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KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:PC78MR-60 1507 and up) – pdf download
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- KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual
- Serial Number:PC78MR-60 1507 and up
- Publication Number:TEN00074-00
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Description
KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:PC78MR-60 1507 and up)
KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:PC78MR-60 1507 AND UP) – PDF DOWNLOAD:
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Description:
KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:PC78MR-60 1507 and 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. Operators and maintenance personnel must always do as follows before beginning operation or maintenance. Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
- Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you understand them fully. Keep this manual in the storage location forthe operation and maintenance manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor. If you sell the machine, be sure to give this manual to the new owners together with the machine.
- Komatsu delivers machines that comply with all applicable regulations and standards ofthe country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
Table of Contents:
KOMATSU GALEO PC78MR-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:PC78MR-60 1507 and 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 PROBLEMS 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............................................................................... 69 CONTROL LEVERS AND PEDALS.............................................................. 74 SUN ROOF............................................................................... 79 WINDSHIELD............................................................................. 80 SLIDING DOOR........................................................................... 85 EMERGENCY ESCAPE HAMMER................................................................ 85 CAP WITH LOCK.......................................................................... 87 ENGINE HOOD............................................................................ 88 MUD COVER.............................................................................. 89 BATTERY INSPECTION COVER............................................................... 90 FUSE................................................................................... 91 FUSIBLE LINK........................................................................... 92 AUXILIARY ELECTRIC POWER............................................................... 92 CONTROLLERS............................................................................ 92 AIR CONDITIONER CONTROLS............................................................... 93 HEATER AND DEFROSTER CONTROLS.......................................................... 99 RADIO..................................................................................104 OPERATION MANUAL STORAGE...............................................................109 TOOL BOX...............................................................................109 GREASE PUMP HOLDER.....................................................................109 ASHTRAY................................................................................109 FIRE EXTINGUISHER......................................................................110 MACHINE OPERATIONS AND CONTROLS............................................................111 BEFORE STARTING ENGINE.................................................................111 STARTING ENGINE........................................................................127 AFTER STARTING ENGINE..................................................................132 STOPPING THE ENGINE....................................................................135 CHECK AFTER SHUT OFF ENGINE............................................................135 MACHINE OPERATION......................................................................136 STEERING THE MACHINE...................................................................140 SWINGING...............................................................................142 WORK EQUIPMENT CONTROLS AND OPERATIONS.................................................143 WORKING MODE...........................................................................145 PROHIBITED OPERATIONS..................................................................146 GENERAL OPERATION INFORMATION..........................................................148 TRAVELING ON SLOPES....................................................................150 ESCAPE FROM MUD........................................................................152 RECOMMENDED APPLICATIONS...............................................................153 MACHINE READY FOR ATTACHMENT...........................................................155 BUCKET REPLACEMENT AND INVERSION.......................................................161 PARKING MACHINE........................................................................163 MACHINE INSPECTION AFTER DAILY WORK....................................................164 LOCKING................................................................................164 ROAD LINERS AND RUBBER SHOES...........................................................165 TRANSPORTATION.............................................................................170 TRANSPORTATION PROCEDURE...............................................................170 LOADING AND UNLOADING WITH TRAILER.....................................................170 LIFTING MACHINE........................................................................176 COLD WEATHER OPERATION.....................................................................178 COLD WEATHER OPERATION INFORMATION.....................................................178 AFTER DAILY WORK COMPLETION............................................................180 AFTER COLD WEATHER SEASON..............................................................180 LONG TERM STORAGE..........................................................................181 BEFORE STORAGE.........................................................................181 DURING STORAGE.........................................................................181 AFTER STORAGE..........................................................................181 TROUBLES AND ACTIONS.......................................................................182 RUNNING OUT OF FUEL....................................................................182 PHENOMENA THAT ARE NOT FAILURES........................................................182 TOWING THE MACHINE.....................................................................183 SEVERE JOB CONDITION...................................................................183 DISCHARGED BATTERY.....................................................................184 HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY.......................189 OTHER TROUBLE..........................................................................190 MAINTENANCE....................................................................................196 MAINTENANCE INFORMATION....................................................................197 OUTLINE OF SERVICE.........................................................................199 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................199 ELECTRIC SYSTEM MAINTENANCE............................................................202 WEAR PARTS.................................................................................203 WEAR PARTS LIST........................................................................203 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................204 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................205 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....206 TIGHTENING TORQUE SPECIFICATIONS...........................................................207 TIGHTENING TORQUE LIST.................................................................207 SAFETY CRITICAL PARTS......................................................................208 SAFETY CRITICAL PARTS LIST.............................................................208 MAINTENANCE SCHEDULE.......................................................................209 MAINTENANCE SCHEDULE CHART.............................................................209 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.............................................210 MAINTENANCE PROCEDURE......................................................................211 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS).........................211 REPLACE FUEL FILTER CARTRIDGE......................................................256 CHANGE OIL IN ENGINE OIL PAN, REPLACE OIL FILTER CARTRIDGE.........................257 WHEN REQUIRED..........................................................................212 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.......................................212 CLEAN INSIDE OF COOLING SYSTEM.....................................................216 REPLACE WATER SEPARATOR ELEMENT....................................................219 CLEAN FUEL TANK....................................................................220 CHECK AND TIGHTEN TRACK SHOE BOLTS.................................................221 CHECK AND ADJUST TRACK TENSION.....................................................222 CHECK ROAD LINERS OR RUBBER SHOES..................................................224 CHECK AND ADJUST RUBBER SHOE TENSION...............................................226 REPLACE ROAD LINERS................................................................227 REPLACE RUBBER SHOES...............................................................228 CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES...................................230 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...........................................231 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE).........................................234 ADJUST BUCKET CLEARANCE............................................................235 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.........................................236 CHECK AND ADJUST AIR CONDITIONER...................................................237 CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER..........................238 REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT..............................239 WASH WASHABLE FLOOR................................................................240 BLEEDING AIR FROM HYDRAULIC SYSTEM.................................................242 CHECK BEFORE STARTING..................................................................245 EVERY 50 HOURS MAINTENANCE.............................................................246 DRAIN WATER FROM FUEL TANK.........................................................246 EVERY 100 HOURS MAINTENANCE............................................................247 LUBRICATING........................................................................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 CHANGE OIL IN FINAL DRIVE CASE.....................................................266 EVERY 2000 HOURS MAINTENANCE...........................................................267 CHECK PTO GEAR CASE, ADD OIL.......................................................267 CLEAN, CHECK TURBOCHARGER..........................................................267 CHECK ALTERNATOR, STARTING MOTOR...................................................267 EVERY 4000 HOURS MAINTENANCE...........................................................268 CHECK WATER PUMP...................................................................268 EVERY 5000 HOURS MAINTENANCE...........................................................269 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER.......................................269 SPECIFICATIONS.................................................................................272 SPECIFICATIONS.............................................................................273 ATTACHMENTS, OPTIONS...........................................................................276 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION..............................................277 SAFETY FIRST...........................................................................277 ATTACHMENT INSTALLATION................................................................278 BUCKET WITH HOOK...........................................................................279 HOOK CONDITION.........................................................................279 PROHIBITED OPERATIONS..................................................................279 METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT.....................................280 CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)........................282 CONTROL PATTERN CHANGE PROCEDURE.......................................................282 MACHINE CONTROL PATTERNS...............................................................283 ATTACHMENT GUIDE...........................................................................284 OTHER ATTACHMENTS......................................................................284 ATTACHMENT COMBINATIONS................................................................285 SELECTION OF TRACK SHOES...............................................................286 RECOMMENDED ATTACHMENT OPERATIONS..........................................................287 HYDRAULIC BREAKER......................................................................287 INDEX..........................................................................................292
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