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KOMATSU GALEO PC78US-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:11049 & UP) – PDF DOWNLOAD
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- KOMATSU GALEO PC78US-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:11049 & UP
- PUBLICATION NUMBER:TEN00200-00
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Description
KOMATSU GALEO PC78US-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:11049 & UP)
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KOMATSU GALEO PC78US-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:11049 & UP) – PDF DOWNLOAD:
TABLE OF CONTENTS:
KOMATSU GALEO PC78US-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:11049 & UP)
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 EPA NAMEPLATE.......................................................................... 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......................................................................... 26 SAFETY RULES........................................................................... 26 IF PROBLEMS ARE FOUND.................................................................. 26 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS............................................. 26 FIRE EXTINGUISHER AND FIRST AID KIT.................................................... 26 SAFETY EQUIPMENT....................................................................... 26 KEEP MACHINE CLEAN..................................................................... 27 KEEP OPERATOR'S COMPARTMENT CLEAN...................................................... 27 LEAVING OPERATOR'S SEAT WITH LOCK...................................................... 27 HANDRAILS AND STEPS.................................................................... 28 MOUNTING AND DISMOUNTING............................................................... 28 NO PERSONS ON ATTACHMENTS.............................................................. 28 DO NOT GET CAUGHT IN ARTICULATED PORTION............................................... 28 BURN PREVENTION........................................................................ 29 FIRE PREVENTION AND EXPLOSION PREVENTION............................................... 29 ACTION IF FIRE OCCURS.................................................................. 30 WINDSHIELD WASHER FLUID................................................................ 30 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION....................... 30 ATTACHMENT INSTALLATION................................................................ 31 ATTACHMENT COMBINATIONS................................................................ 31 CAB WINDOW GLASSES..................................................................... 31 UNAUTHORIZED MODIFICATIONS............................................................. 31 SAFETY AT JOBSITE...................................................................... 31 WORKING ON LOOSE GROUND................................................................ 32 DISTANCE TO HIGH VOLTAGE CABLES........................................................ 32 ENSURE GOOD VISIBILITY................................................................. 32 VENTILATION FOR ENCLOSED AREA.......................................................... 33 SIGNALMAN'S SIGNAL AND SIGNS........................................................... 33 EMERGENCY EXIT FROM OPERATOR'S CAB..................................................... 33 ASBESTOS DUST HAZARD PREVENTION........................................................ 33 SAFETY MACHINE OPERATION................................................................... 34 STARTING ENGINE........................................................................ 34 CHECKS BEFORE STARTING ENGINE...................................................... 34 SAFETY RULES FOR STARTING ENGINE................................................... 34 STARTING ENGINE IN COLD WEATHER.................................................... 35 OPERATION.............................................................................. 36 CHECKS BEFORE OPERATION............................................................ 36 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS....................................... 36 SAFETY RULES FOR TRAVELING......................................................... 37 TRAVELING ON SLOPES................................................................ 38 OPERATIONS ON SLOPES............................................................... 39 PROHIBITED OPERATIONS.............................................................. 39 OPERATIONS ON SNOW................................................................. 40 PARKING MACHINE.................................................................... 41 TRANSPORTATION......................................................................... 42 LOADING AND UNLOADING.............................................................. 42 SHIPPING THE MACHINE............................................................... 42 BATTERY................................................................................ 43 BATTERY HAZARD PREVENTION.......................................................... 43 STARTING ENGINE WITH BOOSTER CABLES................................................ 44 TOWING................................................................................. 45 SAFETY RULES FOR TOWING............................................................ 45 LIFTING OBJECTS WITH BUCKET............................................................ 46 SAFETY RULES FOR LIFTING OBJECTS................................................... 46 SAFETY MAINTENANCE INFORMATION............................................................. 47 WARNING TAG............................................................................ 47 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........................................................................... 49 PERSONNEL.............................................................................. 49 ATTACHMENTS............................................................................ 50 WORK UNDER THE MACHINE................................................................. 50 NOISE.................................................................................. 50 WHEN USING HAMMER...................................................................... 50 WELDING WORKS.......................................................................... 50 REMOVING BATTERY TERMINALS............................................................. 51 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION................... 51 DO NOT DISASSEMBLE RECOIL SPRINGS...................................................... 51 SAFETY RULES FOR HIGH-PRESSURE OIL..................................................... 51 SAFETY HANDLING HIGH-PRESSURE HOSES.................................................... 52 WASTE MATERIALS........................................................................ 52 AIR CONDITIONER MAINTENANCE............................................................ 52 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............................................................................... 68 CONTROL LEVERS AND PEDALS.............................................................. 73 SUN ROOF............................................................................... 76 WINDSHIELD............................................................................. 77 SLIDING DOOR........................................................................... 83 EMERGENCY ESCAPE HAMMER................................................................ 83 CAP WITH LOCK.......................................................................... 84 ENGINE HOOD............................................................................ 85 MUD COVER.............................................................................. 86 BATTERY INSPECTION COVER............................................................... 87 FUSE................................................................................... 88 FUSIBLE LINK........................................................................... 89 AUXILIARY ELECTRIC POWER............................................................... 89 CONTROLLERS............................................................................ 89 HEATER AND DEFROSTER CONTROLS.......................................................... 90 AIR CONDITIONER CONTROLS............................................................... 95 RADIO..................................................................................101 OPERATION MANUAL STORAGE...............................................................107 TOOL, GREASE PUMP STORAGE PLACE........................................................107 ASHTRAY................................................................................107 FIRE EXTINGUISHER......................................................................107 MACHINE OPERATIONS AND CONTROLS............................................................108 BEFORE STARTING ENGINE.................................................................108 STARTING ENGINE........................................................................125 AFTER STARTING ENGINE..................................................................130 STOPPING THE ENGINE....................................................................133 MACHINE OPERATION......................................................................134 STEERING THE MACHINE...................................................................138 SWINGING...............................................................................140 WORK EQUIPMENT CONTROLS AND OPERATIONS.................................................141 WORKING MODE...........................................................................143 PROHIBITED OPERATIONS..................................................................143 GENERAL OPERATION INFORMATION..........................................................146 TRAVELING ON SLOPES....................................................................148 ESCAPE FROM MUD........................................................................150 RECOMMENDED APPLICATIONS...............................................................151 BUCKET REPLACEMENT AND INVERSION.......................................................153 PARKING MACHINE........................................................................156 MACHINE INSPECTION AFTER DAILY WORK....................................................158 LOCKING................................................................................158 ROAD LINERS AND RUBBER SHOES...........................................................159 TRANSPORTATION.............................................................................164 TRANSPORTATION PROCEDURE...............................................................164 LOADING AND UNLOADING WITH TRAILER.....................................................164 LIFTING MACHINE........................................................................170 COLD WEATHER OPERATION.....................................................................172 COLD WEATHER OPERATION INFORMATION.....................................................172 AFTER DAILY WORK COMPLETION............................................................174 AFTER COLD WEATHER SEASON..............................................................174 LONG TERM STORAGE..........................................................................175 BEFORE STORAGE.........................................................................175 DURING STORAGE.........................................................................175 AFTER STORAGE..........................................................................176 TROUBLES AND ACTIONS.......................................................................177 RUNNING OUT OF FUEL....................................................................177 PHENOMENA THAT ARE NOT FAILURES........................................................177 TOWING THE MACHINE.....................................................................178 LIGHTWEIGHT TOWING HOLE................................................................178 SEVERE JOB CONDITION...................................................................179 DISCHARGED BATTERY.....................................................................179 HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY.......................183 OTHER TROUBLE..........................................................................184 MAINTENANCE....................................................................................189 MAINTENANCE INFORMATION....................................................................190 OUTLINE OF SERVICE.........................................................................192 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................192 ELECTRIC SYSTEM MAINTENANCE............................................................195 WEAR PARTS.................................................................................196 WEAR PARTS LIST........................................................................196 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................197 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................198 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....199 TIGHTENING TORQUE SPECIFICATIONS...........................................................200 TIGHTENING TORQUE LIST.................................................................200 SAFETY CRITICAL PARTS......................................................................201 SAFETY CRITICAL PARTS LIST.............................................................201 MAINTENANCE SCHEDULE.......................................................................202 MAINTENANCE SCHEDULE CHART.............................................................202 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.............................................203 MAINTENANCE PROCEDURE......................................................................204 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS).........................204 WHEN REQUIRED..........................................................................205 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.......................................205 CLEAN INSIDE OF COOLING SYSTEM.....................................................211 REPLACE WATER SEPARATOR ELEMENT....................................................214 CHECK AND TIGHTEN TRACK SHOE BOLTS.................................................215 CHECK AND ADJUST TRACK TENSION.....................................................216 CHECK ROAD LINERS OR RUBBER SHOES..................................................218 CHECK AND ADJUST RUBBER SHOE TENSION...............................................220 REPLACE ROAD LINERS................................................................221 REPLACE RUBBER SHOES...............................................................222 CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES...................................224 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...........................................225 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE).........................................228 ADJUST BUCKET CLEARANCE............................................................229 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.........................................230 CHECK AND MAINTENANCE AIR CONDITIONER..............................................231 CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER..........................232 REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT..............................233 WASH WASHABLE FLOOR................................................................234 BLEEDING AIR FROM HYDRAULIC SYSTEM.................................................236 CHECK BEFORE STARTING..................................................................239 EVERY 50 HOURS MAINTENANCE.............................................................240 DRAIN WATER FROM FUEL TANK.........................................................240 EVERY 100 HOURS MAINTENANCE............................................................241 LUBRICATING........................................................................241 CHECK SWING MACHINERY CASE OIL, ADD OIL............................................242 EVERY 250 HOURS MAINTENANCE............................................................243 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................243 CHECK LEVEL OF BATTERY ELECTROLYTE.................................................244 CHECK AND ADJUST COOLING FAN BELT TENSION..........................................246 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................248 EVERY 500 HOURS MAINTENANCE............................................................249 LUBRICATING........................................................................249 REPLACE FUEL FILTER CARTRIDGE......................................................251 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................252 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS.........................................253 CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS.....................255 LUBRICATE SWING CIRCLE.............................................................257 CHECK SWING PINION GREASE LEVEL, ADD GREASE........................................257 EVERY 1000 HOURS MAINTENANCE...........................................................258 REPLACE HYDRAULIC OIL FILTER ELEMENT...............................................258 CHANGE OIL IN SWING MACHINERY CASE.................................................260 GREASE SWING MACHINERY BEARING.....................................................260 CHANGE OIL IN FINAL DRIVE CASE.....................................................261 EVERY 2000 HOURS MAINTENANCE...........................................................262 CHECK PTO GEAR CASE, ADD OIL.......................................................262 CLEAN, CHECK TURBOCHARGER..........................................................262 CHECK ALTERNATOR, STARTING MOTOR...................................................262 CHECK ENGINE VALVE CLEARANCE, ADJUST...............................................262 EVERY 4000 HOURS MAINTENANCE...........................................................263 CHECK WATER PUMP...................................................................263 EVERY 5000 HOURS MAINTENANCE...........................................................264 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER.......................................264 SPECIFICATIONS.................................................................................266 SPECIFICATIONS.............................................................................267 ATTACHMENTS, OPTIONS...........................................................................269 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION..............................................270 SAFETY FIRST...........................................................................270 ATTACHMENT INSTALLATION................................................................271 BUCKET WITH HOOK...........................................................................272 HOOK CONDITION.........................................................................272 PROHIBITED OPERATIONS..................................................................272 MACHINE READY FOR ATTACHMENT...............................................................273 LOCATIONS..............................................................................273 HYDRAULIC CIRCUIT......................................................................275 ATTACHMENT OPERATIONS..................................................................276 LONG TERM STORAGE......................................................................278 SPECIFICATIONS.........................................................................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 RECOMMENDED ATTACHMENT OPERATIONS..........................................................285 HYDRAULIC BREAKER......................................................................285 CRUSHER................................................................................290 INDEX..........................................................................................293
DESCRIPTION:
KOMATSU GALEO PC78US-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:11049 & 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.
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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