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KOMATSU PC78US-5 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:1001 and up) KOMATSU PC78US 5 – PDF DOWNLOAD
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- KOMATSU PC78US-5 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:1001 and up
- PUBLICATION NUMBER:SEAM046100T
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KOMATSU PC78US-5 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:1001 and up) KOMATSU PC78US 5
KOMATSU PC78US-5 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:1001 AND UP) KOMATSU PC78US 5 – PDF DOWNLOAD:
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KOMATSU PC78US-5 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:1001 and up) KOMATSU PC78US 5
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 hazard when performing operation and maintenance.
TABLE OF CONTENTS:
KOMATSU PC78US-5 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:1001 and up) KOMATSU PC78US 5
MAIN MENU..................................................................................... 0 COVER......................................................................................... 1 FOREWORD...................................................................................... 2 FOREWORD.................................................................................. 3 SAFETY INFORMATION........................................................................ 6 INTRODUCTION.............................................................................. 8 DIRECTIONS OF MACHINE................................................................. 8 PRODUCT INFORMATION....................................................................... 9 MACHINE SERIAL NUMBER PLATE AND ITS LOCATION.......................................... 9 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION........................................... 9 SERVICE METER LOCATION................................................................ 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR........................................... 10 CONTENTS.................................................................................. 11 SAFETY........................................................................................ 16 SAFETY INFORMATION........................................................................ 17 POSITION FOR ATTACHING SAFETY LABELS...................................................... 19 POSITION FOR ATTACHING SAFETY LABELS.................................................. 20 SAFETY LABELS......................................................................... 21 SAFETY INFORMATION........................................................................ 25 SAFETY RULES.......................................................................... 25 IF ABNORMALITIES ARE FOUND............................................................ 25 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS............................................ 25 FIRE EXTINGUISHER AND FIRST AID KIT................................................... 25 SAFETY EQUIPMENT...................................................................... 26 KEEP MACHINE CLEAN.................................................................... 26 KEEP OPERATOR'S COMPARTMENT CLEAN..................................................... 26 LEAVING OPERATOR'S SEAT WITH LOCK..................................................... 26 HANDRAILS AND STEPS................................................................... 27 CRUSHING OR CUTTING PREVENTION........................................................ 28 MOUNTING AND DISMOUNTING.............................................................. 28 NO PERSONS ON ATTACHMENTS............................................................. 28 BURN PREVENTION....................................................................... 28 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............................................................... 30 ATTACHMENT COMBINATIONS............................................................... 31 CAB WIDOW GLASSES..................................................................... 31 UNAUTHORIZED MODIFICATIONS............................................................ 31 SAFETY AT JOBSITE..................................................................... 31 WORKING ON LOOSE GROUND............................................................... 31 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.................................................. 35 STARTING ENGINE IN COLD WEATHER................................................... 35 OPERATION............................................................................. 36 CHECKS AFTER STARTING ENGINE...................................................... 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................................................................ 41 PARKING MACHINE................................................................... 41 TRANSPORTATION........................................................................ 42 LOADING AND UNLOADING............................................................. 42 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........................................... 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......................................................................... 52 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.................................................... 53 SAFETY HANDLING HIGH-PRESSURE HOSES................................................... 53 WASTE MATERIALS....................................................................... 53 AIR CONDITIONER MAINTENANCE........................................................... 54 COMPRESSED AIR........................................................................ 54 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS......................................... 54 OPERATION..................................................................................... 56 GENERAL VIEW.............................................................................. 57 GENERAL VIEW OF MACHINE............................................................... 57 GENERAL VIEW CONTROLS AND GAUGES...................................................... 58 EXPLANATION OF COMPONENTS................................................................. 59 MACHINE MONITOR....................................................................... 59 SWITCHES.............................................................................. 65 CONTROL LEVERS, PEDALS................................................................ 70 CEILING WINDOW........................................................................ 73 FRONT WINDOW.......................................................................... 74 SLIDING DOOR.......................................................................... 77 REAR WINDOW........................................................................... 78 HAMMER FOR EMERGENCY ESCAPE........................................................... 78 CAP, COVER WITH LOCK.................................................................. 79 ENGINE HOOD........................................................................... 80 RIGHT SIDE INSPECTION COVER........................................................... 81 FUEL TANK FILLER COVER................................................................ 82 FUSE.................................................................................. 83 FUSIBLELINK........................................................................... 83 HANDLING AIR CONDITIONER.............................................................. 84 CAR RADIO............................................................................. 87 OPERATION AND MAINTENANCE MANUAL HOLDER............................................... 92 TOOL COMPARTMENT...................................................................... 92 GREASE GUN HOLDER..................................................................... 92 ASHTRAY............................................................................... 92 MACHINE OPERATIONS AND CONTROLS........................................................... 93 BEFORE STARTING ENGINE................................................................ 93 STARTING ENGINE.......................................................................106 AFTER STARTING ENGINE.................................................................109 STOPPING THE ENGINE...................................................................112 CHECK AFTER SHUT OFF ENGINE...........................................................112 MACHINE OPERATION.....................................................................113 STEERING THE MACHINE..................................................................117 SWINGING..............................................................................119 WORK EQUIPMENT CONTROLS AND OPERATIONS................................................120 PROHIBITED OPERATIONS.................................................................122 GENERAL OPERATION INFORMATION.........................................................126 TRAVELING ON SLOPES...................................................................127 ESCAPE FROM MUD.......................................................................129 RECOMMENDED APPLICATIONS..............................................................130 REPLACEMENT AND INVERSION OF BUCKET...................................................132 PARKING MACHINE.......................................................................136 CHECK AFTER FINISHING WORK............................................................138 LOCKING...............................................................................138 HANDLING RUBBER SHOE AND ROAD LINER...................................................139 TRANSPORTATION............................................................................144 TRANSPORTATION PROCEDURE..............................................................144 LOADING AND UNLOADING WITH TRAILER....................................................145 LIFTING MACHINE.......................................................................151 COLD WEATHER OPERATION....................................................................153 COLD WEATHER OPERATION INFORMATION....................................................153 AFTER DAILY WORK COMPLETION...........................................................155 AFTER COLD WEATHER SEASON.............................................................156 LONG TERM STORAGE.........................................................................157 BEFORE STORAGE........................................................................157 DURING STORAGE........................................................................157 AFTER STORAGE.........................................................................158 TROUBLESHOOTING...........................................................................159 AFTER RUNNING OUT OF FUEL.............................................................159 PHENOMENA THAT ARE NOT FAILURES.......................................................159 TOWING THE MACHINE....................................................................160 PRECAUTIONS ON PARTICULAR JOBSITES....................................................160 DISCHARGED BATTERY....................................................................161 OTHER TROUBLE.........................................................................166 MAINTENANCE...................................................................................170 MAINTENANCE INFORMATION...................................................................171 LUBRICANTS, COOLANT AND FILTERS...........................................................174 OUTLINE OF OIL, FUEL, COOLANT.........................................................174 ELECTRIC SYSTEM MAINTENANCE...........................................................176 HANDLING HYDRAULIC SYSTEM.............................................................176 WEAR PARTS LIST...........................................................................178 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE......................179 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS......................................179 TIGHTENING TORQUE SPECIFICATIONS..........................................................183 TIGHTENING TORQUE LIST................................................................183 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.............................................184 SAFETY CRITICAL PARTS.................................................................184 MAINTENANCE SCHEDULE......................................................................185 MAINTENANCE SCHEDULE CHART............................................................185 Initial 250 Hours Maintenance (Only after the first 250 hours)....................185 When Required.....................................................................185 Checks Before Starting............................................................186 Every 50 Hours Maintenance........................................................186 Every 100 Hours Maintenance.......................................................186 Every 250 Hours Maintenance.......................................................186 Every 500 Hours Maintenance.......................................................186 Every 1000 Hours Maintenance......................................................186 Every 2000 Hours Maintenance......................................................186 Every 4000 Hours Maintenance......................................................186 Every 5000 Hours Maintenance......................................................186 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER............................................187 MAINTENANCE PROCEDURE.....................................................................188 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)........................188 WHEN REQUIRED.........................................................................189 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT......................................189 CLEAN INSIDE OF COOLING SYSTEM....................................................191 WASH INSIDE OF FUEL TANK..........................................................193 REPLACE FEED PUMP PRE-FILTER CARTRIDGE............................................194 CHECK AND TIGHTEN TRACK SHOE BOLTS................................................195 CHECK AND ADJUST TRACK TENSION....................................................196 Inspection....................................................................196 Adjustment....................................................................197 CHECK RUBBER SHOES, ROAD LINER....................................................199 CHECK AND ADJUST RUBBER SHOES TENSION.............................................201 Inspection....................................................................201 Adjustment....................................................................202 Adjustment....................................................................202 REPLACE RUBBER SHOES..............................................................203 REPLACE ROAD LINER................................................................206 CHANGE STEEL SHOES OR ROAD LINERS TO RUBBER SHOES.................................206 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)..........................................207 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)........................................210 ADJUST BUCKET CLEARANCE...........................................................211 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID........................................212 Mixture ratio of pure washer fluid and water..................................212 CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)....213 CHECK LEVEL OF REFRIGERANT (GAS)..............................................213 CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER.........................214 REPLACE ADDITIONAL BREAKER FILTER ELEMENT.........................................215 WASHING WASHABLE FLOOR............................................................216 Method of washing.............................................................216 METHOD OF SETTING MACHINE ANGLE...............................................217 BLEEDING AIR FROM HYDRAULIC SYSTEM................................................219 CHECK BEFORE STARTING.................................................................222 EVERY 50 HOURS MAINTENANCE............................................................223 DRAIN WATER AND SEDIMENT FROM FUEL TANK...........................................223 EVERY 100 HOURS MAINTENANCE...........................................................224 LUBRICATING.......................................................................224 EVERY 250 HOURS MAINTENANCE...........................................................226 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL......................................226 CHECK LEVEL OF BATTERY ELECTROLYTE................................................227 INSPECT AND ADJUST COOLING FAN BELT TENSION.......................................228 Inspection....................................................................228 Adjustment....................................................................228 CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT..........................230 Adjusting.....................................................................230 EVERY 500 HOURS MAINTENANCE...........................................................231 REPLACE FUEL FILTER CARTRIDGE.....................................................231 PROCEDURE FOR BLEEDING AIR....................................................232 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.................234 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM.................235 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS...............236 LUBRICATE SWING CIRCLE (2 POINTS).................................................236 CHECK SWING PINION GREASE LEVEL, ADD GREASE.......................................237 REPLACE HYDRAULIC FILTER ELEMENT..................................................238 EVERY 1000 HOURS MAINTENANCE..........................................................239 CHANGE OIL IN SWING MACHINERY CASE................................................239 CHANGE OIL IN FINAL DRIVE CASE....................................................240 EVERY 2000 HOURS MAINTENANCE..........................................................241 CHECK OIL LEVEL IN PTO GEAR CASE, ADD OIL.........................................241 CHECK ALTERNATOR, STARTING MOTOR..................................................241 CHECK ENGINE VALVE CLEARANCE, ADJUST..............................................241 EVERY 4000 HOURS MAINTENENCE..........................................................242 CHECK WATER PUMP..................................................................242 EVERY 5000 HOURS MAINTENANCE..........................................................243 CHANGE OIL IN HYDRAULIC TANK......................................................243 SPECIFICATIONS................................................................................246 SPECIFICATIONS............................................................................247 ATTACHMENTS AND OPTIONS.......................................................................250 GENERAL PRECAUTIONS.......................................................................251 PRECAUTIONS RELATED TO SAFETY.........................................................251 PRECAUTIONS WHEN INSTALLING ATTACHMENTS...............................................253 HANDLING BUCKET WITH HOOK.................................................................254 CHECKING FOR DAMAGE TO BUCKET WITH HOOK...............................................254 PROHIBITED OPERATIONS.................................................................254 PRECAUTIONS DURING OPERATIONS.....................................................254 HANDLING CAR HEATER.......................................................................255 EXPLANATION OF COMPONENTS.............................................................255 PREPARING CAR HEATER..................................................................255 MACHINES READY FOR ATTACHMENTS............................................................256 EXPLANATION OF COMPONENTS.............................................................256 STOP VALVE........................................................................256 SELECTOR VALVE....................................................................257 ATTACHMENT CONTROL PEDAL..........................................................257 LOCK PIN..........................................................................257 ADDITIONAL FILTER FOR BREAKER.....................................................257 HYDRAULIC CIRCUIT.....................................................................258 HYDRAULIC CIRCUIT CONNECTION......................................................258 OPERATION.............................................................................259 WHEN USING BREAKER................................................................259 WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER.....................................260 WHEN ADJUSTING OIL AMOUNT FOR ATTACHMENT..........................................260 LONG-TERM STORAGE.....................................................................261 SPECIFICATIONS........................................................................261 CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED).......................262 CONTROL PATTERN CHANGE PROCEDURE......................................................262 MACHINE CONTROL PATTERNS..............................................................263 INTRODUCTION OF ATTACHMENTS...............................................................264 SPECIFICATION, USE....................................................................264 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS....................................264 ATTACHMENT INSTALLATION COMBINATION TABLE.................................................265 ATTACHMENT COMBINATIONS...............................................................265 RECOMMENDED ATTACHMENT OPERATIONS.........................................................266 HYDRAULIC BREAKER.....................................................................266 MAIN APPLICATIONS.................................................................266 PROHIBITED WORKS..................................................................268 GREASING POSITION FOR HYDRAULIC BREAKER...........................................270 INDEX.........................................................................................272 A.........................................................................................272 B.........................................................................................272 C.........................................................................................272 D.........................................................................................272 E.........................................................................................272 F.........................................................................................272 G.........................................................................................272 H.........................................................................................272 I.........................................................................................272 L.........................................................................................272 M.........................................................................................272 O.........................................................................................273 P.........................................................................................273 R.........................................................................................273 S.........................................................................................273 T.........................................................................................273 U.........................................................................................273 W.........................................................................................273 Y.........................................................................................273
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