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KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:1001 & UP) – PDF DOWNLOAD
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- KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual
- SERIAL NUMBER:1001 & UP
- PUBLICATION NUMBER:TEN00032-00
(Replaces SEAM052501T)
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Description
KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:1001 & UP)
KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:1001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:1001 & UP)
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
TABLE OF CONTENTS:
KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:1001 & UP)
MAIN MENU........................................................................ 0 COVER............................................................................ 1 FOREWORD......................................................................... 2 FOREWORD..................................................................... 3 SAFETY INFORMATION........................................................... 6 INTRODUCTION................................................................. 8 DIRECTIONS OF MACHINE.................................................... 8 PRODUCT INFORMATION.......................................................... 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE............. 9 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION.............................. 9 EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION...................... 10 SERVICE METER LOCATION................................................... 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR.............................. 11 CONTENTS......................................................................... 12 SAFETY........................................................................... 16 SAFETY INFORMATION........................................................... 17 SAFETY LABELS................................................................ 19 LOCATION OF SAFETY LABELS................................................ 20 SAFETY LABELS............................................................ 21 SAFETY INFORMATION........................................................... 28 SAFETY RULES............................................................. 28 IF ABNORMALITIES ARE FOUND............................................... 28 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS............................... 28 FIRE EXTINGUISHER AND FIRST AID KIT...................................... 28 SAFETY EQUIPMENT......................................................... 28 KEEP MACHINE CLEAN....................................................... 29 KEEP OPERATOR'S COMPARTMENT CLEAN........................................ 29 LEAVING OPERATOR'S SEAT WITH LOCK........................................ 29 HANDRAILS AND STEPS...................................................... 30 MOUNTING AND DISMOUNTING................................................. 30 NO PERSONS ON ATTACHMENTS................................................ 30 DO NOT GET CAUGHT IN ARTICULATED PORTION................................. 30 BURN PREVENTION.......................................................... 31 FIRE PREVENTION AND EXPLOSION PREVENTION................................. 31 ACTION IF FIRE OCCURS.................................................... 32 WINDSHIELD WASHER FLUID.................................................. 32 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION......... 32 ATTACHMENT INSTALLATION.................................................. 33 ATTACHMENT COMBINATIONS.................................................. 33 CAB WINDOW GLASSES....................................................... 33 UNAUTHORIZED MODIFICATIONS............................................... 33 SAFETY AT JOBSITE........................................................ 33 WORKING ON LOOSE GROUND.................................................. 34 DISTANCE TO HIGH VOLTAGE CABLES.......................................... 34 ENSURE GOOD VISIBILITY................................................... 34 VENTILATION FOR ENCLOSED AREA............................................ 35 SIGNALMAN'S SIGNAL AND SIGNS............................................. 35 EMERGENCY EXIT FROM OPERATOR'S CAB....................................... 35 ASBESTOS DUST HAZARD PREVENTION.......................................... 35 SAFETY MACHINE OPERATION..................................................... 36 STARTING ENGINE.......................................................... 36 CHECKS BEFORE STARTING ENGINE........................................ 36 SAFETY RULES FOR STARTING ENGINE..................................... 37 STARTING ENGINE IN COLD WEATHER...................................... 37 OPERATION................................................................ 38 CHECKS BEFORE OPERATION.............................................. 38 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS......................... 38 SAFETY RULES FOR TRAVELING........................................... 39 TRAVELING ON SLOPES.................................................. 40 OPERATIONS ON SLOPES................................................. 41 PROHIBITED OPERATIONS................................................ 41 OPERATIONS ON SNOW................................................... 42 PARKING MACHINE...................................................... 43 TRANSPORTATION........................................................... 44 LOADING AND UNLOADING................................................ 44 SHIPPING THE MACHINE................................................. 44 BATTERY.................................................................. 45 BATTERY HAZARD PREVENTION............................................ 45 STARTING ENGINE WITH BOOSTER CABLES.................................. 46 TOWING................................................................... 47 SAFETY RULES FOR TOWING.............................................. 47 LIFTING OBJECTS WITH BUCKET.............................................. 48 SAFETY RULES FOR LIFTING OBJECTS..................................... 48 SAFETY MAINTENANCE INFORMATION............................................... 49 WARNING TAG.............................................................. 49 KEEP WORK PLACE CLEAN AND TIDY........................................... 49 APPOINT LEADER WHEN WORKING WITH OTHERS.................................. 49 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.............................. 49 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....................... 50 PROPER TOOLS............................................................. 51 ACCUMULATOR.............................................................. 51 PERSONNEL................................................................ 51 ATTACHMENTS.............................................................. 51 WORK UNDER THE MACHINE................................................... 52 NOISE.................................................................... 52 WHEN USING HAMMER........................................................ 52 WELDING WORKS............................................................ 52 REMOVING BATTERY TERMINALS............................................... 52 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION..... 53 DO NOT DISASSEMBLE RECOIL SPRINGS........................................ 53 SAFETY RULES FOR HIGH-PRESSURE OIL....................................... 53 SAFETY HANDLING HIGH-PRESSURE HOSES...................................... 53 WASTE MATERIALS.......................................................... 54 AIR CONDITIONER MAINTENANCE.............................................. 54 COMPRESSED AIR........................................................... 54 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................ 54 OPERATION........................................................................ 56 MACHINE VIEW ILLUSTRATIONS................................................... 57 OVERALL MACHINE VIEW..................................................... 57 CONTROLS AND GAUGES...................................................... 58 DETAILED CONTROLS AND GAUGES................................................. 59 MONITORING SYSTEM........................................................ 59 SWITCHES................................................................. 70 CONTROL LEVERS AND PEDALS................................................ 75 SUN ROOF................................................................. 81 WINDSHIELD............................................................... 82 SLIDING DOOR............................................................. 87 EMERGENCY ESCAPE HAMMER.................................................. 87 CAP WITH LOCK............................................................ 89 ENGINE HOOD.............................................................. 90 MUD COVER................................................................ 91 BATTERY INSPECTION COVER................................................. 92 FUSE..................................................................... 93 FUSIBLE LINK............................................................. 94 AUXILIARY ELECTRIC POWER................................................. 94 CONTROLLERS.............................................................. 94 AIR CONDITIONER CONTROLS................................................. 95 HEATER AND DEFROSTER CONTROLS............................................101 RADIO....................................................................106 OPERATION MANUAL STORAGE.................................................111 TOOL BOX.................................................................111 GREASE PUMP HOLDER.......................................................111 ASHTRAY..................................................................111 FIRE EXTINGUISHER........................................................112 MACHINE OPERATIONS AND CONTROLS..............................................113 BEFORE STARTING ENGINE...................................................113 STARTING ENGINE..........................................................129 AFTER STARTING ENGINE....................................................134 STOPPING THE ENGINE......................................................137 CHECK AFTER SHUT OFF ENGINE..............................................137 MACHINE OPERATION........................................................138 STEERING THE MACHINE.....................................................142 SWINGING.................................................................144 WORK EQUIPMENT CONTROLS AND OPERATIONS...................................145 WORKING MODE.............................................................147 PROHIBITED OPERATIONS....................................................148 GENERAL OPERATION INFORMATION............................................150 TRAVELING ON SLOPES......................................................152 ESCAPE FROM MUD..........................................................154 RECOMMENDED APPLICATIONS.................................................155 MACHINE READY FOR ATTACHMENT.............................................157 BUCKET REPLACEMENT AND INVERSION.........................................163 PARKING MACHINE..........................................................165 MACHINE INSPECTION AFTER DAILY WORK......................................166 LOCKING..................................................................166 ROAD LINERS AND RUBBER SHOES.............................................167 TRANSPORTATION...............................................................172 TRANSPORTATION PROCEDURE.................................................172 LOADING AND UNLOADING WITH TRAILER.......................................172 LIFTING MACHINE..........................................................178 COLD WEATHER OPERATION.......................................................180 COLD WEATHER OPERATION INFORMATION.......................................180 AFTER DAILY WORK COMPLETION..............................................182 AFTER COLD WEATHER SEASON................................................182 LONG TERM STORAGE............................................................183 BEFORE STORAGE...........................................................183 DURING STORAGE...........................................................183 AFTER STORAGE............................................................183 TROUBLES AND ACTIONS.........................................................184 RUNNING OUT OF FUEL......................................................184 PHENOMENA THAT ARE NOT FAILURES..........................................184 TOWING THE MACHINE.......................................................185 SEVERE JOB CONDITION.....................................................185 DISCHARGED BATTERY.......................................................186 HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY.........191 OTHER TROUBLE............................................................192 MAINTENANCE......................................................................198 MAINTENANCE INFORMATION......................................................199 OUTLINE OF SERVICE...........................................................201 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...................201 ELECTRIC SYSTEM MAINTENANCE..............................................204 WEAR PARTS...................................................................205 WEAR PARTS LIST..........................................................205 RECOMMENDED FUEL, COOLANT, AND LUBRICANT.....................................206 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....207 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN..........208 TIGHTENING TORQUE SPECIFICATIONS.............................................209 TIGHTENING TORQUE LIST...................................................209 SAFETY CRITICAL PARTS........................................................210 SAFETY CRITICAL PARTS LIST...............................................210 MAINTENANCE SCHEDULE.........................................................211 MAINTENANCE SCHEDULE CHART...............................................211 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...............................212 MAINTENANCE PROCEDURE........................................................213 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...........213 REPLACE FUEL FILTER CARTRIDGE........................................258 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....259 WHEN REQUIRED............................................................214 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.........................214 CLEAN INSIDE OF COOLING SYSTEM.......................................218 REPLACE WATER SEPARATOR ELEMENT......................................221 CLEAN FUEL TANK......................................................222 CHECK AND TIGHTEN TRACK SHOE BOLTS...................................223 CHECK AND ADJUST TRACK TENSION.......................................224 CHECK ROAD LINERS OR RUBBER SHOES....................................226 CHECK AND ADJUST RUBBER SHOE TENSION.................................228 REPLACE ROAD LINERS..................................................229 REPLACE RUBBER SHOES.................................................230 CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES.....................232 REPLACE BUCKET TEETH (VERTICAL PIN TYPE).............................233 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...........................236 ADJUST BUCKET CLEARANCE..............................................237 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...........................238 CHECK AND ADJUST AIR CONDITIONER.....................................239 CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER............240 REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT................241 WASH WASHABLE FLOOR..................................................242 BLEEDING AIR FROM HYDRAULIC SYSTEM...................................244 CHECK BEFORE STARTING....................................................247 EVERY 50 HOURS MAINTENANCE...............................................248 DRAIN WATER FROM FUEL TANK...........................................248 EVERY 100 HOURS MAINTENANCE..............................................249 LUBRICATING..........................................................249 EVERY 250 HOURS MAINTENANCE..............................................250 LUBRICATING..........................................................250 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.........................252 CHECK LEVEL OF BATTERY ELECTROLYTE...................................253 CHECK AND ADJUST COOLING FAN BELT TENSION............................255 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST................257 EVERY 500 HOURS MAINTENANCE..............................................258 REPLACE FUEL FILTER CARTRIDGE........................................258 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....259 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS...........................260 CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS.......262 LUBRICATE SWING CIRCLE...............................................264 CHECK SWING PINION GREASE LEVEL, ADD GREASE..........................264 EVERY 1000 HOURS MAINTENANCE.............................................265 REPLACE HYDRAULIC OIL FILTER ELEMENT.................................265 CHANGE OIL IN SWING MACHINERY CASE...................................267 CHANGE OIL IN FINAL DRIVE CASE.......................................268 EVERY 2000 HOURS MAINTENANCE.............................................269 CHECK PTO GEAR CASE, ADD OIL.........................................269 CLEAN, CHECK TURBOCHARGER............................................269 CHECK ALTERNATOR, STARTING MOTOR.....................................269 CHECK ENGINE VALVE CLEARANCE, ADJUST.................................269 EVERY 4000 HOURS MAINTENANCE.............................................270 CHECK WATER PUMP.....................................................270 EVERY 5000 HOURS MAINTENANCE.............................................271 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER.........................271 SPECIFICATIONS...................................................................274 SPECIFICATIONS...............................................................275 ATTACHMENTS, OPTIONS.............................................................278 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION................................279 SAFETY FIRST.............................................................279 ATTACHMENT INSTALLATION..................................................280 BUCKET WITH HOOK.............................................................281 HOOK CONDITION...........................................................281 PROHIBITED OPERATIONS....................................................281 METHOD FOR REMOVING AND INSTALLING EXTRA.....................................282 CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE..........................284 CONTROL PATTERN CHANGE PROCEDURE.........................................284 MACHINE CONTROL PATTERNS.................................................285 ATTACHMENT GUIDE.............................................................286 OTHER ATTACHMENTS........................................................286 ATTACHMENT COMBINATIONS..................................................287 SELECTION OF TRACK SHOES.................................................288 RECOMMENDED ATTACHMENT OPERATIONS............................................289 HYDRAULIC BREAKER........................................................289 INDEX............................................................................294
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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