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Komatsu Galeo PC27MR-2 Operation & Maintence Manual

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Summary of Contents for Komatsu Galeo PC27MR-2

  • Page 2 1 - 1...

  • Page 3: Foreword

    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.
  • Page 4 FOREWORD FOREWORD 1 - 3...
  • Page 5 FOREWORD FOREWORD 1 - 4...

  • Page 6: Safety Information

    FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
  • Page 7 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.

  • Page 8: Introduction

    FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: Digging work Leveling work Ditching work Loading work Demolition work See the section "WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR (PAGE 3-79)" for further details.

  • Page 9: Product Information

    FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, 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.

  • Page 10: Emission Control Information Label And Its Location

    FOREWORD PRODUCT 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: Your Machine Serial Numbers And Distributor

    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: Table Of Contents

    FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTRODUCTION DIRECTIONS OF MACHINE PRODUCT INFORMATION PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ENGINE SERIAL NUMBER PLATE AND ITS LOCATION EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION SERVICE METER LOCATION YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1- 10 SAFETY SAFETY INFORMATION...
  • Page 13 FOREWORD CONTENTS BEFORE STARTING ENGINE 3- 39 STARTING ENGINE 3- 54 AFTER STARTING ENGINE 3- 58 STOPPING THE ENGINE 3- 61 MACHINE OPERATION 3- 62 STEERING THE MACHINE 3- 67 SWINGING 3- 69 WORK EQUIPMENT CONTROLS AND OPERATIONS 3- 70 PROHIBITED OPERATIONS 3- 72 GENERAL OPERATION INFORMATION...
  • Page 14 FOREWORD CONTENTS SAFETY CRITICAL PARTS LIST 4- 14 MAINTENANCE SCHEDULE 4- 15 MAINTENANCE SCHEDULE CHART 4- 15 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4- 16 MAINTENANCE PROCEDURE 4- 17 WHEN REQUIRED 4- 17 CHECK BEFORE STARTING 4- 44 EVERY 500 HOURS MAINTENANCE 4- 45 EVERY 1000 HOURS MAINTENANCE 4- 54...
  • Page 15 2 - 1...
  • Page 16 SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY LABELS LOCATION OF SAFETY LABELS SAFETY LABELS SAFETY INFORMATION 2- 10 Safety Rules 2- 10 If Problems are Found 2- 10 Working Wear and Personal Protective Items 2- 10 Fire Extinguisher and First Aid Kit 2- 10 Safety Equipment 2- 11...

  • Page 17: Safety

    SAFETY SAFETY INFORMATION SAFETY MACHINE OPERATION 2- 19 STARTING ENGINE 2- 19 Checks Before Starting Engine 2- 19 Safety Rules for Starting Engine 2- 20 Starting Engine in Cold Weather 2- 20 OPERATION 2- 21 Checks Before Operation 2- 21 Safety Rules for Changing Machine Directions 2- 21 Safety Rules for Traveling...

  • Page 18: Safety Labels

    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 actual label, and place an order with Komatsu distributor. LOCATION OF SAFETY LABELS...

  • Page 19: Safety Labels

    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 SAFETY LABELS 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 SAFETY SAFETY SAFETY LABELS SAFETY 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 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (11) Prohibited 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 SAFETY SAFETY SAFETY LABELS 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: Safety Information

    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.

  • Page 25: Safety Equipment

    SAFETY SAFETY INFORMATION SAFETY EQUIPMENT Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. Understand the method of use of safety features and use them properly. Never remove any safety features. Always keep them in good operating condition. KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation.

  • Page 26: Handrails And Steps

    SAFETY SAFETY INFORMATION HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine. machine equipped with cab To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and...

  • Page 27: Burn Prevention

    SAFETY SAFETY INFORMATION BURN PREVENTION Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation.

  • Page 28: Action If Fire Occurs

    SAFETY SAFETY INFORMATION Fire caused by accumulated flammable material Remove any accumulated flammable material, such as dry leaves, chips, pieces of paper, and coal dust from inside the undercover or around the engine exhaust manifold, muffler, or battery. Remove also any chlorides accumulated on top of the battery or around the terminals.

  • Page 29: Falling Objects, Flying Objects And Intruding Objects Prevention

    If ROPS is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always Komatsu contact your distributor for advice of the method of repair.

  • Page 30: Attachment Installation

    Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu.

  • Page 31: Distance To High Voltage Cables

    SAFETY SAFETY INFORMATION DISTANCE TO HIGH VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as follows.

  • Page 32: Signalman's Signal And Signs

    Do not allow other persons to approach during the operation. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2 - 18...

  • Page 33: Safety Machine Operation

    SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION STARTING ENGINE If there is a warning tag hanging from the work equipment control lever, do not start the engine or touch the levers . CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view.

  • Page 34: Safety Rules For Starting Engine

    (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 distributor to carry out repairs. SAFETY RULES FOR STARTING ENGINE Start and operate the machine only while seated.

  • Page 35: Operation

    SAFETY SAFETY MACHINE OPERATION OPERATION CHECKS BEFORE OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check that the movement of the machine matches the display on the control pattern card.

  • Page 36: Safety Rules For Traveling

    SAFETY SAFETY MACHINE OPERATION SAFETY RULES FOR TRAVELING It is dangerous to drive too fast, or to start suddenly, stop suddenly, or to turn sharply. When traveling on flat ground, keep the work equipment 40 to 50 cm (16 to 20 in) high above the ground. When traveling on rough ground, travel at low speed and do not operate the steering suddenly.

  • Page 37: Traveling On Slopes

    SAFETY SAFETY MACHINE OPERATION TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. Keep the work equipment approx. 20 to 30 cm (8 to 12 in) above the ground. In case of emergency, lower the work equipment to the ground immediately to help stop the machine.

  • Page 38: Operations On Slopes

    SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION Always travel straight up or down a slope. Traveling at an angle or across the slope is extremely dangerous. Do not turn on slopes or travel across slopes. Always go down to a flat place to change the position of the machine, then travel on to the slope again.
  • Page 39 SAFETY SAFETY SAFETY MACHINE OPERATION SAFETY MACHINE OPERATION To make it easier to escape if there is any problem, set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when carrying out operations. Do not carry out demolition work under the machine.

  • Page 40: Operations On Snow

    SAFETY SAFETY MACHINE OPERATION OPERATIONS ON SNOW Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.

  • Page 41: Transportation

    SAFETY SAFETY MACHINE OPERATION TRANSPORTATION LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary. Always do as follows. Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of the road or cliff.

  • Page 42: Battery

    SAFETY SAFETY MACHINE OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.

  • Page 43: Starting Engine With Booster Cables

    SAFETY SAFETY MACHINE OPERATION STARTING ENGINE WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery).

  • Page 44: Towing

    SAFETY SAFETY MACHINE OPERATION TOWING SAFETY RULES FOR TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For towing, see "TOWING THE MACHINE (PAGE 3-106)". Always wear leather gloves when handling wire rope.

  • Page 45: Lifting Objects With Bucket

    SAFETY SAFETY MACHINE OPERATION LIFTING OBJECTS WITH BUCKET SAFETY RULES FOR LIFTING OBJECTS Do not carry out lifting work on slopes, soft ground, or other places where the machine is not stable. Use wire rope that conforms to the specified standard. Do not exceed the specified lifting load.

  • Page 46: Safety Maintenance Information

    SAFETY SAFETY MAINTENANCE INFORMATION SAFETY MAINTENANCE INFORMATION WARNING TAG Always attach the "DO NOT OPERATE" warning tag to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.

  • Page 47: Stop Engine Before Carrying Out Maintenance

    SAFETY SAFETY MAINTENANCE INFORMATION STOP ENGINE BEFORE CARRYING OUT MAINTENANCE Stop 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. Place the work equipment control lever to the neutral position, set lock lever (1) to LOCK position (L), then stop the engine.

  • Page 48: Cautions For Opening (Tilting) Floor

    SAFETY SAFETY MAINTENANCE INFORMATION CAUTIONS FOR OPENING (TILTING) FLOOR When opening (tilting) the cab or floor, see "METHOD OF OPENING (TILTING) FLOOR (PAGE 3-31)" for details. Precautions when 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.

  • Page 49: Two Workers For Maintenance When Engine Is Running

    SAFETY SAFETY MAINTENANCE INFORMATION TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows.

  • Page 50: Attachments

    SAFETY SAFETY MAINTENANCE INFORMATION ATTACHMENTS Appoint a leader before starting removal or installation operations for attachments. Place attachments that have been removed from the machine in a stable condition so that they do not fall. And take steps to prevent unauthorized persons from entering the storage area. WORK UNDER THE MACHINE If it is necessary to go under the work equipment or the machine to carry out service and maintenance, support the work...

  • Page 51: Removing Battery Terminals

    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.

  • Page 52: Safety Handling High-Pressure Hoses

    If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.
  • Page 53 3 - 1...

  • Page 54: Machine View Illustrations

    OPERATION MACHINE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW Bucket Track shoe Bucket cylinder Sprocket Track frame Arm cylinder (10) Idler Boom (11) Blade cylinder Boom cylinder (12) Blade 3 - 2...

  • Page 55: Controls And Gauges

    OPERATION MACHINE VIEW ILLUSTRATIONS CONTROLS AND GAUGES Operator's seat (13) Fuel control lever Heater switch (cab specification machine) (14) Starting switch Lock lever (left) (15) Floor lock cancel lever Left work equipment control lever (16) Service meter Travel Levers (with pedals) (17) Engine coolant temperature gauge Boom swing control pedal...

  • Page 56: Detailed Controls And Gauges

    OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES The following is an explanation of devices 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 Emergency monitors Pilot lamps...
  • Page 57 OPERATION DETAILED CONTROLS AND GAUGES Emergency Monitors CAUTION If the monitor flashes or the buzzer sounds, stop the engine immediately or run it at low idle, then inspect the problem point immediately and repair the problem. These are items which need to be observed when the engine is running. If there is any problem, the abnormal location on the monitor will lights up and the buzzer will sound.
  • Page 58 OPERATION DETAILED CONTROLS AND GAUGES Charge Level Monitor If there is a problem in the charging when 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.
  • Page 59 OPERATION DETAILED CONTROLS AND GAUGES Meter Display Portion Engine coolant temperature gauge Service meter Fuel gauge Engine Coolant Temperature Gauge This meter (1) shows the engine coolant temperature. During operation, the indicator should be in range (A). If the indicator enters red range (B) during operation, pilot lamp (C) flashes and the buzzer sounds at the same time.
  • Page 60 OPERATION DETAILED CONTROLS AND GAUGES Service Meter This meter (3) shows the total time that 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.
  • Page 61 OPERATION DETAILED CONTROLS AND GAUGES Pilot Lamps Engine pre-heating monitor Travel speed boost monitor Engine Pre-heating Monitor This monitor (1) flashes when the starting switch is set to the HEAT position. After approx. 18 seconds, the buzzer sounds and the monitor goes out.
  • Page 62 OPERATION DETAILED CONTROLS AND GAUGES Monitor Switches Portion Lamp switch 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.
  • Page 63 OPERATION DETAILED CONTROLS AND GAUGES Travel Speed Selector Switch WARNING When loading or unloading from a trailer, always travel at low speed. Never operate the travel speed selector switch during the loading or unloading operation. If the travel speed is switched between Hi and Lo when the machine is traveling, the machine may deviate to one side, even when traveling in a straight line.

  • Page 64: Switches

    OPERATION DETAILED CONTROLS AND GAUGES SWITCHES Starting switch Windshield wiper switch Horn switch (Machines equipped with cab) Lamp switch Room lamp switch Travel speed selector switch (Machines equipped with cab) Cab heater switch Cigarette lighter (Machines equipped with cab) (Machines equipped with cab) 3 - 12...
  • Page 65 OPERATION DETAILED CONTROLS AND GAUGES Starting Switch This switch (1) is used to start or stop the engine. OFF position The key can be inserted or with drawn. The switches for the electric system are all turned off and the engine is stopped. ON position Electric current flows in the charging and lamp circuits.
  • Page 66 OPERATION DETAILED CONTROLS AND GAUGES Cab Heater Switch (Machines equipped with cab) This switch (5) is used to heat the operator's compartment. The flow rate of the hot air can be set to two levels. Position 0: Off Position 1: Weak Position 2: Strong Hot water from the engine is used to carry out heating, so heating is possible when the engine coolant is hot.
  • Page 67 OPERATION DETAILED CONTROLS AND GAUGES Room Lamp Switch (Machines equipped with cab) This switch (7) is used 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.

  • Page 68: Control Levers And Pedals

    OPERATION DETAILED CONTROLS AND GAUGES CONTROL LEVERS AND PEDALS Lock lever Blade control lever (Machine equipped with cab: left side only) Travel levers (with pedals) Left work equipment control lever Swing lock cover Right work equipment control lever Boom swing control pedal Fuel control lever Floor lock cancel lever 3 - 16...
  • Page 69 OPERATION DETAILED CONTROLS AND GAUGES Lock Lever WARNING When leaving the operator's compartment, set the lock lever securely to the LOCK position (L). If the lock lever is not at the LOCK position (L) and the control levers are touched by mistake, it may lead to serious personal injury. If the lock lever is not set securely to LOCK position (L), it may cause serious personal injury.
  • Page 70 WARNING The operating pattern is set to the standard operating pattern (ISO pattern). When changing the operating pattern, please contact your Komatsu distributor. The method of using operating patterns other than the ISO pattern is given in the ATTACHMENT AND OPTIONS section. Always read and understand the contents before operating the machine.
  • Page 71 OPERATION DETAILED CONTROLS AND GAUGES Fuel Control Lever This lever (4) is used to control the engine speed 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.
  • Page 72 OPERATION DETAILED CONTROLS AND GAUGES Travel Levers (with Pedals) WARNING Do not put your foot on the pedal unless the machine is traveling. If you leave your foot on the pedal and press it by mistake, the machine will move suddenly, and this may lead to a serious accident. Do not rest a foot on the pedal except when traveling or steering the machine, using the pedal.
  • Page 73 OPERATION DETAILED CONTROLS AND GAUGES Swing Lock Cover WARNING When the boom swing is not being used, lock the boom swing with the swing lock cover. If the control pedal is accidentally depressed when it is not locked, it may lead to a serious accident or injury. This cover (7) is used to lock the boom swing control pedal.

  • Page 74: Windshield

    OPERATION DETAILED CONTROLS AND GAUGES WINDSHIELD (Machines equipped with cab) WARNING When opening or closing the front window, bottom window, or door, always set the lock lever to the LOCK position. If the control levers are not locked and they are touched by accident, this may lead to a serious accident. When opening or closing the window at the front of the cab, stop the machine on horizontal ground, lower the work equipment completely to the ground, stop the engine, then carry out the operation.
  • Page 75 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 4. Grip 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).
  • Page 76 OPERATION DETAILED CONTROLS AND GAUGES Closing WARNING When closing the window, lower it slowly and be careful not to get your hand caught. 1. Stop the machine on level ground, lower the work equipment completely to the ground, then stop the engine. 2.
  • Page 77 OPERATION DETAILED CONTROLS AND GAUGES Removing Lower Windshield 1. Open the front window, then hold grip (A), pull up, and remove the bottom window. 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.

  • Page 78: Sliding Door

    OPERATION DETAILED CONTROLS AND GAUGES SLIDING DOOR (Machines equipped with cab) CAUTION Be sure to check that the sliding door is locked in position both when it is open and when it is closed. Always stop the machine on level ground when opening or closing the door. If the door is opened or closed on a slope, there is danger that the operating effort will suddenly change.

  • Page 79: Emergency Escape Hammer

    OPERATION DETAILED CONTROLS AND GAUGES EMERGENCY ESCAPE HAMMER (Machines equipped with cab) CAUTION If it is necessary to break the window glass with the hammer, be extremely careful not 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.

  • Page 80: Cover With Lock

    OPERATION DETAILED CONTROLS AND GAUGES COVER WITH LOCK Opening and Closing Covers with Lock Use the starting switch key to open or close the cover with the lock. For details of the position of the cover with the lock, see "LOCKING (PAGE 3-84)".

  • Page 81: Engine Rear Cover

    OPERATION DETAILED CONTROLS AND GAUGES ENGINE REAR COVER CAUTION When carrying out inspection and service inside the engine rear cover, always open the cover fully until it is secured in position by the rod. NOTICE Except when opening the cover, always keep it locked. When it is locked, opening knob (1) of the cover does not move.

  • Page 82: Mud Cover

    OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 3. Pull cooling cover (3) and open it fully. Cover (3) is secured in position by rod (4). 4. When closing cooling cover (3), lift up rod (4) and close cover (3) slightly.

  • Page 83: Method Of Opening (Tilting) Floor

    Do not start the engine when the floor is open. If there is any breakage or problem in 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.
  • Page 84 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 4. Fit blocks securely under the track to prevent the machine from moving. 9 J A 0 5 4 6 6 5. Open dirt cover (2) 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)")
  • Page 85 OPERATION OPERATION DETAILED CONTROLS AND GAUGES DETAILED CONTROLS AND GAUGES 10. Open inspection window (7), use your left hand to pull floor lock release lever (8) in the direction of the arrow (to the rear) while holding knob (9) with your right hand and pushing it up in the direction of the arrow (approx 45°).
  • Page 86 Before closing the floor, check that there is no damage or problem in the wiring, piping, or seats inside the floor or revolving frame. If any damage or problem is found, please ask your Komatsu distributor to carry out repairs.
  • Page 87 OPERATION OPERATION DETAILED CONTROLS AND GAUGES 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.

  • Page 88: Fuse

    OPERATION DETAILED CONTROLS AND GAUGES FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.

  • Page 89: Block Fuse

    OPERATION DETAILED CONTROLS AND GAUGES BLOCK FUSE If the starting motor does not turn even when the starting switch is turned to the ON position, block fuse (1) is probably blown, so open the cover at the right side of the machine and check or replace the fuse.

  • Page 90: Operation Manual Storage

    OPERATION DETAILED CONTROLS AND GAUGES 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 so that it can be seen at any time.

  • Page 91: Machine Operations And Controls

    Leakage of oil and fuel will cause the machine to catch fire. Always check thoroughly and repair any problems or contact your Komatsu distributor. Check that the floor is fixed securely in position by bolts (1). If it is not fixed securely in position, it may cause serious personal injury.
  • Page 92 Komatsu distributor to carry out repairs. 10. Check bucket with hook (if equipped) for damage. Check for damage to the hook, guide, and hook mount. If any problem is found, contact your Komatsu distributor for repairs. 3 - 40...
  • Page 93 OPERATION MACHINE OPERATIONS AND CONTROLS Checks Before Starting Always check the items in this section before starting the engine each day. Check Coolant Level, Add Coolant WARNING Do not open the radiator cap unless necessary. Wait for the engine to cool down before checking the coolant in the sub-tank. Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
  • Page 94 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE 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.
  • Page 95 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Engine Oil Pan, Add Oil WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. REMARK If the machine is at an angle, reposition it to level before checking.
  • Page 96 OPERATION MACHINE OPERATIONS AND CONTROLS Check Fuel Level, Add Fuel WARNING When adding fuel, never spill the fuel or let it overflow. It will cause fire. If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand. Fuel is highly flammable and dangerous.
  • Page 97 OPERATION MACHINE OPERATIONS AND CONTROLS Check Oil Level in Hydraulic Tank, Add Oil WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
  • Page 98 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 5. Extend the boom, arm, and bucket cylinder fully as shown in the diagram on the right, remove the oil filler cap, then install the cap and pressurize the inside of the tank. NOTICE Be sure to pressurize the hydraulic tank.
  • Page 99 Check Function of Horn 1. Turn the starting switch to the ON position. 2. Confirm that the horn sounds immediately when the horn button is pressed. If the horn does not sound, contact your Komatsu distributor for repair. 3 - 47...
  • Page 100 OPERATION MACHINE OPERATIONS AND CONTROLS Adjustment WARNING Adjust the seat position before starting operations or after changing the operator. Adjust the seat so that the control levers and switchis can be operated freely and easily with the operator back against the backrest.
  • Page 101 OPERATION 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 OPERATION MACHINE OPERATIONS AND CONTROLS Seat Belt WARNING Before fastening the seat belt, check that there is no problem in the securing brackets or belt. If there is any wear or damage, replace. Even if there appears to be no problem in the seat belt, replace the seat belt once every 3 years. The date of manufacture is woven on the reverse side of the belt.
  • Page 103 OPERATION MACHINE 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 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Before Starting Engine WARNING When standing up from the operator's seat, always set the lock lever to the LOCK position, regardless of whether the engine is running or 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.
  • Page 105 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.

  • Page 106: Starting Engine

    OPERATION MACHINE OPERATIONS AND CONTROLS STARTING ENGINE Normal Starting WARNING Sit down in the operator's seat before starting the engine. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire.
  • Page 107 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Turn the key in starting switch (3) to the START position. The engine will start. 4. When the engine start, release the key in the starting switch (3). The key will return automatically to the ON position. Starting Engine in Cold Weather WARNING Start the engine only after sitting down in the operator's seat.
  • Page 108 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 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 will not start. REMARK For machines equipped with a cab, there is only a lock lever on the left.
  • Page 109 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS 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: After Starting Engine

    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 100 hours (as indicated by the service meter).
  • Page 111 OPERATION MACHINE OPERATIONS AND CONTROLS Warming-up Operation NOTICE When the hydraulic oil is at a low temperature, do not carry out operations or move the lever suddenly. Always carry out the warming-up operation. This will help to extend the machine life. Do not suddenly accelerate the engine before the warming-up operation is completed.
  • Page 112 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.

  • Page 113: Stopping The Engine

    OPERATION MACHINE OPERATIONS AND CONTROLS STOPPING THE ENGINE NOTICE If the engine is stopped abruptly, service life of component parts of the engine may be considerably reduced. Do 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.

  • Page 114: Machine Operation

    OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATION WARNING Before operating the travel levers, check the direction of the track frame. If the sprocket is at the front, the operation of 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.
  • Page 115 OPERATION MACHINE OPERATIONS AND CONTROLS Moving Machine Forward 1. Set lock lever (2) to the FREE position, then raise the work equipment 40 to 50 cm (16 to 20 in) from the ground. 2. Raise the blade. 3. Opearate the both travel levers (3) as explained below. When the sprocket (A) is at the rear of the machine.
  • Page 116 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 work equipment 40 to 50 cm (16 to 20 in) from the ground.
  • Page 117 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. 3 - 65...
  • Page 118 OPERATION 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: Steering The Machine

    OPERATION MACHINE OPERATIONS AND CONTROLS STEERING THE MACHINE Steering WARNING Before operating the travel levers, check the direction of the track frame (the position of the sprocket). If the sprocket is at the rear, the machine moves in the reverse direction to the operation of the travel levers. REMARK When traveling at high speed, if the load increases, the automatic travel speed shifting function automatically shifts the transmission to low speed and the machine travels slowly.
  • Page 120 OPERATION MACHINE OPERATIONS AND CONTROLS Changing Direction of the Machine When turning to the left: If the left travel lever is returned to the neutral position, the machine will turn to the left. REMARK When turning to the right, operate the right travel lever in the same way.

  • Page 121: Swinging

    OPERATION MACHINE OPERATIONS AND CONTROLS SWINGING WARNING When operating the swing, check that the area around the machine is safe. 1. Operate left work equipment control lever (1) to swing the upper structure. 2. When not using the swing, set left work equipment control lever (1) to the N position.

  • Page 122: Work Equipment Controls And Operations

    OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS WARNING For operation modes other than the standard one (ISO pattern), refer to the chapter of ATTACHMENTS AND OPTIONS in this manual. Use the control levers to operate 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.
  • Page 123 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS Bucket control 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.

  • Page 124: Prohibited Operations

    OPERATION MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS WARNING Do not attempt to operate the work equipment control lever, while the machine is traveling. Operations Using Swing Force Do not use the swing force to compact soil or break earth mounds or walls.
  • Page 125 OPERATION MACHINE OPERATIONS AND CONTROLS Operations Using Bucket Dropping Force Do not use the dropping force of the machine for digging, or use the dropping force of the bucket as a pickaxe, breaker, or pile driver. This will markedly reduce the life of the machine. Operations Using Machine Dropping Force It is prohibited to carry out digging operations using the dropping force of the machine.

  • Page 126: General Operation Information

    OPERATION MACHINE OPERATIONS AND CONTROLS GENERAL OPERATION INFORMATION Traveling Traveling over boulders, tree stumps, or other obstacles will cause a big shock to the chassis (and in particular to the tracks), and this will cause damage to the machine. For this reason, always remove any obstacles or travel around them, or take other steps to avoid traveling over such obstacles as far as possible.
  • Page 127 OPERATION MACHINE OPERATIONS AND CONTROLS Permissible Water Depth CAUTION When driving the machine out of water, if the angle of the machine exceeds 15°, the rear of the upper structure will go under water, 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.

  • Page 128: Traveling On Slopes

    OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELING ON SLOPES WARNING Turning or operating the work equipment when working on slopes may cause the machine to lose its balance and turn over, so avoid such operations. It is particularly dangerous to swing downhill when the bucket is loaded. If such operations have to be carried out, pile soil to make a platform on the slope so that the machine can be kept horizontal when operating.
  • Page 129 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 2. When traveling up a steep hill of more than 15°, set the work equipment to the posture shown in the diagram on the right. Traveling Downhill Put the travel lever in the neutral position. This will cause the brake to be automatically applied. Engine Stopped on Slope If the engine stops when traveling uphill, move the travel levers to the neutral position, lower the bucket to the ground, stop the machine, then start the engine again.

  • Page 130: Escape From Mud

    OPERATION MACHINE OPERATIONS AND CONTROLS ESCAPE FROM MUD Always operate carefully to avoid getting affixed in mud. If the machine does get affixed in mud, do as follows to get the machine out. Track on One Side Stuck NOTICE When using the boom or arm to raise the machine, always have the bottom of the bucket in contact with the ground.

  • Page 131: Work Possible Using Compact Hydraulic Excavator

    OPERATION MACHINE OPERATIONS AND CONTROLS WORK POSSIBLE USING COMPACT HYDRAULIC EXCAVATOR In addition to the following, it is possible to further increase the range of applications by using various attachments. Backhoe Work This is suitable for excavating places lower than the machine. When work equipment is in condition shown in diagram on right Bucket cylinder and link When the center line of arm cylinder and arm foot pin is at 90°, the...
  • Page 132 OPERATION MACHINE OPERATIONS AND CONTROLS 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: Bucket Replacement

    OPERATION MACHINE OPERATIONS AND CONTROLS BUCKET REPLACEMENT WARNING When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equipment. When the bucket is removed, place it in a stable condition.

  • Page 134: Parking Machine

    OPERATION MACHINE OPERATIONS AND CONTROLS PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. Park the machine on the firm, level ground. Avoid parking the machine on slopes. If it is unavoidably necessary to park the machine on a slope, put blocks under the tracks and dig the work equipment into the ground surface to stop the machine from moving.

  • Page 135: Machine Inspection After Daily Work

    OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS 3. Lower the bucket horizontally until the bottom touches the ground. 4. Lower the blade to the ground. 5. Set lock lever (3) in the LOCK position. REMARK For machines equipped with a cab, there is only a lock lever on the left.

  • Page 136: Locking

    OPERATION MACHINE OPERATIONS AND CONTROLS LOCKING Always lock the following places. (1) Operator'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)".

  • Page 137: Rubber Shoes And Road Liners

    OPERATION MACHINE OPERATIONS AND CONTROLS RUBBER SHOES AND ROAD LINERS (Machine equipped with rubber shoe or road liner) Rubber Shoes and Road Liners Information Rubber shoes and road liner have excellent properties that are not found in steel shoes. However, if they are used in the same way as steel shoes, full use cannot be made of their advantages.
  • Page 138 OPERATION MACHINE OPERATIONS AND CONTROLS Using Rubber Shoes and Road Liners Prohibited Works Do not carry out the following types of work. Carrying out operations and steering on crushed rock, extremely rough hard rock, steel beams, scrap iron, or near the edges of steel plates will cause damage to the rubber shoes and road liners.
  • Page 139 OPERATION MACHINE OPERATIONS AND CONTROLS Always maintain the rubber shoes at the proper tension to prevent them from coming off. If the tension is low, the rubber shoes will come off under the following conditions. Even if the tension is correct, be extremely careful when carrying out operations. 1.
  • Page 140 OPERATION MACHINE OPERATIONS AND CONTROLS Mechanism of rubber shoe coming off track 1) When traveling over an obstacle, a gap is formed between the track roller and the rubber shoe. In this condition, the rubber shoe may come off. 2) Furthermore, if the machine travels in reverse, a gap is formed between the track roller, idler, and rubber shoe.
  • Page 141 OPERATION OPERATION MACHINE OPERATIONS AND CONTROLS MACHINE OPERATIONS AND CONTROLS If the machine is turned in this condition, the rubber shoe will come off. 3 - 89...

  • Page 142: Transportation

    OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure 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.

  • Page 143: Loading And Unloading With Trailer

    OPERATION TRANSPORTATION LOADING AND UNLOADING WITH TRAILER WARNING When loading or unloading, check that travel speed boost monitor (1) is off, and always travel at low speed. If the monitor is on, the speed is set to high-speed travel, so press travel speed selector switch (2).
  • Page 144 OPERATION TRANSPORTATION Loading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Properly apply the brakes on the trailer and put blocks under the tires to ensure that the trailer does not move. Make the slope of the ramps a maximum of 15°.
  • Page 145 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 5. When loading, set the work equipment at the front and the blade at the rear, with the undercarriage and upper structure set parallel. 6. Before moving onto the ramps, make sure that the machine is positioned in a straight line with the ramps and that the centerline of the machine matches that of the trailer.
  • Page 146 OPERATION TRANSPORTATION Securing Machine After placing the machine on the specified position of the trailer, secure it according to the following procedure. NOTICE To prevent damage to the bucket cylinder during transportation, fit a wooden block at one end of the bucket cylinder to prevent it from touching the floor.
  • Page 147 OPERATION TRANSPORTATION Unloading 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Properly apply the brakes on the trailer and put blocks under the tires to ensure that the trailer does not move. Make the slope of the ramps a maximum of 15°.
  • Page 148 OPERATION OPERATION TRANSPORTATION TRANSPORTATION Machine equipped with cab REMARK For machines equipped with a cab, there is only a lock lever 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.

  • Page 149: Lifting Machine

    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 your Komatsu distributor for information. When lifting the machine, carry out the operation on flat ground as follows.
  • Page 150 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 5. Operate the lock lever to the LOCK position (L). REMARK For machines equipped with a cab, there is only a lock lever on the left. 6. Stop the engine, check that there is nothing around the operator's compartment, then get off the machine. For cab specification machines, close the cab door and front glass securely.
  • Page 151 OPERATION OPERATION TRANSPORTATION 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: Cold Weather Operation

    When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.

  • Page 153: Cab Heater In Cold Weather

    OPERATION COLD WEATHER OPERATION Battery WARNING The battery generates flammable gas. Do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.

  • Page 154: After Daily Work Completion

    OPERATION COLD WEATHER OPERATION AFTER DAILY WORK COMPLETION WARNING Performing idle-running of the tracks is dangerous, stay well away from the tracks. To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, observe the following precautions.

  • Page 155: Long Term Storage

    OPERATION LONG TERM STORAGE LONG TERM STORAGE BEFORE STORAGE NOTICE To protect the hydraulic cylinder piston rod while in storage, keep the work equipment in the posture shown at right. (This prevents rust from developing on the piston rod) When keeping in long-term storage (more than one month), store as follows. Clean and wash all parts, then store the machine indoors.

  • Page 156: During Storage

    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.

  • Page 157: Troubles And Actions

    OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS RUNNING OUT OF FUEL When starting the engine after running out of fuel, fill with fuel and bleed the air from the fuel system before starting. For details of bleeding the air, see "Air Bleeding (PAGE 4-50)". PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: When the arm control lever is operated to the IN position and the...

  • Page 158: Towing The Machine

    OPERATION TROUBLES AND ACTIONS TOWING THE MACHINE WARNING When towing the machine, use a wire rope that has ample strength for the weight of the machine that is being towed. Do not apply a sudden load to the wire rope. When the machine is stuck in soft ground and cannot escape under its own power, or when towing a heavy machine, pass the wire rope through the front of the track frame as shown in the...

  • Page 159: Discharged Battery

    OPERATION TROUBLES AND ACTIONS DISCHARGED BATTERY WARNING It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion.
  • Page 160 OPERATION TROUBLES AND ACTIONS Battery Removal and Installation NOTICE After securing the battery, check that it does not move. If it moves, tighten it again securely. Before removing the battery, remove the ground cable (normally connected to the negative (-) terminal). If any tool touches between the positive terminal and the chassis, there is a hazard of sparks being generated.
  • Page 161 OPERATION TROUBLES AND ACTIONS Starting Engine with Booster Cables When starting the engine with a booster cable, do as follows: Connecting and Disconnecting Booster Cables WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, always wear safety glasses.
  • Page 162 OPERATION TROUBLES AND ACTIONS Starting the Engine CAUTION Always check that the lock lever is set to the LOCK position, regardless of whether the machine is working normally or has failed. Check also that all the control levers are at the HOLD or neutral position. 1.

  • Page 163: Other Trouble

    TROUBLES AND ACTIONS OTHER TROUBLE Electrical System ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy...
  • Page 164 OPERATION TROUBLES AND ACTIONS Engine ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure monitor flashes...
  • Page 165 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Exhaust gas occasionally turns Clogging air cleaner element Clean or replace, see WHEN black REQUIRED Defective nozzle ( Replace nozzles) Defective compression ( See defective compression above) Combustion noise occasionally Defective nozzle ( Replace nozzle) makes bresthing sound Abnornal noise generated...
  • Page 166 4 - 1...

  • Page 167: Maintenance

    Komatsu Genuine Replacement Parts Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu Genuine Lubricants Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. Windshield Washer Fluid Use automobile window washer fluid, and be careful not to let any dirt get into it.
  • Page 168 MAINTENANCE MAINTENANCE INFORMATION Clean and replace the fuel filter frequently. Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust. When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting into the oil.

  • Page 169: Outline Of Service

    When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual. Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. This anti-freeze is effective in preventing corrosion of the cooling system.
  • Page 170 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.
  • Page 171 Perform sampling at regular fixed intervals. Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor. Oil and Fuel Storage Keep indoors to prevent any water, dirt, or other impurities from getting in.

  • Page 172: Electric System Maintenance

    Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, before installing a radio receiver or other wireless equipment, contact your Komatsu distributor.

  • Page 173: Wear Parts

    When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor 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.

  • Page 174: Lubricants, Fuel And Coolant Specifications

    MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS *1: ASTM D975 No.1 NOTICE Use only diesel fuel. The engine mounted on this machine employs electronic control and a high-pressure fuel injection device to obtain good fuel consumption and 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.
  • Page 175 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.
  • Page 176 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.) EO10-CD AF-ACL EO30-CD GO90 G2-LI AF-PTL KOMATSU EO10-30CD GO140 G2-LI-S AF-PT(Winter, one EO15-40CD season type) Diesel sigma S super dieselmulti- AGIP Rotra MP GR MU/EP...
  • Page 177 MAINTENANCE MAINTENANCE LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS Engine Oil Anti-freeze [CD or CE] Gear Oil Grease Coolant SAE10W, 30, 40 No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30, 15W40 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type...

  • Page 178: Tightening Torque Specifications

    Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.

  • Page 179: Safety Critical Parts

    To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out periodic maintenance. In addition, to further improve safety, please contact your Komatsu distributor for periodic replacement of parts related to safety and fire prevention in the "SAFETY CRITICAL PARTS LIST".
  • Page 180 MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts will be different. For details, see "MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER (PAGE 4-16)" to confirm the correct maintenance schedule when carrying out maintenance. MAINTENANCE SCHEDULE CHART WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...

  • Page 181: Maintenance Schedule

    MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER For machine equipped with a hydraulic breaker, the hydraulic oil deteriorates faster 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.

  • Page 182: Maintenance Procedure

    MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury.
  • Page 183 MAINTENANCE MAINTENANCE PROCEDURE Air Cleaner Element - Clean/Replace 1. Open the engine rear cover and cooling cover. For details, see "COOLING COVER (PAGE 3-29)". 2. Remove clips (2), then remove dust cup (3). PC27MR PC35MR 3. Take out element (4) and cover the air connector at the end of the air cleaner body with a clean cloth or tape.
  • Page 184 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 6. If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning, replace the element. NOTICE When cleaning the element, do not hit it or beat it against something. Do not use an element whose folds or gasket or seal are damaged.

  • Page 185: Clean Inside Of Cooling System

    Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
  • Page 186 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 supply must be used, please consult your Komatsu distributor.
  • Page 187 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 4. Place a container to catch the coolant under the drain hose installed to drain valve (2) and under coolant drain plug (3) on the engine block. 5. Open drain valve (2) and drain the water. Remove drain plug (3) from the engine cylinder block and drain the water.
  • Page 188 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE 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: Check Level Of Battery Electrolyte

    If distilled water is added to above the U.L. line, use a syringe to lower the level to the U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4 - 24...
  • Page 190 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 removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. When It is Possible to Use Indicator to Check Electrolyte Level If it is possible to use an indicator to check the electrolyte level, follow the instructions given.

  • Page 191: Clean Water Separator Element

    MAINTENANCE MAINTENANCE PROCEDURE CLEAN WATER SEPARATOR ELEMENT WARNING Do not bring any fire or flame close. Prepare a filter wrench Prepare a container to catch the fuel that is drained. 1. Open the engine rear cover. 2. Set handle (1) of the water separator to CLOSED position (A). 3.

  • Page 192: Check And Tighten Track Shoe Bolts (Machine Equipped With Road Liner, Steel Shoe)

    MAINTENANCE MAINTENANCE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS (Machine equipped with road liner) If the machine is used with track shoe bolts (1) loose, they will break, so tighten any 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.

  • Page 193: Check And Adjust Track Tension (Machine Equipped With Road Liner, Steel Shoe)

    Never loosen plug (1) more than 1 turn. Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened with the procedure given here, please contact your Komatsu distributor. 4 - 28...
  • Page 194 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.

  • Page 195: Check, Rubber Shoes Or Road Liners (Machine Equipped With Rubber Shoes, Road Liner)

    (Machine equipped with rubber shoes, road liner) If the rubber shoes or road liner are in the following condition, they must be repaired or replaced, so please contact your Komatsu distributor for repairs or replacement. Lug Height If lug height "a" is reduced by wear, the drawbar pull will drop.
  • Page 196 If the length is less than 30 mm (1.18 in) or the depth of the crack is less than 10 mm (0.39 in), there is no particular need to carry out repairs. When making judgement whether to replace, repair, or continue using rubber shoe and load liner, please contact your Komatsu distributor. 4 - 31...

  • Page 197: Check And Adjust Rubber Shoe Tension (Machine Equipped With Rubber Shoes)

    When loosening plug (1), never loosen it more than one turn. Never loosen any part other than plug (1). Never put your face in line with the mount of plug (1). If the Rubber shoe tension is not relieved by this procedure, please contact your Komatsu distributor. 4 - 32...
  • Page 198 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.

  • Page 199: Replace Rubber Shoes (Machine Equipped With Rubber Shoes)

    It is extremely dangerous to release the grease by any method except the procedure given below. If the rubber shoe tension is not relieved by this procedure, please contact your Komatsu distributor for repairs. Check that all the grease has been released before rotating the sprocket to remove the rubber shoe.
  • Page 200 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 2. Loosen plug (1) gradually to release the grease. 3. When loosening plug (1), turn it a maximum of one turn. 4. Fit the steel pipes inside the 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.

  • Page 201: Replace Road Liners (Machine Equipped With Road Liner)

    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 replacing only part of the road liner, use the special road liner removal tool. Please order the tool from your Komatsu distributor.

  • Page 202: Replace Bucket Teeth

    MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, stop the engine, then set the lock lever securely to the LOCK position (L). The pin is knocked out by force, so there is danger of the pin flying out.
  • Page 203 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE The rubber of the rubber pin lock is torn, and the steel balls may come out. The steel balls are buried when they are pressed by hand. 4. Clean the surface of adapter (4) and remove the soil with a knife. 5.
  • Page 204 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 8. Insert lock pin (2) in the hole of the teeth and hit it until its top is the same level as the surface of teeth (1). 9. After replacing a bucket tooth, always check the following. 1) After the lock pin has been knocked in completely, check that it is secured by the point and surface.

  • Page 205: Check Window Washer Fluid Level, Add Fluid

    MAINTENANCE MAINTENANCE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (Machine equipped with cab) If there is air in the window washer fluid, check the level of the fluid in window washer tank. Add automobile window washer fluid if necessary. REMARK Open the engine rear cover and cooling cover.

  • Page 206: Check, Clean And Lubricate Cab Slide Door Rail And Roller

    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...

  • Page 207: Bleeding Air From Hydraulic System

    MAINTENANCE MAINTENANCE PROCEDURE BLEEDING AIR FROM HYDRAULIC SYSTEM NOTICE If the pump is operated without filling the pump case with hydraulic oil, there is danger that the pump may be prematurely damaged. Be sure to bleed the air completely. 1. Bleeding air from piston pump 1) Remove bolts (1) (M10 x 3), then remove triangular cover (2).
  • Page 208 MAINTENANCE MAINTENANCE PROCEDURE 3. Bleeding air from cylinders NOTICE If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder may cause damage to the piston packing. 1) Run the engine at low idle, and extend and retract each cylinder 4 to 5 times, taking care that a cylinder is not moved to the end of its stroke.

  • Page 209: Check Before Starting

    MAINTENANCE MAINTENANCE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "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...

  • Page 210: Every 500 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 500 HOURS MAINTENANCE LUBRICATING Lubricating Swing Components WARNING When lubricating the swing circle and the swing pinion, do not swing the upper structure while carrying out the lubricating. NOTICE For the first 100 hours on new machines where the parts are settling in, carry out greasing every 10 hours. Prepare a grease gun 1.
  • Page 211 MAINTENANCE MAINTENANCE PROCEDURE Lubricating Work Equipment NOTICE When breaking in a new machine, carry out lubrication every 10 hours for the first 100 hours of operation. If any abnormal sound comes from the greasing point, carry out greasing regardless of the inspection and maintenance interval.
  • Page 212 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE 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: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge

    2. Remove drain plug (P) slowly to avoid getting oil on yourself, 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).

  • Page 214: Replace Fuel Filter Cartridge

    MAINTENANCE MAINTENANCE PROCEDURE REPLACE FUEL FILTER CARTRIDGE WARNING The engine is at high temperature immediately after the machine has been operated. Wait for the engine to cool down before replacing the filter. Do not bring fire or sparks near the fuel. Prepare a filter wrench Prepare for cloth.
  • Page 215 MAINTENANCE MAINTENANCE PROCEDURE Air Bleeding 1. Fill the fuel tank with fuel. 2. Set handle (1) of the water separator to OPEN position (B). 3. Loosen air bleed bolt (2) of the water separator 2 or 3 turns. 4. When no more bubbles come out with the fuel from air bleed bolt (2), tighten air bleed bolt (2).

  • Page 216: Check Oil Level In Final Drive Case, Add Oil

    MAINTENANCE MAINTENANCE PROCEDURE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING The parts and oil are at high temperature immediately 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.

  • Page 217: Clean And Inspect Radiator Fins And Oil Cooler Fins

    MAINTENANCE MAINTENANCE PROCEDURE CLEAN AND INSPECT RADIATOR FINS AND OIL COOLER FINS WARNING If compressed air, high-pressure water, or steam hit your body directly, or they cause dirt or dust to be blown up, there is a hazard of serious injury. Always use safety glasses, dust mask, or other protective equipment. NOTICE When use the compressed air, keep a distance from air nozzle, to prevents damage to the fins.

  • Page 218: Check And Adjust Cooling Fan Belt Tension

    6. 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. 7. If the belt is stretched, leaving no allowance for adjustment, or if it is cut or cracked, contact your Komatsu distributor for replacement.

  • Page 219: Every 1000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE Carry out the maintenance for EVERY 500 HOURS SERVICE at the same time. REPLACE HYDRAULIC OIL FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.

  • Page 220: Change Oil In Final Drive Case

    6. When oil comes out from the hole of plug (G), install plug (G). CHECK ENGINE VALVE CLEARANCE, ADJUST As special tools is required for removing and adjusting the parts, you should request service from your Komatsu distributor. 4 - 55...

  • Page 221: Every 2000 Hours Maintenance

    Before starting the operation to open the floor, read the precautions in "CAUTIONS FOR OPENING (TILTING) FLOOR (PAGE 2-34)" in the safety and maintenance sections thoroughly, and refer to the explanation for each part in "METHOD OF OPENING (TILTING) FLOOR (PAGE 3-31)" when carrying out the operation. Or ask your Komatsu distributor to carry out the maintenance.
  • Page 222 MAINTENANCE MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE 5. Open dust cover (1) fully until it is secured 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)") 6.

  • Page 223: Check Alternator, Starting Motor

    MAINTENANCE PROCEDURE 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.
  • Page 224 5 - 1...

  • Page 225: Specifications

    3,740 (8,247) Operating kg (lb) Weight Cab specified 2,955 (6,516) 3,915 (8,633) Bucket capacity (cu.yd) 0.08 (0.10) 0.11 (0.14) Komatsu Komatsu Name of engine 3D82AE-5M 3D88E-5P diesel engine diesel engine Engine horsepower kW (HP)/rpm 19 (26)/2,600 21.7 (29.1)/2,400 A Overall length mm (ft in) 4,320 (14' 2")
  • Page 226 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC27MR-2 PC35MR-2 A Max. digging reach mm (ft in) 4,700 (15' 5") 5,360 (17' 7") B Max. digging depth mm (ft in) 2,650 (8' 8") 3,170 (10' 5") Canopy specified mm (ft in) 4,500 (14' 9") 5,010 (16' 5") C Max.
  • Page 227 6 - 1...

  • Page 228: Attachments And Options

    ATTACHMENTS AND OPTIONS - GENERAL INFORMATION SAFETY FIRST If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distributor first.

  • Page 229: Attachment Installation

    If the correct procedure is not used when installing the boom and arm, it may lead to serious damage. Please consult your Komatsu distributor. When long work equipment is installed, the working range will suddenly become larger, so there is danger of mistaking the distance and hitting other objects.

  • Page 230: Bucket With Hook

    It is prohibited to swing or offset the boom when carrying out lifting operations. Set the boom facing the center. If a hook is to be installed, please consult your Komatsu distributor. 6 - 4...

  • Page 231: Air Conditioner

    ATTACHMENTS AND OPTIONS AIR CONDITIONER AIR CONDITIONER CONTROL PANEL AND COMPONENTS Temperature control switch FRESH/RECIRC selector lever Air flow selector switch Vent Air conditioner switch 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;...

  • Page 232: Air Conditioner Controls

    ATTACHMENTS AND OPTIONS AIR CONDITIONER Air Conditioner Switch This switch (3) is used as the ON/OFF switch for the air conditioner. Each time this switch is pressed, it switches between ON and OFF. When the switch is ON, the lamp inside the switch lights up. FRESH/RECIRC Selector Lever Use this lever (4) to switch between recirculation of the air inside the cab and intake of fresh air from outside.

  • Page 233: Air Conditioner Maintenance

    Colorless, transparent: 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.
  • Page 234 ATTACHMENTS AND OPTIONS AIR CONDITIONER Every 250 Hours Maintenance CHECK AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION Checking The belt should deflect 5 to 6 mm (0.197 to 0.236 in) when pressed with a finger force of approx. 58.8 N (6 kgf) at a point midway between the idle pulley and compressor pulley.
  • Page 235 ATTACHMENTS AND OPTIONS AIR CONDITIONER Every 500 Hours Maintenance Clean Air Conditioner Condenser WARNING If compressed air, high-pressure water, or steam hit your body directly, or they cause dirt or dust to be blown up, there is a hazard of serious injury. Always use safety glasses, dust mask, or other protective equipment. NOTICE When using compressed air, keep the air nozzle at a distance to prevent damage to the fins.
  • Page 236 ATTACHMENTS AND OPTIONS AIR CONDITIONER Clean Air Conditioner FRESH 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 protective equipment. NOTICE As a guideline, the filters should be cleaned every 500 hours, but on dusty jobsites, clean the filters more frequently. If the air conditioner has been used, the air filter should be cleaned.

  • Page 237: Windshield Washer

    ATTACHMENTS AND OPTIONS WINDSHIELD WASHER WINDSHIELD WASHER (Machine equipped with operator's cab) If the windshield washer is installed, operate it according to the following procedure. WINDSHIELD WASHER OPERATION Wiper and window washer When the wiper is working and the switch is kept pushed to position (B), washer fluid is sprayed out.

  • Page 238: Machine Ready For Attachment

    ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT MACHINE READY FOR ATTACHMENT LOCATIONS Quick coupler Attachment control pedal Selector valve Attachment lock cover Quick Coupler This quick coupler (1) is used to connect the piping equipped with quick coupler at the attachment end. The following products are used for the quick coupler.
  • Page 239 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Selector Valve This valve (2) switches the flow of hydraulic oil. Position (a): When using breaker Turn spool (A) to the left until it is stopped by the stopper. Position (b): When using general attachment Turn spool (A) to the right until it is stopped by the stopper.

  • Page 240: Hydraulic Circuit

    Right side of arm (shaft side): PC27MR G1/2 PC35MR G3/4 REMARK If the quick coupler size does not match, please contact your Komatsu distributor. NOTICE When connecting the piping, operate the bucket fully to the dump position and be careful not to interfere with link (a).
  • Page 241 ATTACHMENTS AND OPTIONS MACHINE READY FOR ATTACHMENT Bleeding Air After connecting the piping, bleed the air from the circuit. 1. Starting engine Start the engine according to "STARTING ENGINE (PAGE 3-54)" keep running the engine at low idle for 10 minutes, and carry out the following procedure.

  • Page 242: Attachment Operations

    When Using Breaker Depress the bottom of the pedal to operate the breaker. REMARK If it is necessary to adjust the oil flow, 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).

  • Page 243: Long Term Storage

    Bottom of pedal depressed: Oil flows to left side of arm (operator's seat side). REMARK If it is necessary to adjust the oil flow, please ask your Komatsu distributor to carry out the adjustment. Precautions when Using Check that selector valve (1) is at the 2 WAY (crusher or other attachment) position (b).

  • Page 244: Changing Machine Control Pattern (If Pattern Change Valve Equipped)

    ATTACHMENTS AND OPTIONS CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) WARNING When changing the operating pattern of the machine, set the machine in the parking posture, stop the engine, check that the lock lever is at the LOCK position, then change the operating pattern.

  • Page 245: Machine Control Patterns

    ATTACHMENTS AND OPTIONS CHANGING 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: Power Angle Blade

    ATTACHMENTS AND OPTIONS POWER ANGLE BLADE POWER ANGLE BLADE (PC35MR) With this blade, the angle and lift operations can be carried out with the blade control lever. 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...

  • Page 247: When Required

    ATTACHMENTS AND OPTIONS POWER ANGLE BLADE WHEN REQUIRED Lubricating Carry out greasing if the work equipment has been removed or repaired. Carry out greasing also if any abnormal noise is heard from the pin portion when carrying out the angling operation. 1.

  • Page 248: Wear Parts List

    ATTACHMENTS AND OPTIONS POWER ANGLE BLADE WEAR PARTS LIST Part No. Part Name Q'ty 20S-910-3131 Cutting edge (02090-10840) (Bolt) (02290-10813) (Nut) 20U-910-1980 End bit (02090-10840) (Bolt) (02090-10813) (Nut) SPECIFICATIONS Blade (width x height) 1770 mm x 380 mm (69.7 in x 15.0 in) Rubber shoes 390 mm (15.4 in) RAISE amount...

  • Page 249: Attachment Guide

    WARNING Please read the instruction manual for the attachment and the sections of this manual related to attachments and options. When installing any attachment or option, there may be problems with safety, so please contact your Komatsu distributor before installing.

  • Page 250: Recommended Attachment Operations

    Select the optimum model of attachment for a hydraulic excavator on which it is to be mounted. Depending on machine models of hydraulic excavator, the kind of attachments or the model of specific attachments that can be mounted will vary. Hence, consult your Komatsu distributor for the selection of optimum attachments. HYDRAULIC BREAKER...
  • Page 251 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS RECOMMENDED ATTACHMENT OPERATIONS When applying continuous impact to the same impact surface, if the chisel does not penetrate or break the surface within 1 minute, change the point of impact and carry out breaking operations closer to the edge.
  • Page 252 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Prohibited Works To ensure that the machine has a long life, and to ensure that operations are carried out in safety, 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...
  • Page 253 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS 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 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Greasing Supply grease in the correct position. 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.
  • Page 255 7 - 1...

  • Page 256: High-Altitude Specification Machine

    HIGH-ALTITUDE SPECIFICATION MACHINE The high-altitude specification is available only for the PC35MR. LOCATIONS Fuse NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.

  • Page 257: Maintenance Procedure

    HIGH-ALTITUDE SPECIFICATION MACHINE MAINTENANCE 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: Specifications

    Unit PC35MR-2 Operating Weight kg (lb) 3,930 (8,666) Bucket capacity (cu.yd) 0.11 (0.14) Name of engine Komatsu S3D84E-5PBA diesel engine Engine horsepower kW (HP)/rpm 23.9 (32.5)/2,400 Overall length mm (ft in) 4,850 (15' 11") Overall height mm (ft in) 2,530 (8' 4")

  • Page 259: Index

    INDEX INDEX <A> Engine, Stopping the 3- 61 Air Conditioner Escape from Mud 3- 78 Air Conditioner Controls Every 500 Hours Service 6- 21 Air Conditioner Maintenance Control Panel and Components <F> Ashtray 3- 38 Foreword Attachment Guide 6- 23 Fuse 3- 36 Attachment Combinations...
  • Page 260 INDEX Every 500 Hours 4- 45 Sliding Door 3- 26 Every 1000 Hours 4- 54 Sliding Window 3- 26 Every 2000 Hours 4- 56 Specifications When Required 4- 17 Specifications 6- 22 MAINTENANCE PROCEDURE SPECIFICATIONS EVERY 2000 HOURS MAINTENANCE Swinging 3- 69 Maintenance Schedule 4- 15...
  • Page 261 PC27MR-2, PC35MR-2 GALEO HYDRAULIC EXCAVATOR Form No. TEN00115-00 © 2005 KOMATSU All Rights Reserved Printed in Japan 06-05...

This manual is also suitable for:

Galeo pc35mr-2

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