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KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:3253 & UP) KOMATSU PC78MR-6 – PDF Download
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- KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:3253 & UP
- PUBLICATION NUMBER:TEN00202-00
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KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:3253 & UP) KOMATSU PC78MR-6
KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:3253 & UP) KOMATSU PC78MR-6 – PDF DOWNLOAD:
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KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:3253 & UP) KOMATSU PC78MR-6
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:3253 & UP) KOMATSU PC78MR-6
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......................................................................................... 15 SAFETY INFORMATION......................................................................... 16 SAFETY LABELS.............................................................................. 18 LOCATION OF SAFETY LABELS.............................................................. 19 SAFETY LABELS.......................................................................... 20 SAFETY INFORMATION......................................................................... 27 SAFETY RULES........................................................................... 27 IF PROBLEMS ARE FOUND.................................................................. 27 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS............................................. 27 FIRE EXTINGUISHER AND FIRST AID KIT.................................................... 27 SAFETY EQUIPMENT....................................................................... 27 KEEP MACHINE CLEAN..................................................................... 28 KEEP OPERATOR'S COMPARTMENT CLEAN...................................................... 28 LEAVING OPERATOR'S SEAT WITH LOCK...................................................... 28 HANDRAILS AND STEPS.................................................................... 29 MOUNTING AND DISMOUNTING............................................................... 29 NO PERSONS ON ATTACHMENTS.............................................................. 29 DO NOT GET CAUGHT IN ARTICULATED PORTION............................................... 29 BURN PREVENTION........................................................................ 30 FIRE PREVENTION AND EXPLOSION PREVENTION............................................... 30 ACTION IF FIRE OCCURS.................................................................. 31 WINDSHIELD WASHER FLUID................................................................ 31 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION....................... 31 ATTACHMENT INSTALLATION................................................................ 32 ATTACHMENT COMBINATIONS................................................................ 32 CAB WINDOW GLASSES..................................................................... 32 UNAUTHORIZED MODIFICATIONS............................................................. 32 SAFETY AT JOBSITE...................................................................... 32 WORKING ON LOOSE GROUND................................................................ 33 DISTANCE TO HIGH VOLTAGE CABLES........................................................ 33 ENSURE GOOD VISIBILITY................................................................. 33 VENTILATION FOR ENCLOSED AREA.......................................................... 34 SIGNALMAN'S SIGNAL AND SIGNS........................................................... 34 EMERGENCY EXIT FROM OPERATOR'S CAB..................................................... 34 ASBESTOS DUST HAZARD PREVENTION........................................................ 34 SAFETY MACHINE OPERATION................................................................... 35 STARTING ENGINE........................................................................ 35 CHECKS BEFORE STARTING ENGINE...................................................... 35 SAFETY RULES FOR STARTING ENGINE................................................... 36 STARTING ENGINE IN COLD WEATHER.................................................... 36 OPERATION.............................................................................. 37 CHECKS BEFORE OPERATION............................................................ 37 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS....................................... 37 SAFETY RULES FOR TRAVELING......................................................... 38 TRAVELING ON SLOPES................................................................ 39 OPERATIONS ON SLOPES............................................................... 40 PROHIBITED OPERATIONS.............................................................. 40 OPERATIONS ON SNOW................................................................. 41 PARKING MACHINE.................................................................... 42 TRANSPORTATION......................................................................... 43 LOADING AND UNLOADING.............................................................. 43 SHIPPING THE MACHINE............................................................... 43 BATTERY................................................................................ 44 BATTERY HAZARD PREVENTION.......................................................... 44 STARTING ENGINE WITH BOOSTER CABLES................................................ 45 TOWING................................................................................. 46 SAFETY RULES FOR TOWING............................................................ 46 LIFTING OBJECTS WITH BUCKET............................................................ 47 SAFETY RULES FOR LIFTING OBJECTS................................................... 47 SAFETY MAINTENANCE INFORMATION............................................................. 48 WARNING TAG............................................................................ 48 KEEP WORK PLACE CLEAN AND TIDY......................................................... 48 APPOINT LEADER WHEN WORKING WITH OTHERS................................................ 48 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE............................................ 48 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING..................................... 49 PROPER TOOLS........................................................................... 50 ACCUMULATOR............................................................................ 50 PERSONNEL.............................................................................. 50 ATTACHMENTS............................................................................ 50 WORK UNDER THE MACHINE................................................................. 51 NOISE.................................................................................. 51 WHEN USING HAMMER...................................................................... 51 WELDING WORKS.......................................................................... 51 REMOVING BATTERY TERMINALS............................................................. 51 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION................... 52 DO NOT DISASSEMBLE RECOIL SPRINGS...................................................... 52 SAFETY RULES FOR HIGH-PRESSURE OIL..................................................... 52 SAFETY HANDLING HIGH-PRESSURE HOSES.................................................... 52 WASTE MATERIALS........................................................................ 53 AIR CONDITIONER MAINTENANCE............................................................ 53 COMPRESSED AIR......................................................................... 53 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.......................................... 53 OPERATION...................................................................................... 54 MACHINE VIEW ILLUSTRATIONS................................................................. 55 OVERALL MACHINE VIEW................................................................... 55 CONTROLS AND GAUGES.................................................................... 56 DETAILED CONTROLS AND GAUGES............................................................... 57 MONITORING SYSTEM...................................................................... 57 SWITCHES............................................................................... 67 CONTROL LEVERS AND PEDALS.............................................................. 72 SUN ROOF............................................................................... 77 WINDSHIELD............................................................................. 78 SLIDING DOOR........................................................................... 83 EMERGENCY ESCAPE HAMMER................................................................ 83 CAP WITH LOCK.......................................................................... 85 ENGINE HOOD............................................................................ 86 MUD COVER.............................................................................. 87 BATTERY INSPECTION COVER............................................................... 88 FUSE................................................................................... 89 FUSIBLE LINK........................................................................... 90 AUXILIARY ELECTRIC POWER............................................................... 90 CONTROLLERS............................................................................ 90 AIR CONDITIONER CONTROLS............................................................... 91 HEATER AND DEFROSTER CONTROLS.......................................................... 97 RADIO..................................................................................102 OPERATION MANUAL STORAGE...............................................................107 TOOL BOX...............................................................................107 GREASE PUMP HOLDER.....................................................................107 ASHTRAY................................................................................107 FIRE EXTINGUISHER......................................................................108 MACHINE OPERATIONS AND CONTROLS............................................................109 BEFORE STARTING ENGINE.................................................................109 STARTING ENGINE........................................................................125 AFTER STARTING ENGINE..................................................................130 STOPPING THE ENGINE....................................................................133 CHECK AFTER SHUT OFF ENGINE............................................................133 MACHINE OPERATION......................................................................134 STEERING THE MACHINE...................................................................138 SWINGING...............................................................................140 WORK EQUIPMENT CONTROLS AND OPERATIONS.................................................141 WORKING MODE...........................................................................143 PROHIBITED OPERATIONS..................................................................144 GENERAL OPERATION INFORMATION..........................................................146 TRAVELING ON SLOPES....................................................................148 ESCAPE FROM MUD........................................................................150 RECOMMENDED APPLICATIONS...............................................................151 MACHINE READY FOR ATTACHMENT...........................................................153 BUCKET REPLACEMENT AND INVERSION.......................................................159 PARKING MACHINE........................................................................162 MACHINE INSPECTION AFTER DAILY WORK....................................................163 LOCKING................................................................................163 ROAD LINERS AND RUBBER SHOES...........................................................164 TRANSPORTATION.............................................................................169 TRANSPORTATION PROCEDURE...............................................................169 LOADING AND UNLOADING WITH TRAILER.....................................................169 LIFTING MACHINE........................................................................175 COLD WEATHER OPERATION.....................................................................177 COLD WEATHER OPERATION INFORMATION.....................................................177 AFTER DAILY WORK COMPLETION............................................................179 AFTER COLD WEATHER SEASON..............................................................179 LONG TERM STORAGE..........................................................................180 BEFORE STORAGE.........................................................................180 DURING STORAGE.........................................................................180 AFTER STORAGE..........................................................................180 TROUBLES AND ACTIONS.......................................................................181 RUNNING OUT OF FUEL....................................................................181 PHENOMENA THAT ARE NOT FAILURES........................................................181 TOWING THE MACHINE.....................................................................182 SEVERE JOB CONDITION...................................................................182 DISCHARGED BATTERY.....................................................................183 HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY.......................188 OTHER TROUBLE..........................................................................189 MAINTENANCE....................................................................................194 MAINTENANCE INFORMATION....................................................................195 OUTLINE OF SERVICE.........................................................................197 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................197 ELECTRIC SYSTEM MAINTENANCE............................................................201 WEAR PARTS.................................................................................202 WEAR PARTS LIST........................................................................202 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................203 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................204 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....205 TIGHTENING TORQUE SPECIFICATIONS...........................................................206 TIGHTENING TORQUE LIST.................................................................206 SAFETY CRITICAL PARTS......................................................................207 SAFETY CRITICAL PARTS LIST.............................................................207 MAINTENANCE SCHEDULE.......................................................................208 MAINTENANCE SCHEDULE CHART.............................................................208 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.............................................209 MAINTENANCE PROCEDURE......................................................................210 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS).........................210 WHEN REQUIRED..........................................................................211 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.......................................211 CLEAN INSIDE OF COOLING SYSTEM.....................................................215 REPLACE WATER SEPARATOR ELEMENT....................................................218 CLEAN FUEL TANK....................................................................219 CHECK AND TIGHTEN TRACK SHOE BOLTS.................................................220 CHECK AND ADJUST TRACK TENSION.....................................................221 CHECK ROAD LINERS OR RUBBER SHOES..................................................223 CHECK AND ADJUST RUBBER SHOE TENSION...............................................225 REPLACE ROAD LINERS................................................................226 REPLACE RUBBER SHOES...............................................................227 CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES...................................229 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...........................................230 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE).........................................233 ADJUST BUCKET CLEARANCE............................................................234 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.........................................235 CHECK AND MAINTENANCE AIR CONDITIONER..............................................236 CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER..........................237 REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT..............................238 WASH WASHABLE FLOOR................................................................239 BLEEDING AIR FROM HYDRAULIC SYSTEM.................................................241 CHECK BEFORE STARTING..................................................................244 EVERY 50 HOURS MAINTENANCE.............................................................245 DRAIN WATER FROM FUEL TANK.........................................................245 EVERY 100 HOURS MAINTENANCE............................................................246 LUBRICATING........................................................................246 CHECK SWING MACHINERY CASE OIL, ADD OIL............................................247 EVERY 250 HOURS MAINTENANCE............................................................248 LUBRICATING........................................................................248 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................250 CHECK LEVEL OF BATTERY ELECTROLYTE.................................................251 CHECK AND ADJUST COOLING FAN BELT TENSION..........................................253 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................255 EVERY 500 HOURS MAINTENANCE............................................................256 REPLACE FUEL FILTER CARTRIDGE......................................................256 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................257 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS.........................................258 CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS.....................260 LUBRICATE SWING CIRCLE.............................................................262 CHECK SWING PINION GREASE LEVEL, ADD GREASE........................................262 EVERY 1000 HOURS MAINTENANCE...........................................................263 REPLACE HYDRAULIC OIL FILTER ELEMENT...............................................263 CHANGE OIL IN SWING MACHINERY CASE.................................................265 GREASE SWING MACHINERY BEARING.....................................................266 CHANGE OIL IN FINAL DRIVE CASE.....................................................267 EVERY 2000 HOURS MAINTENANCE...........................................................268 CHECK PTO GEAR CASE, ADD OIL.......................................................268 CLEAN, CHECK TURBOCHARGER..........................................................268 CHECK ALTERNATOR, STARTING MOTOR...................................................268 CHECK ENGINE VALVE CLEARANCE, ADJUST...............................................268 EVERY 4000 HOURS MAINTENANCE...........................................................269 CHECK WATER PUMP...................................................................269 EVERY 5000 HOURS MAINTENANCE...........................................................270 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER.......................................270 SPECIFICATIONS.................................................................................272 SPECIFICATIONS.............................................................................273 ATTACHMENTS, OPTIONS...........................................................................275 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION..............................................276 SAFETY FIRST...........................................................................276 ATTACHMENT INSTALLATION................................................................277 BUCKET WITH HOOK...........................................................................278 HOOK CONDITION.........................................................................278 PROHIBITED OPERATIONS..................................................................278 METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT.....................................279 CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)........................281 CONTROL PATTERN CHANGE PROCEDURE.......................................................281 MACHINE CONTROL PATTERNS...............................................................282 ATTACHMENT GUIDE...........................................................................283 OTHER ATTACHMENTS......................................................................283 ATTACHMENT COMBINATIONS................................................................284 SELECTION OF TRACK SHOES...............................................................285 RECOMMENDED ATTACHMENT OPERATIONS..........................................................286 HYDRAULIC BREAKER......................................................................286 INDEX..........................................................................................291
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⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
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