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KOMATSU PC78US-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:PC78US – 4562 & up) – PDF DOWNLOAD
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- KOMATSU PC78US-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual
- SERIAL NUMBER:PC78US – 4562 & up
- PUBLICATION NUMBER:SEAM044601T
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Description
KOMATSU PC78US-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:PC78US – 4562 & up)
KOMATSU PC78US-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:PC78US – 4562 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC78US-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:PC78US – 4562 & up)
- This manual provides mics and guidelines which will help you use this machine safely and effectively. The precautions in tlis manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety niles for the operation and maintenance of machines.
- Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance. Keep this manual at the storage location for the 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 of the 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 PC78US-6 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:PC78US – 4562 & up)
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 POSITION............................. 9 ENGINE SERIAL NUMBER PLATE AND ITS POSITION.............................. 9 SERVICE METER LOCATION................................................... 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR.............................. 10 CONTENTS......................................................................... 11 SAFETY........................................................................... 14 SAFETY INFORMATION........................................................... 15 WARNING LABELS AND PICTOGRAMS................................................ 17 WARNING LABELS AND PICTOGRAMS-LOCATION................................... 18 WARNING LABELS AND PICTOGRAMS-ACTUAL..................................... 19 SAFETY INFORMATION........................................................... 24 SAFETY RULES............................................................. 15 IF ABNORMALITIES ARE FOUND............................................... 15 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS............................... 15 FIRE EXTINGUISHER AND FIRST AID KIT...................................... 15 SAFETY EQUIPMENT......................................................... 24 KEEP MACHINE CLEAN....................................................... 25 KEEP OPERATOR'S COMPARTMENT CLEAN........................................ 25 LEAVING OPERATOR'S SEAT WITH LOCK........................................ 25 HANDRAILS AND STEPS...................................................... 26 MOUNTING AND DISMOUNTING................................................. 26 NO PERSONS ON ATTACHMENTS................................................ 26 CRUSHING OR CUTTING PREVENTION........................................... 26 BURN PREVENTION.......................................................... 27 FIRE PREVENTION AND EXPLOSION PREVENTION................................. 27 ACTION IF FIRE OCCURS................................................... 28 WINDSHEILD WASHER FLUID.................................................. 28 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION......... 28 ATTACHMENT INSTALLATION.................................................. 29 ATTACHMENT COMBINATIONS.................................................. 29 CAB WINDOW GLASSES....................................................... 29 UNAUTHORIZED MODIFICATIONS............................................... 29 SAFETY AT JOBSITE........................................................ 29 WORKING ON LOOSE GROUND.................................................. 30 DISTANCE TO HIGH VOLTAGE CABLES.......................................... 30 ENSURE GOOD VISIBILTY.................................................... 30 VENTILATION FOR ENCLOSED AREA ........................................... 31 SIGNALMAN'S SIGNAL AND SIGNS............................................. 31 EMERGENCY EXIT FROM OPERATOR'S CAB....................................... 31 ASBESTOS DUST HAZARD PREVENTION.......................................... 31 SAFETY MACHINE OPERATION..................................................... 32 STARTING ENGINE.......................................................... 32 CHECKS BEFORE STARTING ENGINE........................................ 32 SAFETY RULES FOR STARTING ENGINE..................................... 32 STARTING ENGINE INCOLD WEATHER....................................... 33 OPERATION................................................................ 34 CHECKS BEFORE OPERATION.............................................. 34 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS......................... 34 SAFETY RULES FOR TRAVELING .......................................... 35 TRAVELING ON SLOPES.................................................. 36 OPERATIONS ON SLOPES................................................. 37 PROHIBITED OPERATIONS................................................ 37 OPERATION ON SNOW.................................................... 38 PARKING MACHINE...................................................... 39 TRANSPORTATION........................................................... 40 LOADING AND UNLOADING................................................ 40 SHIPPING THE MACHINE................................................. 40 BATTERY.................................................................. 41 BATTERY HAZARD PREVENTION............................................ 41 STARTING ENGINE WITH BOOSTER CABLES.................................. 42 TOWING................................................................... 43 SAFETY RULES FOR TOWING.............................................. 43 LIFTING OBJECTS WITH BUCKET.............................................. 44 SAFETY RULES FOR LIFTING OBJECTS..................................... 44 SAFETY MAINTENANCE INFORMATION............................................... 45 WARNING TAG.............................................................. 45 KEEP WORK PLACE CLEAN AND TIDY........................................... 45 APPOINT LEADER WHEN WORKING WITH OTHERS.................................. 45 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.............................. 45 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....................... 46 PROPER TOOLS............................................................. 47 PERSONNEL................................................................ 47 ATTACHMENTS.............................................................. 47 WORK UNDER THE MACHINE................................................... 47 NOISE ................................................................... 47 WHEN USING HAMMER........................................................ 48 WELDING WORKS............................................................ 48 REMOVING BATTERY TERMINALS............................................... 48 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION..... 48 DO NOT DISASSEMBLE RECOIL SPRINGS........................................ 48 SAFETY RULES FOR HIGH-PRESSURE OIL....................................... 49 SAFETY HANDLING HIGH-PRESSURE HOSES...................................... 49 WASTE MATERIALS.......................................................... 49 AIR CONDITIONER MAINTENANCE ............................................. 49 COMPRESSED AIR........................................................... 50 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................ 50 OPERATION........................................................................ 52 MACHINE VIEW ILLUSTRATIONS................................................... 53 OVERALL MACHINE VIEW..................................................... 53 CONTROLS AND GAUGES...................................................... 54 DETAILED CONTROLS AND GAUGES................................................. 55 MONITORING SYSTEM........................................................ 55 SWITCHES................................................................. 66 CONTROL LEVERS AND PEDALS................................................ 71 SUN ROOF................................................................. 75 WINDSHEILD............................................................... 76 SLIDING DOOR............................................................. 82 EMERGENCY ESCAPE HAMMER.................................................. 82 SIDE WINDOW.............................................................. 0 EMERGENCY ESCAPE HAMMER.................................................. 0 CAP WITH LOCK............................................................ 84 ENGINE HOOD.............................................................. 85 MUD COVER................................................................ 86 BATTERY INSPECTION COVER................................................. 87 FUSE..................................................................... 88 FUSIBLELINK.............................................................. 89 AUXILIARY ELECTRIC POWER................................................. 89 CONTROLLERS.............................................................. 89 HEATER AND DEFROSTAR CONTROLS............................................ 90 AIR CONDITIONER CONTROLS................................................. 95 RADIO....................................................................101 OPERATION MANUAL STORAGE.................................................106 TOOL BOX.................................................................106 GREASE PUMP HOLDER.......................................................106 ASHTRAY..................................................................106 FIRE EXTINGUISHER........................................................107 MACHINE OPERATIONS AND CONTROLS..............................................108 BEFORE STARTING ENGINE...................................................108 STARTING ENGINE..........................................................124 AFTER STARTING ENGINE....................................................128 STOPPING ENGINE..........................................................131 CHECK AFTER STOPPING ENGINE..............................................131 MACHINE OPERATION........................................................132 STEERING THE MACHINE.....................................................136 SWINGING.................................................................138 WORK EQUIPMENT CONTROLS AND OPERATIONS...................................139 WORKING MODE.............................................................141 PROHIBITED OPERATIONS....................................................142 GENERAL OPERATION INFORMATION............................................144 TRAVELING ON SLOPES......................................................146 ESCAPE FROM MUD..........................................................148 RECOMMENDED APPLICATIONS.................................................149 BUCKET REPLACEMENT AND INVERSION.........................................151 PARKING MACHINE..........................................................153 MACHINE INSPECTION AFTER DAILY WORK......................................154 LOCKING..................................................................154 ROAD LINERS AND RUBBER SHOES.............................................155 TRANSPORTATION...............................................................160 TRANSPORTATION PROCEDURE.................................................160 LOADING AND UNLOADING WITH TRAILER.......................................160 LIFTING MACHINE..........................................................166 COLD WEATHER OPERATION.......................................................168 COLD WEATHER OPERATION INFORMATION.......................................168 AFTER DAILY WORK COMPLETION..............................................170 AFTER COLD WEATHER SEASON................................................170 LONG TERM STORAGE............................................................171 BEFORE STORAGE...........................................................171 DURING STORAGE...........................................................171 AFTER STORAGE............................................................171 TROUBLES AND ACTIONS.........................................................172 RUNNING OUT OF FUEL......................................................172 PHENOMENA THAT ARE NOT FAILURES..........................................172 TOWING THE MACHINE.......................................................172 SEVERE JOB CONDITION.....................................................173 DISCHARGED BATTERY.......................................................173 HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY.........177 OTHER TROUBLE............................................................178 MAINTENANCE......................................................................184 MAINTENANCE INFORMATION......................................................185 LUBRICANTS, COOLANT AND FILTERS..............................................187 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...................187 ELECTRIC SYSTEM MAINTENANCE..............................................189 WEAR PARTS ..................................................................190 WEAR PARTS LIST..........................................................190 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS..................................191 PROPER SELECTION.........................................................191 TIGHTENING TORQUES SPECIFICATIONS............................................195 TIGHENING TORQUE LIST....................................................195 SAFETY CRITICAL PARTS........................................................196 SAFETY CRITICAL PARTS LIST...............................................196 MAINTENANCE SCHEDULE.........................................................197 MAINTENANCE SCHEDULE CHART...............................................197 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...............................198 MAINTENANCE PROCEDURE........................................................199 INITIAL 250 HOURS SERVICE (ONLY AFETR THE FIRST 250 HOURS)...............199 FUEL FILTER ELEMENT - REPLACE........................................ 0 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.... 0 WHEN REQUIRED............................................................200 AIR CLEANER ELEMENT-CHECK/CLEAN/REPLACE..............................200 COOLING SYSTEM COOLANT - CLEAN/CHANGE................................204 WATER SEPARATOR ELEMENT-ELEMENT......................................206 FUEL TANK - CLEAN....................................................207 TRACK SHOE BOLTS - CHECK /TIGHTEN....................................208 TRACK TENSION - CHECK/ADJUST.........................................209 ROAD LINERS OR RUBBER SHOES - CHECK..................................211 RUBBER SHOE TENSION - CHECK/ADJUST...................................213 ROAD LINERS - REPLACE................................................214 RUBBER SHOES - REPLACE...............................................215 STEEL SHOES OR ROAD LINERS TO RUBBER SHOES - CHANGE..................217 BUCKET TEETH (VERTICAL OIN TYPE) - REPLACE...........................218 BUCKET TEETH (HORIZONTAL OIN TYPE) - REPLACE.........................221 BUCKET CLEARANCE - ADJUST............................................222 WINDSHIELD WASHER FLUID LEVEL - CHECK/ADD............................223 AIR CONDITIONER - CHECK/MAINTENANCE..................................224 CAB SLIDE DOOR RAIL AND ROOLER - CHECK/CLEAN/LUBRICATE...............225 BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT - REPLACE..............226 WASH WASHABLE FLOOR..................................................227 HYDRAULIC SYSTEM - BLEED AIR.........................................228 CHECK BEFORE STARTING....................................................231 EVERY 50 HOURS MAINTENANCE...............................................232 FUEL TANK - DRAIN....................................................232 EVERY 100 HOURS MAINTENANCE..............................................233 LUBRICATING..........................................................233 EVERY 250 HOURS MAINTENANCE..............................................234 LUBRICATING..........................................................234 FINAL DRIVE CASE OIL LEVEL - CHECK/ADD...............................236 BATTERY ELECTROLYTE LEVEL - CHECK....................................237 COOLING FAN BELT TENSION - INSPECT/ADJUST............................239 AIR CONDITIONER COMPRESSOR BELT TENSION - INSPECT/ADJUST.............241 EVERY 500 HOURS MAINTENANCE..............................................242 FUEL FILTER CARTRIDGE - REPLACE......................................242 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....243 AIR CONDITIONER AIR FILTER (IF EQUIPPED) - CLEAN.....................244 RADITOR FINS, OIL COOLER FINS AND CONDENSOR FINS - CLEAN/CHECK......246 SWING CIRCLE - LUBRICATE.............................................247 SWING PINION GEAR OIL LEVEL - CHECK/ADD..............................248 EVERY 1000 HOURS MAINTENANCE.............................................249 HYDRAULIC OIL FILTER ELEMENT - REPLACE...............................249 SWING MACHINERY CASE OIL - CHANGE....................................251 FINAL DRIVE CASE OIL-CHANGE..........................................252 EVERY 2000 HOURS MAINTENANCE.............................................253 PTO GEAR CASE OIL LEVEL - CHECK/ADD..................................253 ALTERNATOR AND STARTER MOTOR - INSPECT...............................253 ENGINE VALVE CLEARANCES - INSPECT....................................253 EVERY 4000 HOURS MAINTENENCE.............................................254 WATER PUMP - INSPECT.................................................254 EVERY 5000 HOURS MAINTENENCE.............................................255 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER.........................255 SPECIFICATIONS...................................................................258 SPECIFICATIONS...............................................................259 ATTACHMENTS, OPTIONS.............................................................262 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION................................263 SAFETY FIRST.............................................................263 ATTACHMENT INSTALLATION..................................................264 BUCKET WITH HOOK.............................................................265 HOOK CONDITION...........................................................265 PROHIBITED OPERATIONS....................................................265 MACHINE READY FOR ATTACHMENT.................................................266 LOCATIONS................................................................266 HYDRAULIC CIRCUIT........................................................268 ATTACHMENT OPERATIONS....................................................269 LONG TERM STORAGE........................................................271 SPECIFICATIONS...........................................................271 METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT.......................272 CHANGING MACHINE CONTROL PATTERN (IF PATERN CHANGE VALVE EQUIPPED)...........274 CONTROL PATTERN CHANGE PROCEDURE.........................................274 MACHINE CONTROL PATTERNS.................................................275 ATTACHMENT GUIDE.............................................................276 OTHER ATTACHMENTS........................................................276 ATTACHMENT COMBINATIONS..................................................277 RECOMMENDED ATTACHMENT OPERATIONS............................................278 HYDRAULIC BREAKER........................................................278 INDEX............................................................................284
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]
