used for quick coupler cap A Arm left si...

Page 239: ...ent Control Pedal This pedal 3 is used to operate the attachment Top of pedal depressed Oil flows to right side of arm hydraulic tank side Bottom of pedal depressed Oil flows to left side of arm operator s seat side Attachment Lock Cover WARNING When attachment operation is not required lock the attachment control pedal with the attachment lock cover If the attachment control pedal is accidentally...

Page 240: ... lose the parts that are removed 3 Connect the piping quick coupler supplied by the attachment manufacturer The following products are used for the quick coupler Arm left side hole end STUCCHI F FIRG12A BSP Arm right side shaft end PC27MR STUCCHI APM13 1 2 BSP PC35MR STUCCHI APM15 3 4 BSP The size of the quick coupler mounting screws for the elbow installed to the block is as follows Left side of ...

Page 241: ...linder may cause damage to the piston packing or other parts 3 Bleeding air from attachment if equipped For machine equipped with attachment such as the breaker actuate the attachment pedal about 10 times to bleed the air completely from the attachment circuit while running the engine at low idle NOTICE If the attachment bleeding procedure is specified by the manufacture bleed the attachment accor...

Page 242: ...ow please ask your Komatsu distributor to carry out the adjustment Precautions when Using Check that selector valve 1 is at the 1 WAY breaker position a When using the breaker pull the fuel control lever back fully then return it slightly and keep it in this position for operations The position for 80 of engine output If the breaker is operated with the engine at full throttle it will lead to fail...

Page 243: ...ther precautions when handling the attachment read and use correctly the instruction manual provided by the attachment manufacturer LONG TERM STORAGE If the machine is not to be used for a long time do as follows Install the cap to the quick coupler Set the selector valve to the position for general attachments such as the crusher Lock the attachment control pedal with the attachment lock cover If...

Page 244: ...h the card that matches the operating pattern When checking the movement of the machine check carefully that the surrounding area is safe and operate slowly CONTROL PATTERN CHANGE PROCEDURE 1 Open the hatch at the bottom left side of the machine The pattern selector valve is inside 2 Follow the steps explained below when switching the patterns 1 Loosen hexagon socket head bolt 1 2 The operating pa...

Page 245: ...NG MACHINE CONTROL PATTERN IF PATTERN CHANGE VALVE EQUIPPED MACHINE CONTROL PATTERNS WARNING After changing the operating pattern always change the operating pattern card in the operator s compartment ISO pattern Backhoe pattern 6 19 ...

Page 246: ...ever BLADE CONTROL LEVER Lifting or Angling Control This lever is used to lift or angle the blade Lifting Control Position a LOWER Position b RAISE N neutral Blade is stopped and held in position Angling Control Position c RIGHT ANGLE Position d LEFT ANGLE N neutral Blade is stopped and held in position The angle amount is 25 on both the left and right 6 20 ...

Page 247: ...in grease through the grease fittings shown by arrows 2 After greasing wipe off any old grease that was pushed out 1 Angle pin 1 place EVERY 500 HOURS SERVICE Lubricating 1 Using a grease pump pump in grease through the grease fittings shown by arrows 2 After greasing wipe off any old grease that was pushed out 1 Lift cylinder foot pin 1 place 2 Lift cylinder rod end pin 1 place 3 Blade foot pin 2...

Page 248: ...dge Bolt Nut 1 7 7 20U 910 1980 02090 10840 02090 10813 End bit Bolt Nut 2 6 6 SPECIFICATIONS Blade width x height 1770 mm x 380 mm 69 7 in x 15 0 in RAISE amount Rubber shoes Steel shoes 390 mm 15 4 in 382 mm 15 1 in LOWER amount Rubber shoes Steel shoes 405 mm 16 0 in 413 mm 16 3 in Amount of angle Left and right each 20 6 22 ...

Page 249: ...familiar work equipment for the first time check before starting if there is any danger of interference and operate with caution This is the combination table for buckets that can be installed to the standard arm If a long arm is installed do not pull the bucket fully in towards the machine It will hit the machine body When lowering the boom while digging diagonally be careful not to let the bucke...

Page 250: ...will vary Hence consult your Komatsu distributor for the selection of optimum attachments HYDRAULIC BREAKER Main Applications Crushed rock Demolition work Road construction This attachment can be used for a wide range of applications including demolition of buildings breaking up road surfaces or slag tunnel work rock crushing and breaking operations in quarries Keep the chisel pushed perpendicular...

Page 251: ...e surface within 1 minute change the point of impact and carry out breaking operations closer to the edge The direction of penetration of the chisel and the direction of the breaker body will graduallymove out of line with each other always adjust the bucket cylinder to keep them aligned Always keep the chisel pressed against the impact surface properly to prevent using the impact force when there...

Page 252: ... do not operate the machine in any of the following ways Do not operate all cylinders to the end of their strokes Always leave approx 5 cm 2 in to spare Using the mount to gather in pieces of rock Operations using the swing force Moving the chisel while carrying out impacting operations Holding the chisel horizontal or pointed up when carrying out impacting operations 6 26 ...

Page 253: ...TTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Twisting the chisel when it has penetrated the rock Pecking operations Extending the bucket cylinder fully and thrusting to raise the machine off the ground 6 27 ...

Page 254: ...n NOTICE If the breaker is greased in an improper posture it is filled with more grease than necessary As a result soil and sand will enter the hydraulic circuit and can damage the hydraulic components while the breaker is in use Therefore be sure to grease the breaker holding it in the right posture 6 28 ...

Page 255: ... 7 1 ...

Page 256: ... Fuse Capacities and Circuit Names PAGE 3 36 and replace the fuse with a fuse of the same capacity Operation Manual Storage NOTICE Except when opening the cover for some reason always keep the cover locked This is under the operator s seat There is a box for keeping the Operation and Maintenance Manual in the rear of the operator s seat backrest Keep the Operation and Maintenance Manual in the box...

Page 257: ...NCE PROCEDURE MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE Carry out the maintenance for EVERY 500 HOURS and EVERY 1000 HOURS SERVICE at the same time Clean Check Turbocharger Contact your Komatsu distributor for cleaning and inspection 7 3 ...

Page 258: ...orsepower kW HP rpm 23 9 32 5 2 400 A Overall length mm ft in 4 850 15 11 B Overall height mm ft in 2 530 8 4 C Overall width mm ft in 1 740 5 9 D Track width mm ft in 300 11 8 E Radius of upper structure mm ft in 950 3 1 F Length of track mm ft in 2 105 6 11 G Tumbler center distance mm ft in 1 650 5 5 Min ground clearance mm ft in 290 11 4 Travel speed Low High km h MPH 2 8 4 6 1 7 2 9 Swing spe...

Page 259: ...ape Hammer 3 27 Emission Control Information Label and Its Location 1 9 Engine After Starting 3 58 Engine Before Starting 3 39 Engine Rear Cover 3 29 Engine Serial No Plate and Its Location 1 8 Engine Starting 3 54 Engine Stopping the 3 61 Escape from Mud 3 78 Every 500 Hours Service 6 21 F Foreword 1 2 Fuse 3 36 G General Operation Information 3 74 Grease Gun Holder 3 38 H Handling Hydraulic Syst...

Page 260: ...Operation 2 19 Battery 2 28 Lifting Objects with Bucket 2 31 Operation 2 21 Starting Engine 2 19 Towing 2 30 Transportation 2 27 Safety Maintenance Information 2 32 Service Meter Location 1 9 Sliding Door 3 26 Sliding Window 3 26 Specifications 5 2 Specifications 6 22 SPECIFICATIONS 7 4 Swinging 3 69 Switches 3 12 T Tightening Torque Specifications 4 13 Tightening Torque List 4 13 Tool Box 3 38 Tr...

Page 261: ... PC27MR 2 PC35MR 2 GALEO HYDRAULIC EXCAVATOR Form No TEN00115 00 2005 KOMATSU All Rights Reserved Printed in Japan 06 05 ...

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