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GALEO PC20MR-2
Komatsu Utility GALEO PC20MR-2 User Manual
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Operation & Maintenance
Manual
WEAM007000
Unsaf
e
use
of
this
machine
ma
y
cause
serious
injur
y
or
death.
Operators
and
maintenance
personnel
must
read
this
manual
before
operating
or
maintaining
this
machine.
This
man
ual
should
be
k
ept
inside
the
cab
f
or
ref
erence
and
periodically re
viewed
b
y
all
personnel
who
will
come
into
contact
with
the
machine.
WARNING
PC20MR
-2
HYDRAULIC EXCA
V
A
TOR
SERIAL NUMBER
PC20MR
-2
15001
and
up
2
Table of Contents
Foreword 1.1 Foreword
3
Information on Safety
4
Introduction
6
Intended Uses
6
Improper or Unauthorized Uses
6
Main Characteristics
6
Running-In
7
Directions of Machine
7
Product Identification
8
Machine Serial Number
8
Machine Identification Plate and Product Identification Number (Pin)
8
Engine Serial Number and Exhaust Gas Emission Plate
9
Travel Reduction Gear Serial Number
9
Swing Reduction Gear Serial Number
10
Cab Serial Number
10
Serial Numbers and Dealer's Address
11
Table of Contents
12
Safety and Accident Prevention
19
Safety, Noise and Vibration Plates
20
Position of the Safety Plates
20
Pictograms and Relevant Meanings
21
Position of the Noise Plates on Machines with Cab
26
Position of the Noise Plates on Machines with Canopy
27
Vibrations to Which the Operator Is Subjected
27
General Precautions
28
General Safety Rules
28
Safety Devices and Guards
28
Clothing and Personal Protection Items
28
Unauthorized Modifications
29
Leaving the Operator's Seat
29
Getting on and off the Machine
30
Preventing Fires Due to Fuel and Oil
31
Preventing Burns
31
Preventing Damage Due to Asbestos Powder
32
Preventing Damage Caused by the Work Equipment
32
Fire Extinguishers and First Aid Kit
33
Precautions Concerning the Cab Structure
33
Precautions Concerning the Equipment
33
Precautions to be Taken before Starting the Engine
34
Safety on the Work Site
34
Fire Prevention
34
Precautions to be Taken for the Operator's Cab
34
Room Ventilation
35
Precautions to be Taken for the Lights
35
Cleaning the Windows - Checking the Windshield Wiper Blades
35
Precautions to be Taken When Working
36
Starting the Engine
36
Check the Direction before Starting the Machine
36
Checks for Travelling in Reverse
37
Moving the Machine
37
Moving on Slopes
38
Working on Slopes
39
Unauthorized Operations
39
Preventing Electrocution
41
Visibility
41
Working on Icy or Snow-Covered Surfaces
41
Preventing Damage Caused by the Work Equipment
42
Working on Loose Ground
42
Parking the Machine
42
Transporting the Machine on Motor Vehicles
43
Loading and Unloading
43
Transport
43
Battery
44
Preventing Risks that May be Due to the Battery
44
Starting with Booster Cables
44
Precautions for the Removal
45
Precautions for Maintenance
46
Warning Plates
46
Tools
46
Personnel
46
Equipment
47
Working under the Machine
47
Cleaning the Machine
47
Use of the Engine During Maintenance Operations
48
Periodical Change of the Parts that Are Critical for Safety
48
Stop the Engine before Carrying out any Maintenance Operation or Inspection
48
Rules to be Followed During Fuel or Oil Topping up
49
Checking the Coolant Level in the Radiator
49
Using Lamps
49
Precautions Concerning the Battery and the Alternator
50
Precautions Concerning the Starter
50
Handling High-Pressure Pipes
50
Precautions to be Taken When Handling High-Pressure Oil
51
Precautions for Maintenance Operations at High Temperatures and High Pressure
51
Precautions to be Taken When Using High-Pressure Grease to Adjust the Track Tension
52
Do Not Remove the Shock Absorbing Spring from the Shock Absorber Unit
52
Hydraulic Accumulator
52
Cooling Fan and Belt
53
Waste Materials
53
Compressed Air
53
PRECAUTIONS for the USE of the Synthetic Biodegradable Oil Type HEES
53
The Machine and Its Operations
55
Machine View Illustrations
56
Overall Machine View
56
Controls and Gauges
57
Detailed Controls and Gauges
58
Monitoring System
58
Emergency Monitors
59
Meter Display Portion
61
Pilot Lamps
63
Monitor Switches Portion
64
Switches
66
Control Levers and Pedals
69
WINDSHIELD (Machines Equipped with Cab)
76
SLIDING DOOR (Machines Equipped with Cab)
80
SLIDING WINDOW (Machines Equipped with Cab)
80
EMERGENCY ESCAPE HAMMER (Machines Equipped with Cab)
81
Caps and Covers with Lock
82
Engine Rear Cover
83
Cooling Cover
84
Tank Cover
85
Method of Opening (Tilting) Floor
86
Fuse
90
Block Fuse
90
Operation Manual Storage
91
Tool Box
91
Grease Gun Holder
91
ASHTRAY (Machines Equipped with Cab)
91
Machine Operations and Controls
92
Before Starting Engine
92
Walk-Around Checks
92
Checks before Starting
94
Adjustment
100
Operations before Starting Engine
103
Starting Engine
105
After Starting Engine
108
Breaking-In the New Machine
108
Warming-Up Operation
108
Stopping the Engine
110
Machine Operation
111
Preparations for Moving the Machine off
111
Moving Machine Forward
111
Moving Machine Backward
113
Stopping Machine
114
Steering the Machine
115
Steering
115
Swinging
117
Work Equipment Controls and Operations
118
Prohibited Operations
120
General Operation Information
122
Traveling on Slopes
124
Escape from Mud
126
Work Possible Using Compact Hydraulic Excavator
127
Changing the Bucket
129
Parking Machine
130
Check after Shut off Engine
131
Machine Inspection after Daily Work
131
Locking
131
RUBBER SHOES (Machines Equipped Only with Rubber Shoes)
132
Optimal Use of the Rubber Shoes
132
Rubber Shoe Warranty
132
Using the Rubber Shoes
132
Transportation
136
Transportation Procedure
136
Loading and Unloading with Trailer
136
Lifting Machine
142
Cold Weather Operation
144
Cold Weather Operation Information
144
Fuel and Lubricants
144
Cooling System Coolant
144
Battery
145
CAB HEATER in COLD WEATHER (Machines Equipped with Cab)
145
After Daily Work Completion
146
After Cold Weather Season
146
Long Term Storage
147
Before Storage
147
During Storage
147
After Storage
147
Troubles and Actions
148
Running out of Fuel
148
Phenomena that Are Not Failures
148
Towing the Machine
148
Severe Job Condition
149
Discharged Battery
149
Battery Removal and Installation
150
Battery Charges
150
Starting Engine with Booster Cables
151
Other Trouble
153
Electrical System
153
Chassis
154
Engine
154
Maintenance
157
Maintenance Information
158
Lubricants, Coolant and Filters
161
Handling Oil, Fuel, Coolant, and Performing Oil Clinic
161
Oil
161
Fuel
161
Cooling System Coolant
162
Grease
162
Carrying out Kowa (Komatsu Oil Wear Analysis)
163
Oil and Fuel Storage
164
Filters
164
Electric System Maintenance
165
Handling Hydraulic System
165
Wear Parts
166
Wear Parts List
166
Lubricants, Fuel and Coolant Specifications
167
Homologated Hees Synthetic Biodegradable Lubricants
171
Tightening Torque Specifications
172
Tightening Torque List
172
Lubrication
173
Lubrication Diagram
173
Safety Critical Parts
174
Safety Critical Parts List
174
Maintenance Schedule
175
Maintenance Schedule Chart
175
Maintenance Interval for Hydraulic Breaker
176
Changing the Hydraulic Oil Filter
176
Changing the Hydraulic Oil
176
Maintenance Procedure
177
When Required
177
Check, Clean and Replace Air Cleaner Element
177
Clean Inside of Cooling System
179
Check Level of Battery Electrolyte
182
Cleaning the Fuel Filter (with Water Separator)
184
Drain Water and Sediment from Fuel Tank
184
CHECK and ADJUST TRACK TENSION (Machines Equipped with Steel Shoes)
185
CHECKING the RUBBER SHOES (Machines Equipped with Rubber Shoes)
187
CHECK and ADJUST RUBBER SHOE TENSION (Machine Equipped with Rubber Shoes)
189
REPLACE RUBBER SHOES (Machine Equipped with Rubber Shoes)
191
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (Machine Equipped with Cab)
193
CHECK, CLEAN and LUBRICATE CAB SLIDE DOOR RAIL and ROLLER (Machine Equipped with Cab)
194
Bleeding Air from Hydraulic System
194
Check before Starting
195
Checks before Starting
195
Every 500 Hours Maintenance
196
Lubricating
196
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge
198
Changing the Fuel Filter Element (with Water Separator)
199
Check Oil Level in Final Drive Case, Add Oil
200
Replace Feed Pump Pre-Filter
201
Clean and Inspect Radiator Fins and Oil Cooler Fins
201
Check and Adjust Cooling Fan Belt Tension
202
Every 1000 Hours Maintenance
203
Changing the Hydraulic Oil Filter Element
203
Change Oil in Final Drive Case
204
Check Engine Valve Clearance, Adjust
204
Every 2000 Hours Maintenance
205
Change Oil in Hydraulic Tank, Clean Strainer
205
Check Alternator, Starting Motor
206
Technical Specifications
207
Specifications
208
Lifting Capacities
210
Lifting Capacities (with Canopy)
210
Lifting Capacities (with Cabin)
213
Authorized Optional Equipment
217
Attachments and Options - General Information
218
Safety First
218
Attachment Installation
219
Characteristics of the Optional Equipment
220
Machine Ready for Attachment
221
Locations
221
Hydraulic Circuit
223
Assemblying and Connecting the Equipment
223
Maintenance
224
Bleeding Air
224
Attachment Operations
225
Long Term Storage
226
Specifications
226
Attachment Guide
227
Attachment Combinations
227
Recommended Attachment Operations
228
Hydraulic Breaker
228
4
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Komatsu Utility GALEO PC20MR-2 Specifications
General
Brand
Komatsu Utility
Model
GALEO PC20MR-2
Category
Industrial Equipment
Language
English
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