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KOMATSU GALEO PC78US-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:7615 & UP) – PDF DOWNLOAD
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- KOMATSU GALEO PC78US-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:7615 & UP
- PUBLICATION NUMBER:TEN00072-01
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Description
KOMATSU GALEO PC78US-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:7615 & UP)
KOMATSU GALEO PC78US-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:7615 & UP) – PDF DOWNLOAD:
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KOMATSU GALEO PC78US-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:7615 & 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 PC78US-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:7615 & 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......................................................................................... 16 SAFETY INFORMATION......................................................................... 17 SAFETY LABELS.............................................................................. 19 LOCATION OF SAFETY LABELS.............................................................. 20 SAFETY LABELS.......................................................................... 21 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................................................... 35 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......................................................... 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........................................................................... 50 PERSONNEL.............................................................................. 50 ATTACHMENTS............................................................................ 51 WORK UNDER THE MACHINE................................................................. 51 NOISE.................................................................................. 51 WHEN USING HAMMER...................................................................... 51 WELDING WORKS.......................................................................... 51 REMOVING BATTERY TERMINALS............................................................. 52 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.................................................... 53 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............................................................................... 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...............................................................106 TOOL, GREASE PUMP STORAGE PLACE........................................................106 ASHTRAY................................................................................106 FIRE EXTINGUISHER......................................................................106 MACHINE OPERATIONS AND CONTROLS............................................................107 BEFORE STARTING ENGINE.................................................................107 STARTING ENGINE........................................................................124 AFTER STARTING ENGINE..................................................................129 STOPPING THE ENGINE....................................................................132 MACHINE OPERATION......................................................................133 STEERING THE MACHINE...................................................................137 SWINGING...............................................................................139 WORK EQUIPMENT CONTROLS AND OPERATIONS.................................................140 WORKING MODE...........................................................................142 PROHIBITED OPERATIONS..................................................................142 GENERAL OPERATION INFORMATION..........................................................145 TRAVELING ON SLOPES....................................................................147 ESCAPE FROM MUD........................................................................149 RECOMMENDED APPLICATIONS...............................................................150 BUCKET REPLACEMENT AND INVERSION.......................................................152 PARKING MACHINE........................................................................154 MACHINE INSPECTION AFTER DAILY WORK....................................................156 LOCKING................................................................................156 ROAD LINERS AND RUBBER SHOES...........................................................157 TRANSPORTATION.............................................................................162 TRANSPORTATION PROCEDURE...............................................................162 LOADING AND UNLOADING WITH TRAILER.....................................................162 LIFTING MACHINE........................................................................167 COLD WEATHER OPERATION.....................................................................169 COLD WEATHER OPERATION INFORMATION.....................................................169 AFTER DAILY WORK COMPLETION............................................................171 AFTER COLD WEATHER SEASON..............................................................171 LONG TERM STORAGE..........................................................................172 BEFORE STORAGE.........................................................................172 DURING STORAGE.........................................................................172 AFTER STORAGE..........................................................................173 TROUBLES AND ACTIONS.......................................................................174 RUNNING OUT OF FUEL....................................................................174 PHENOMENA THAT ARE NOT FAILURES........................................................174 TOWING THE MACHINE.....................................................................175 LIGHTWEIGHT TOWING HOLE................................................................176 SEVERE JOB CONDITION...................................................................176 DISCHARGED BATTERY.....................................................................177 HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY.......................181 OTHER TROUBLE..........................................................................182 MAINTENANCE....................................................................................188 MAINTENANCE INFORMATION....................................................................189 OUTLINE OF SERVICE.........................................................................191 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................191 ELECTRIC SYSTEM MAINTENANCE............................................................194 WEAR PARTS.................................................................................195 WEAR PARTS LIST........................................................................195 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................196 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................197 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....198 TIGHTENING TORQUE SPECIFICATIONS...........................................................199 TIGHTENING TORQUE LIST.................................................................199 SAFETY CRITICAL PARTS......................................................................200 SAFETY CRITICAL PARTS LIST.............................................................200 MAINTENANCE SCHEDULE.......................................................................201 MAINTENANCE SCHEDULE CHART.............................................................201 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.............................................202 MAINTENANCE PROCEDURE......................................................................203 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS).........................203 WHEN REQUIRED..........................................................................204 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.......................................204 CLEAN INSIDE OF COOLING SYSTEM.....................................................210 REPLACE WATER SEPARATOR ELEMENT....................................................213 CHECK AND TIGHTEN TRACK SHOE BOLTS.................................................214 CHECK AND ADJUST TRACK TENSION.....................................................215 CHECK ROAD LINERS OR RUBBER SHOES..................................................217 CHECK AND ADJUST RUBBER SHOE TENSION...............................................219 REPLACE ROAD LINERS................................................................220 REPLACE RUBBER SHOES...............................................................221 CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES...................................223 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...........................................224 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE).........................................227 ADJUST BUCKET CLEARANCE............................................................228 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.........................................229 CHECK AND MAINTENANCE AIR CONDITIONER..............................................230 CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER..........................231 REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT..............................232 WASH WASHABLE FLOOR................................................................233 BLEEDING AIR FROM HYDRAULIC SYSTEM.................................................235 CHECK BEFORE STARTING..................................................................238 EVERY 50 HOURS MAINTENANCE.............................................................239 DRAIN WATER FROM FUEL TANK.........................................................239 EVERY 100 HOURS MAINTENANCE............................................................240 LUBRICATING........................................................................240 EVERY 250 HOURS MAINTENANCE............................................................241 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................241 CHECK LEVEL OF BATTERY ELECTROLYTE.................................................242 CHECK AND ADJUST COOLING FAN BELT TENSION..........................................244 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................246 EVERY 500 HOURS MAINTENANCE............................................................247 LUBRICATING........................................................................247 REPLACE FUEL FILTER CARTRIDGE......................................................249 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................250 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS.........................................251 CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS.....................253 LUBRICATE SWING CIRCLE.............................................................255 CHECK SWING PINION GREASE LEVEL, ADD GREASE........................................255 EVERY 1000 HOURS MAINTENANCE...........................................................256 REPLACE HYDRAULIC OIL FILTER ELEMENT...............................................256 CHANGE OIL IN SWING MACHINERY CASE.................................................258 CHANGE OIL IN FINAL DRIVE CASE.....................................................259 EVERY 2000 HOURS MAINTENANCE...........................................................260 CHECK PTO GEAR CASE, ADD OIL.......................................................260 CLEAN, CHECK TURBOCHARGER..........................................................260 CHECK ALTERNATOR, STARTING MOTOR...................................................260 CHECK ENGINE VALVE CLEARANCE, ADJUST...............................................260 EVERY 4000 HOURS MAINTENANCE...........................................................261 CHECK WATER PUMP...................................................................261 EVERY 5000 HOURS MAINTENANCE...........................................................262 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER.......................................262 SPECIFICATIONS.................................................................................264 SPECIFICATIONS.............................................................................265 ATTACHMENTS, OPTIONS...........................................................................268 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION..............................................269 SAFETY FIRST...........................................................................269 ATTACHMENT INSTALLATION................................................................270 BUCKET WITH HOOK...........................................................................271 HOOK CONDITION.........................................................................271 PROHIBITED OPERATIONS..................................................................271 MACHINE READY FOR ATTACHMENT...............................................................272 LOCATIONS..............................................................................272 HYDRAULIC CIRCUIT......................................................................274 ATTACHMENT OPERATIONS..................................................................275 LONG TERM STORAGE......................................................................277 SPECIFICATIONS.........................................................................277 METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT.....................................278 CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)........................280 CONTROL PATTERN CHANGE PROCEDURE.......................................................280 MACHINE CONTROL PATTERNS...............................................................281 ATTACHMENT GUIDE...........................................................................282 OTHER ATTACHMENTS......................................................................282 ATTACHMENT COMBINATIONS................................................................283 RECOMMENDED ATTACHMENT OPERATIONS..........................................................284 HYDRAULIC BREAKER......................................................................284 CRUSHER................................................................................289 INDEX..........................................................................................292
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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