Komatsu Hydraulic Excavators PC78MR Repair Service Manuals
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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC78MR, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC78MR workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEBM030601 - Hydraulic Excavator PC78MR-6 Shop Manual.pdf
SEBM030604 - Hydraulic Excavator PC78MR-6 Shop Manual.pdf
TEN00032-00 - Hydraulic Excavator GALEO PC78MR-6 Operation & Maintenance Manual.pdf
TEN00074-00 - Hydraulic Excavator GALEO PC78MR-6 Operation & Maintenance Manual.pdf
TEN00202-00 - Hydraulic Excavator GALEO PC78MR-6 Operation & Maintenance Manual.pdf
TEN00288-00 - Hydraulic Excavator PC78MR-6 Operation & Maintenance Manual.pdf
Total Pages: 2,361 pages
File Format: PDF
Language: English
SEBM030601 - Hydraulic Excavator PC78MR-6 Shop Manual....2
SEBM030604 - Hydraulic Excavator PC78MR-6 Shop Manual....594
COVER....594
CONTENTS....595
SAFETY....599
SAFETY NOTICE....599
FOREWARD....601
GENERAL....601
HOW TO READ THE SHOP MANUAL....602
HOISTING INSTRUCTIONS....603
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER....604
COATING MATERIALS....606
STANDARD TIGHTENING TORQUE....608
ELECTRIC WIRE CODE....611
CONVERSION TABLE....612
UNITS....618
01 GENERAL....620
SPECIFICATION DIMENSIONS DRAWING....621
WORKING RANGE DRAWING....623
SPECIFICATIONS....624
WEIGHT TABLE....627
LIST OF LUBRICANTS AND COOLANT....629
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD....631
PTO ....632
COOLING SYSTEM....633
POWER TRAIN SYSTEM....634
SWING CIRCLE....635
SWING MACHINERY....636
TRACK FRAME AND IDLER CUSHION....638
IDLER....640
TRACK ROLLER....641
CARRIER ROLLER....643
SPROCKET....644
TRACK SHOE....645
ARRANGEMENT OF HYDRAULIC COMPONENTS....650
HYDRAULIC TANK AND OIL FILTER....651
CENTER SWIVEL JOINT....652
TRAVEL MOTOR....653
WORK EQUIPMENT CYLINDER....661
SOLENOID VALVE....665
SOLENOID VALVE (FOR EU SPEC.)....673
ACCUMULATOR FOR PPC....677
MULTI-CONTROL VALVE....678
ACCUMULATOR FOR BRAKER....679
HYDRAULIC PUMP....680
CONTROL VALVE....694
CLSS....706
SWING MOTOR....738
WORK EQUIPMENT AND SWING PPC VALVE....746
TRAVEL PPC VALVE....752
BOOM SWING PPC VALVE, BLADE PPC VALVE....756
BOOM HYDRAULIC ANTI-BURST VALVE (FOR EU SPEC)....760
WORK EQUIPMENT....766
DIMENSIONS OF EACH PART OF WORK EQUIPMENT....768
AIR CONDITIONER PIPING (OPTIONAL)....772
ELECTRIC CONTROL SYSTEM....773
SYSTEM COMPONENTS....793
MONITOR SYSTEM....802
SENSORS....807
20 TESTING AND ADJUSTING....810
STANDARD VALUE TABLE FOR ENGINE....811
STANARD VALUE TABLE FOR CHASSIS....812
STANDARD VALUE TABLE FOR ELECTRIC PARTS....820
TESTING AND ADJUSTING....826
LIST OF DEVICES FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....827
MEASURING ENGINE SPEED....828
MEASURING EXHAUST GAS COLOR....829
ADJUSTING VALVE CLEARANCE....830
MEASURING COMPRESSION PRESSURE....831
MEASURING BLOW-BY PRESSURE....832
TESTING AND ADJUSTING FUEL INJECTION TIMING....833
MEASURING ENGINE OIL PRESSURE....837
ADJUSTING ENGINE STOP SOLENOID....838
ADJUSTING FUEL CONTROL LINKAGE....840
ADJUSTING ENGINE SPEED SENSOR....842
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS....843
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE....846
ADJUSTING PC VALVE....848
TESTING TVC-EPC SOLENOID OUTPUT PRESSURE....848
MEASURING CONTROL CIRCUIT PRESSURE....849
MEASURING PPC VALVE OUTPUT PRESSURE....850
TESTING SOLENOID VALVE OUTPUT PRESSURE....851
ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE....853
TESTING TRAVEL DEVIATION....854
TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT....856
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTORS....857
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT....858
TESTING CLEARANCE OF SWING CIRCLE BEARING....859
TESTING AND ADJUSTING TRACK SHOE TENSION....860
BLEEDING AIR FROM HYDRAULIC CIRCUIT....861
REPLACEMENT PROCEDURE OF POTENTIOMETERS....863
PROCEDURE FOR TESTING DIODE....864
TROUBLESHOOTING....866
POINTS TO REMEMBER WHEN TROUBLESHOOTING....867
SEQUENCE OF EVENTS IN TROUBLESHOOTING....868
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....869
CHECKS BEFORE TROUBLESHOOTING....877
TYPE AND LOCATION OF CONNECTORS....879
CONNECTOR ARRANGEMENT DIAGRAM....881
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....884
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL MECHANISM....907
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL....908
TVC VALVE CURRENT ADJUSTMENT TABLE....919
METHOD OF USING JUDGEMENT TABLE....920
HOW TO READ FLOW OF TROUBLESHOOTING....922
CONTENTS AND PROCEDURE OF TROUBLESHOOTING....924
TROUBLESHOOTING OF ENGINE (S MODE)....925
METHOD OF USING TROUBLESHOOTING CHART....926
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....930
S-2 ENGINE DOES NOT START....932
1) ENGINE DOES NOT TURN....932
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)....933
3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....934
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)....935
S-4 ENGINE STOPS DURING OPERATIONS....936
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....937
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)....938
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)....939
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)....940
S-9 OIL BECOMES CONTAMINATED QUICKLY....941
S-10 FUEL CONSUMPTION IS EXCESSIVE....942
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN....943
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)....944
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)....945
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)....946
S-15 ABNORMAL NOISE IS MADE....947
S-16 VIBRATION IS EXCESSIVE....948
TROUBLESHOOTING OF COMMUNICATION SYSTEM (N MODE)....949
N-1 DEFECTIVE COMMUNICATION....950
TROUBLESHOOTING FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)....951
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (GOVERNOR CONTROL SYSTEM)....952
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE....954
JUDGEMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE....956
E-1 CONTROLLER POWER SUPPLY IS DEFECTIVE (LED OF CONTROLLER IS TURNED OFF)....958
E-2 [E323] (SHORT CIRCUIT IN ACCELERATOR RELAY SYSTEM) IS DISPLAYED....959
E-3 [E325] (SHORT CIRCUIT IN DECELERATOR RELAY SYSTEM) IS DISPLAYED....960
E-4 [E328] (STALL OF MOTOR) IS DISPLAYED....961
E-5 [E227] (TROUBLE IN ENGINE SPEED SENSOR) IS DISPLAYED....963
E-6 ONE TOUCH SLOW DOWN MECHANISM DOES NOT WORK....964
E-7 ENGINE DOES NOT START....965
a) [E304] SHORT CIRCUIT IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED....965
b) [E314] DISCONNECTION IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED....965
c) ENGINE STOP SOLENOID SYSTEM....966
d) STARTING SYSTEM....968
E-8 ENGINE DOES NOT STOP....972
TROUBLESHOOTING FOR CONTROLLER PUMP CONTROL SYSTEM (C MODE)....973
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (PUMP CONTROL SYSTEM)....974
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE....976
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC EQUIPMENT....980
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM (FOR STD. SPEC)....982
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM (FOR EU SPEC)....984
C-1 [E232], C-2 [E233] TROUBLE IN TVC-EPC SOLENOID SYSTEM....986
C-3 [E203], C-4 [E213] TROUBLE IN SWING HOLDING BRAKE SOLENOID SYSTEM....987
C-5 [E206], C-6 [E216] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENOID SYSTEM....988
C-7 [E411] TROUBLE IN BOOM SWING ANGLE SENSOR CORRECTION....989
C-8 [E251] TROUBLE IN BOOM BOTTOM PRESSURE SENSOR (OVERLOAD SENSOR) SYSTEM (FOR EU SPEC)....990
C-9 [E258] SHORT CIRCUIT IN 5V SYSTEM OF SENSOR POWER SUPPLY (FOR EU SPEC)....990
C-9 [E258] SHORT CIRCUIT IN 5V SYSTEM OF SENSOR POWER SUPPLY (FOR STD SPEC)....991
C-10 [E412], C-11 [E413] TROUBLE IN BOOM SWING ANGLE SENSOR SYSTEM....992
C-12 [E451] SHORT CIRCUIT IN BOOM SWING LEFT STOP EPC SOLENOID SYSTEM IS DISPLAYED....993
C-13 [E452] DISCONNECTION IN BOOM SWING LEFT STOP EPC SOLENOID SYSTEM IS DISPLAYED....994
C-14 [E453] SHORT CIRCUIT IN BOOM SWING RIGHT STOP EPC SOLENOID SYSTEM IS DISPLAYED....995
C-15 [E454] DISCONNECTION IN BOOM SWING RIGHT STOP EPC SOLENOID SYSTEM IS DISPLAYED....996
C-16 BOOM SWING LEFTT END CUSHION DOES NOT WORK AT ALL OR NORMALLY....997
C-17 BOOM SWING RIGHT END CUSHION DOES NOT WORK AT ALL OR NORMALLY....999
C-18 WORK EQUIPMENT STILL MOVES AFTER WORK EQUIPMENT LOCK LEVER IS SET TO LOCK....1001
C-19 MACHINE DOES NOT SWING....1002
C-20 TRAVEL SPEED DOES NOT RISE....1003
C-21 TROUBLE IN CONTROLLER POWER SUPPLY (LED OF CONTROLLER IS TURNED OFF)....1003
TROUBLESHOOTING FOR CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)....1004
F-1 BIT PATTERN 1023-(4) SWING PRESSURE SWITCH DOES NOT LIGHT UP....1005
F-2 BIT PATTERN 1023-(3) TRAVEL PRESSURE SWITCH DOES NOT LIGHT UP....1006
F-3 BIT PATTERN 1023-(6) BOOM RAISE PRESSURE SWITCH DOES NOT LIGHT UP....1007
F-4 BIT PATTERN 1023-(5) ARM IN PRESSURE SWITCH DOES NOT LIGHT UP....1008
F-5 BIT PATTERN 1026-(1) DECELERATION SWITCH OF LEFT KNOB DOES NOT LIGHT UP....1009
F-6 BIT PATTERN 1026-(4) 2ND TRAVEL SPEED SELECTION SWITCH (PEDAL) DOES NOT LIGHT UP....1010
F-7 BIT PATTERN 1021-(3) COMPRESSOR SIGNAL DOES NOT LIGHT UP....1011
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)....1012
TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES....1015
H-1 SPEED OR POWER OF 2 OR MORE SYSTEMS OF WORK EQUIPMENT (BOOM, ARM, BUCKET) TRAVEL, SWING, AND BLADE IS LOW....1017
a) SPEED OR POWER OF WORK EQUIPMENT (INCLUDING BLADE), TRAVEL, AND SWING SYSTEMS IS LOW....1017
b) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE) AND TRAVEL IS LOW....1018
c) SPEED OR POWER OF SWING AND BLADE IS LOW....1018
d) SPEED OR POWER OF TRAVEL AND BLADE IS LOW....1019
e) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE) IS LOW....1019
f) SPEED OR POWER OF TRAVEL AND SWING IS LOW....1019
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS....1020
H-3 2 OR MORE SYSTEMS OF WORK EQUIPMENT (BOOM, ARM, BUCKET), TRAVEL, SWING, AND BLADE DO NOT MOVE....1022
a) ALL WORK EQUIPMENT (INCLUDING BLADE), TRAVEL, AND SWING SYSTEMS DO NOT MOVE....1022
b) ALL WORK EQUIPMENT (EXCLUDING BLADE) AND TRAVEL SYSTEMS DO NOT MOVE....1023
c) SWING AND BLADE SYSTEMS DO NOT MOVE....1023
d) TRAVEL AND BLADE SYSTEMS DO NOT MOVE....1024
e) ALL WORK EQUIPMENT (EXCLUDING BLADE) DOES NOT MOVE....1024
H-4 ABNORMAL SOUND COMES OUT (FROM AROUND PUMP)....1025
H-5 FINE CONTROLLABILITY OR RESPONSE IS LOW....1026
H-6 HYDRAULIC DRIFT IS LARGE (ALL WORK EQUIPMENT AND BLADE)....1027
H-7 BOOM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)....1028
a) BOOM RAISE SPEED OR POWER IS LOW....1028
b) BOOM LOWER SPEED OR POWER IS LOW....1029
H-8 ARM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)....1030
a) ARM IN SPEED OR POWER IS LOW....1030
b) ARM OUT SPEED OR POWER IS LOW....1031
H-9 BUCKET SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)....1032
a) BUCKET CURL SPEED OR POWER IS LOW....1032
b) BUCKET DUMP SPEED OR POWER IS LOW....1033
H-10 BOOM SWING SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)....1034
a) SWING LEFT SPEED OR POWER IS LOW....1034
b) SWING RIGHT SPEED OR POWER IS LOW....1035
H-11 BOOM DOES NOT MOVE....1036
a) BOOM DOES NOT RISE....1036
b) BOOM DOES NOT LOWER....1037
H-12 ARM DOES NOT MOVE....1038
a) ARM DOES NOT MOVE IN....1038
b) ARM DOES NOT MOVE OUT....1039
H-13 BUCKET DOES NOT MOVE....1040
a) BUCKET DOES NOT CURL....1040
b) BUCKET DOES NOT DUMP....1041
H-14 BOOM SWING DOES NOT MOVE....1042
a) BOOM SWING LEFT DOES NOT MOVE....1042
b) BOOM SWING RIGHT DOES NOT MOVE....1043
H-15 HYDRAULIC DRIFT OF BOOM IS LARGE....1044
H-16 HYDRAULIC DRIFT OF ARM IS LARGE....1044
H-17 HYDRAULIC DRIFT OF BUCKET IS LARGE....1045
H-18 HYDRAULIC DRIFT OF SWING IS LARGE....1045
a) HYDRAULIC DRIFT OF SWING TO LEFT IS LARGE....1045
b) HYDRAULIC DRIFT OF SWING TO RIGHT IS LARGE....1045
H-19 TIME LAG IS LARGE (WHEN ENGINE SPEED IS LOW)....1046
H-20 PART LOADED MORE MOVES SLOWER IN COMPOUND OPERATION OF WORK EQUIPMENT....1046
H-21 BOOM RAISE SPEED IS LOW IN COMPOUND OPERATION OF SWING AND BOOM RAISE....1047
H-22 TRAVEL SPEED LOWERS EXTREMELY IN COMPOUND OPERATION OF TRAVEL AND BOOM RAISE....1047
H-23 SPEED IS LOW IN COMPOUND OPERATION OF WORK EQUIPMENT RELIEF AND SWING, WORK EQUIPMENT RELIEF AND OTHER WORK EQUIPMENT....1047
H-24 TRAVEL DEVIATION IS LARGE....1048
a) TRAVEL DEVIATION IS LARGE DURING ORDINARY TRAVEL....1048
b) TRAVEL DEVIATION IS LARGE WHEN MACHINE STARTS (BUT NORMAL DURING ORDINARY TRAVEL)....1049
H-25 TRAVEL DEVIATION IS LARGE IN COMPOUND OERATION OF TRAVEL AND SWING, TRAVEL AND WORK EQUIPMENT....1050
H-26 TRAVEL SPEED OR POWER IS LOW (WORK EQUIPMENT, SWING, AND BLADE OPERATIONS ARE NORMAL)....1051
H-27 MACHINE CANNOT BE STEERED SHARPLY OR STEERING FORCE IS INSUFFICIENT....1053
H-28 TRAVEL SPEED DOES NOT CHANGE AT ALL OR DOES NOT CHANGE QUICKLY....1054
H-29 MACHINE DOES NOT TRAVEL....1055
H-29 SUPPLEMENT....1056
H-30 OVERRUN OF TRAVEL IS LARGE....1057
H-31 TRAVEL HYDRAULIC DRIFT IS LARGE....1057
H-32 FINE CONTROLLABILITY OR RESPONSE IS LOW....1058
H-33 SWING SPEED OR POWER IS LOW (WORK EQUIPMENT, TRAVEL, AND BLADE OPERATIONS ARE NORMAL)....1059
H-34 MACHINE DOES NOT SWING (WORK EQUIPMENT, TRAVEL, AND BLADE OPERATIONS ARE NORMAL)....1061
a) SWING SPEED OR POWER IS LOW IN BOTH DIRECTIONS....1061
b) SWING SPEED OR POWER IS LOW IN EITHER DIRECTION....1062
H-35 SWING ACCELERATION IS LOW....1063
a) SWING ACCELERATION IS LOW IN BOTH DIRECTIONS....1063
b) SWING ACCELERATION IS LOW IN EITHER DIRECTION....1063
H-36 OVERRUN OF SWING IS LARGE....1064
a) OVERRUN OF SWING IS LARGE IN BOTH DIRECTIONS....1064
b) OVERRUN OF SWING IS LARGE IN EITHER DIRECTION....1064
H-37 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING....1065
H-38 LARGE ABNORMAL SOUND IS MADE WHEN MACHINE STOPS SWINGING....1065
H-39 SWING HYDRAULIC DRIFT IS LARGE....1066
H-40 FINE CONTROLLABILITY OR RESPONSE OF SWING IS LOW....1067
H-41 BLADE SPEED OR POWER IS LOW (WORK EQUIPMENT, TRAVEL, AND SWING OPERATIONS ARE NORMAL)....1068
H-42 BLADE DOES NOT MOVE (WORK EQUIPMENT, TRAVEL, AND SWING OPERATIONS ARE NORMAL)....1069
a) BLADE DOES NOT RISE....1069
b) BLADE DOES NOT LOWER....1070
H-43 HYDRAULIC DRIFT OF BLADE IS LARGE....1071
H-44 FINE CONTROLLABILITY OR RESPONSE OF BLADE IS LOW....1072
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M MODE)....1074
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE....1075
ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM....1077
M-1 [E101] (ERROR HISTORY DATA ARE ABNORMAL) IS DISPLAYED....1079
M-2 [E108] (ENGINE COOLANT TEMPERATURE IS 105 DEGREES C) IS DISPLAYED....1080
M-3 [E112] (WIPER FORWARD OUTPUT IS SHORTED) IS DISPLAYED....1080
M-4 [E113] (WIPER REVERSE OUTPUT IS SHORTED) IS DISPLAYED....1080
M-5 [E114] (CONTACT WITH WASHER OUTPUT OF 24V) IS DISPLAYED....1080
M-6 [E115] (WIPER DOES NOT START WIPING IN 10 SECONDS) IS DISPLAYED....1080
M-7 [E116] (WIPER IS NOT RETRACTED IN 10 SECONDS) IS DISPLAYED....1080
M-8 MONITOR PANEL SEGMENTS DO NOT LIGHT UP AT ALL FOR 3 SECONDS AFTER STARTING SWITCH IS TURNED ON....1081
a) MONITOR PANEL SEGMENTS DO NOT LIGHT UP AT ALL....1081
b) SOME MONITOR PANEL SEGMENTS DO NOT LIGHT UP....1081
M-9 WHEN STARTING SWITCH IS SET TO ON POSITION, ALL MONITOR PANEL SEGMENTS LIGHT UP BUT DO NOT GO OFF....1083
M-10 WHILE PREHEATING IS NOT EXECUTED, "PREHEATER MONITOR" LIGHTS UP....1083
M-11 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH....1084
a) ALTERNATOR SYSTEM....1084
b) ENGINE OIL SYSTEM....1085
M-12 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED), CAUTION ITEMS (EXCLUDING BATTERY AND ENGINE OIL) FLASH....1086
a) ALTERNATOR SYSTEM....1086
b) ENGINE OIL PRESSURE SENSOR SYSTEM....1087
M-13 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH (WHEN THERE IS NOT ABNORMALITY IN INSPECTION ITEMS AND ENGINE BEFORE TROUBLESHOOTING, HOWEVER)....1088
a) "ENGINE OIL" FLASHES....1088
b) "CHARGE LEVEL" FLASHES....1088
c) "COOLANT TEMPERATURE" FLASHES....1089
d) "FUEL LEVEL" FLASHES....1090
M-14 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND WHILE CAUTION ITEM IS FLASHING, BUZZER DOES NOT SOUND....1091
M-15 MONITOR PLANE LAMP FOR NIGHTTIME IS NOT TURNED ON (LC DISPLAY IS NORMAL)....1092
M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE....1093
M-17 COOLANT TEMPERATURE GAUGE IS NOT DISPLAYED (GAUGE DOES NOT RISE TO 1ST LINE DURING OPERATION)....1093
M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL....1094
M-19 FUEL LEVEL GAUGE IS NOT DISPLAYED....1094
M-20 WHILE ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE....1095
M-21 TROUBLE IN FUEL LEVEL SENSOR....1096
M-22 TROUBLE IN COOLANT TEMPERATURE SENSOR....1097
M-23 WIPER DOES NOT OPERATE OR OPERATES WHILE WIPER SWITCH IS TURNED OFF....1098
a) WIPER DOES NOT OPERATE....1098
b) WIPER OPERATES WHILE WIPER SWITCH IS TURNED OFF....1098
M-24 WASHER MOTOR DOES NOT OPERATE OR OPERATES WHILE WASHER SWITCH IS TURNED OFF....1101
a) WASHER MOTOR DOES NOT OPERATE....1101
b) WASHER OPERATES WHILE WIPER SWITCH IS TURNED OFF....1101
30 DISASSEMBLY AND ASSEMBLY....1104
METHOD OF USING MANUAL....1105
PRECAUTIONS WHEN CARRYING OUT OPERATION....1106
SPECIAL TOOL LIST....1110
COUNTERWEIGHT ....1116
REMOVAL AND INSTALLATION....1116
INJECTION PUMP ....1117
REMOVAL....1117
INSTALLATION....1118
CYLINDER HEAD....1119
REMOVAL....1119
INSTALLATION....1122
MAIN PUMP....1123
REMOVAL....1123
INSTALLATION....1124
CONTROL PUMP....1124
REMOVAL AND INSTALLATION....1124
ENGINE AND MAIN PUMP....1125
REMOVAL....1125
INSTALLATION....1127
HYDRAULIC OIL COOLER....1128
REMOVAL AND INSTALLATION....1128
RADIATOR ....1128
REMOVAL....1128
INSTALLATION....1129
SWING MOTOR AND SWING MACHINERY....1130
REMOVAL AND INSTALLATION....1130
SWING MACHINERY....1131
DISASSEMBLY....1131
ASSEMBLY....1133
SWING MOTOR ....1137
REMOVAL AND INSTALLATION....1137
CENTER SWIVEL JOINT....1137
REMOVAL....1137
INSTALLATION....1138
DISASSEMBLY AND ASSEMBLY....1139
CONTROL VALVE....1140
REMOVAL AND INSTALLATION....1140
ASSEMBLY....1141
WORK EQUIPMENT PPC VALVE....1142
ASSEMBLY....1142
TRAVEL PPC VALVE ....1143
ASSEMBLY....1143
HYDRAULIC TANK ....1145
REMOVAL AND INSTALLATION....1145
FUEL TANK....1146
REMOVAL....1146
INSTALLATION....1147
CONTROLLER....1149
REMOVAL AND INSTALLATION....1149
MONITOR PANEL....1150
REMOVAL AND INSTALLATION....1150
AIR CONDITIONER UNIT....1150
REMOVAL....1150
INSTALLATION....1151
OPERATOR'S CAB....1152
REMOVAL AND INSTALLATION....1152
FLOOR FRAME ....1153
REMOVAL....1153
INSTALLATION....1154
REVOLVING FRAME....1155
REMOVAL AND INSTALLATION....1155
SWING CIRCLE....1156
REMOVAL AND INSTALLATION....1156
WORK EQUIPMENT ....1157
REMOVAL....1157
INSTALLATION....1158
SWING BRACKET....1159
REMOVAL....1159
INSTALLATION....1160
STEEL SHOE, RUBBER PAD SHOE, ROAD LINER....1161
EXPANSION AND INSTALLATION....1161
RUBBER SHOE ....1162
REMOVAL AND INSTALLATION....1162
FINAL DRIVE ....1162
REMOVAL....1162
INSTALLATION....1163
IDLER ....1163
ASSEMBLY....1163
RECOIL SPRING....1165
DISASSEMBLY....1165
ASSEMBLY....1166
TRACK ROLLER....1167
DISASSEMBLY....1167
ASSEMBLY....1168
HYDRAULIC CYLINDER....1170
DISASSEMBLY....1170
ASSEMBLY....1172
90 OTHERS....1174
HYDRAULIC CIRCUIT DIAGRAM (FOR STD SPEC)....1175
HYDRAULIC CIRCUIT DIAGRAM (FOR EU SPEC)....1176
ELECTRICAL CIRCUIT DIAGRAM (FOR STD SPEC) (1/2)....1177
ELECTRICAL CIRCUIT DIAGRAM (FOR STD SPEC) (2/2)....1178
ELECTRICAL CIRCUIT DIAGRAM (FOR EU SPEC) (1/2)....1179
ELECTRICAL CIRCUIT DIAGRAM (FOR EU SPEC) (2/2)....1180
ELECTRICAL CIRCUIT DIAGRAM (FOR NORWAY SPEC.) (1/2)....1181
ELECTRICAL CIRCUIT DIAGRAM (FOR NORWAY SPEC.) (2/2)....1182
TEN00032-00 - Hydraulic Excavator GALEO PC78MR-6 Operation & Maintenance Manual....1183
COVER....1183
FOREWORD....1184
FOREWORD....1185
SAFETY INFORMATION....1188
INTRODUCTION....1190
DIRECTIONS OF MACHINE....1190
PRODUCT INFORMATION....1191
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....1191
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION....1191
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION....1192
SERVICE METER LOCATION....1192
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....1193
CONTENTS....1194
SAFETY....1198
SAFETY INFORMATION....1199
SAFETY LABELS....1201
LOCATION OF SAFETY LABELS....1202
SAFETY LABELS....1203
SAFETY INFORMATION....1210
SAFETY RULES....1210
IF ABNORMALITIES ARE FOUND....1210
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS....1210
FIRE EXTINGUISHER AND FIRST AID KIT....1210
SAFETY EQUIPMENT....1210
KEEP MACHINE CLEAN....1211
KEEP OPERATOR'S COMPARTMENT CLEAN....1211
LEAVING OPERATOR'S SEAT WITH LOCK....1211
HANDRAILS AND STEPS....1212
MOUNTING AND DISMOUNTING....1212
NO PERSONS ON ATTACHMENTS....1212
DO NOT GET CAUGHT IN ARTICULATED PORTION....1212
BURN PREVENTION....1213
FIRE PREVENTION AND EXPLOSION PREVENTION....1213
ACTION IF FIRE OCCURS....1214
WINDSHIELD WASHER FLUID....1214
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION....1214
ATTACHMENT INSTALLATION....1215
ATTACHMENT COMBINATIONS....1215
CAB WINDOW GLASSES....1215
UNAUTHORIZED MODIFICATIONS....1215
SAFETY AT JOBSITE....1215
WORKING ON LOOSE GROUND....1216
DISTANCE TO HIGH VOLTAGE CABLES....1216
ENSURE GOOD VISIBILITY....1216
VENTILATION FOR ENCLOSED AREA....1217
SIGNALMAN'S SIGNAL AND SIGNS....1217
EMERGENCY EXIT FROM OPERATOR'S CAB....1217
ASBESTOS DUST HAZARD PREVENTION....1217
SAFETY MACHINE OPERATION....1218
STARTING ENGINE....1218
CHECKS BEFORE STARTING ENGINE....1218
SAFETY RULES FOR STARTING ENGINE....1219
STARTING ENGINE IN COLD WEATHER....1219
OPERATION....1220
CHECKS BEFORE OPERATION....1220
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS....1220
SAFETY RULES FOR TRAVELING....1221
TRAVELING ON SLOPES....1222
OPERATIONS ON SLOPES....1223
PROHIBITED OPERATIONS....1223
OPERATIONS ON SNOW....1224
PARKING MACHINE....1225
TRANSPORTATION....1226
LOADING AND UNLOADING....1226
SHIPPING THE MACHINE....1226
BATTERY....1227
BATTERY HAZARD PREVENTION....1227
STARTING ENGINE WITH BOOSTER CABLES....1228
TOWING....1229
SAFETY RULES FOR TOWING....1229
LIFTING OBJECTS WITH BUCKET....1230
SAFETY RULES FOR LIFTING OBJECTS....1230
SAFETY MAINTENANCE INFORMATION....1231
WARNING TAG....1231
KEEP WORK PLACE CLEAN AND TIDY....1231
APPOINT LEADER WHEN WORKING WITH OTHERS....1231
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE....1231
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....1232
PROPER TOOLS....1233
ACCUMULATOR....1233
PERSONNEL....1233
ATTACHMENTS....1233
WORK UNDER THE MACHINE....1234
NOISE....1234
WHEN USING HAMMER....1234
WELDING WORKS....1234
REMOVING BATTERY TERMINALS....1234
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION....1235
DO NOT DISASSEMBLE RECOIL SPRINGS....1235
SAFETY RULES FOR HIGH-PRESSURE OIL....1235
SAFETY HANDLING HIGH-PRESSURE HOSES....1235
WASTE MATERIALS....1236
AIR CONDITIONER MAINTENANCE....1236
COMPRESSED AIR....1236
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....1236
OPERATION....1238
MACHINE VIEW ILLUSTRATIONS....1239
OVERALL MACHINE VIEW....1239
CONTROLS AND GAUGES....1240
DETAILED CONTROLS AND GAUGES....1241
MONITORING SYSTEM....1241
SWITCHES....1252
CONTROL LEVERS AND PEDALS....1257
SUN ROOF....1263
WINDSHIELD....1264
SLIDING DOOR....1269
EMERGENCY ESCAPE HAMMER....1269
CAP WITH LOCK....1271
ENGINE HOOD....1272
MUD COVER....1273
BATTERY INSPECTION COVER....1274
FUSE....1275
FUSIBLE LINK....1276
AUXILIARY ELECTRIC POWER....1276
CONTROLLERS....1276
AIR CONDITIONER CONTROLS....1277
HEATER AND DEFROSTER CONTROLS....1283
RADIO....1288
OPERATION MANUAL STORAGE....1293
TOOL BOX....1293
GREASE PUMP HOLDER....1293
ASHTRAY....1293
FIRE EXTINGUISHER....1294
MACHINE OPERATIONS AND CONTROLS....1295
BEFORE STARTING ENGINE....1295
STARTING ENGINE....1311
AFTER STARTING ENGINE....1316
STOPPING THE ENGINE....1319
CHECK AFTER SHUT OFF ENGINE....1319
MACHINE OPERATION....1320
STEERING THE MACHINE....1324
SWINGING....1326
WORK EQUIPMENT CONTROLS AND OPERATIONS....1327
WORKING MODE....1329
PROHIBITED OPERATIONS....1330
GENERAL OPERATION INFORMATION....1332
TRAVELING ON SLOPES....1334
ESCAPE FROM MUD....1336
RECOMMENDED APPLICATIONS....1337
MACHINE READY FOR ATTACHMENT....1339
BUCKET REPLACEMENT AND INVERSION....1345
PARKING MACHINE....1347
MACHINE INSPECTION AFTER DAILY WORK....1348
LOCKING....1348
ROAD LINERS AND RUBBER SHOES....1349
TRANSPORTATION....1354
TRANSPORTATION PROCEDURE....1354
LOADING AND UNLOADING WITH TRAILER....1354
LIFTING MACHINE....1360
COLD WEATHER OPERATION....1362
COLD WEATHER OPERATION INFORMATION....1362
AFTER DAILY WORK COMPLETION....1364
AFTER COLD WEATHER SEASON....1364
LONG TERM STORAGE....1365
BEFORE STORAGE....1365
DURING STORAGE....1365
AFTER STORAGE....1365
TROUBLES AND ACTIONS....1366
RUNNING OUT OF FUEL....1366
PHENOMENA THAT ARE NOT FAILURES....1366
TOWING THE MACHINE....1367
SEVERE JOB CONDITION....1367
DISCHARGED BATTERY....1368
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY....1373
OTHER TROUBLE....1374
MAINTENANCE....1380
MAINTENANCE INFORMATION....1381
OUTLINE OF SERVICE....1383
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....1383
ELECTRIC SYSTEM MAINTENANCE....1386
WEAR PARTS....1387
WEAR PARTS LIST....1387
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....1388
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....1389
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN....1390
TIGHTENING TORQUE SPECIFICATIONS....1391
TIGHTENING TORQUE LIST....1391
SAFETY CRITICAL PARTS....1392
SAFETY CRITICAL PARTS LIST....1392
MAINTENANCE SCHEDULE....1393
MAINTENANCE SCHEDULE CHART....1393
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....1394
MAINTENANCE PROCEDURE....1395
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)....1395
REPLACE FUEL FILTER CARTRIDGE....1440
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....1441
WHEN REQUIRED....1396
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT....1396
CLEAN INSIDE OF COOLING SYSTEM....1400
REPLACE WATER SEPARATOR ELEMENT....1403
CLEAN FUEL TANK....1404
CHECK AND TIGHTEN TRACK SHOE BOLTS....1405
CHECK AND ADJUST TRACK TENSION....1406
CHECK ROAD LINERS OR RUBBER SHOES....1408
CHECK AND ADJUST RUBBER SHOE TENSION....1410
REPLACE ROAD LINERS....1411
REPLACE RUBBER SHOES....1412
CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES....1414
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)....1415
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)....1418
ADJUST BUCKET CLEARANCE....1419
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID....1420
CHECK AND ADJUST AIR CONDITIONER....1421
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER....1422
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT....1423
WASH WASHABLE FLOOR....1424
BLEEDING AIR FROM HYDRAULIC SYSTEM....1426
CHECK BEFORE STARTING....1429
EVERY 50 HOURS MAINTENANCE....1430
DRAIN WATER FROM FUEL TANK....1430
EVERY 100 HOURS MAINTENANCE....1431
LUBRICATING....1431
EVERY 250 HOURS MAINTENANCE....1432
LUBRICATING....1432
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL....1434
CHECK LEVEL OF BATTERY ELECTROLYTE....1435
CHECK AND ADJUST COOLING FAN BELT TENSION....1437
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....1439
EVERY 500 HOURS MAINTENANCE....1440
REPLACE FUEL FILTER CARTRIDGE....1440
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....1441
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS....1442
CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS....1444
LUBRICATE SWING CIRCLE....1446
CHECK SWING PINION GREASE LEVEL, ADD GREASE....1446
EVERY 1000 HOURS MAINTENANCE....1447
REPLACE HYDRAULIC OIL FILTER ELEMENT....1447
CHANGE OIL IN SWING MACHINERY CASE....1449
CHANGE OIL IN FINAL DRIVE CASE....1450
EVERY 2000 HOURS MAINTENANCE....1451
CHECK PTO GEAR CASE, ADD OIL....1451
CLEAN, CHECK TURBOCHARGER....1451
CHECK ALTERNATOR, STARTING MOTOR....1451
CHECK ENGINE VALVE CLEARANCE, ADJUST....1451
EVERY 4000 HOURS MAINTENANCE....1452
CHECK WATER PUMP....1452
EVERY 5000 HOURS MAINTENANCE....1453
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER....1453
SPECIFICATIONS....1456
SPECIFICATIONS....1457
ATTACHMENTS, OPTIONS....1460
ATTACHMENTS AND OPTIONS - GENERAL INFORMATION....1461
SAFETY FIRST....1461
ATTACHMENT INSTALLATION....1462
BUCKET WITH HOOK....1463
HOOK CONDITION....1463
PROHIBITED OPERATIONS....1463
METHOD FOR REMOVING AND INSTALLING EXTRA....1464
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE....1466
CONTROL PATTERN CHANGE PROCEDURE....1466
MACHINE CONTROL PATTERNS....1467
ATTACHMENT GUIDE....1468
OTHER ATTACHMENTS....1468
ATTACHMENT COMBINATIONS....1469
SELECTION OF TRACK SHOES....1470
RECOMMENDED ATTACHMENT OPERATIONS....1471
HYDRAULIC BREAKER....1471
INDEX....1476
TEN00074-00 - Hydraulic Excavator GALEO PC78MR-6 Operation & Maintenance Manual....1480
COVER....1480
FOREWORD....1481
FOREWORD....1482
SAFETY INFORMATION....1485
INTRODUCTION....1487
DIRECTIONS OF MACHINE....1487
PRODUCT INFORMATION....1488
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....1488
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION....1488
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION....1489
SERVICE METER LOCATION....1489
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....1490
CONTENTS....1491
SAFETY....1495
SAFETY INFORMATION....1496
SAFETY LABELS....1498
LOCATION OF SAFETY LABELS....1499
SAFETY LABELS....1500
SAFETY INFORMATION....1507
SAFETY RULES....1507
IF PROBLEMS ARE FOUND....1507
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS....1507
FIRE EXTINGUISHER AND FIRST AID KIT....1507
SAFETY EQUIPMENT....1507
KEEP MACHINE CLEAN....1508
KEEP OPERATOR'S COMPARTMENT CLEAN....1508
LEAVING OPERATOR'S SEAT WITH LOCK....1508
HANDRAILS AND STEPS....1509
MOUNTING AND DISMOUNTING....1509
NO PERSONS ON ATTACHMENTS....1509
DO NOT GET CAUGHT IN ARTICULATED PORTION....1509
BURN PREVENTION....1510
FIRE PREVENTION AND EXPLOSION PREVENTION....1510
ACTION IF FIRE OCCURS....1511
WINDSHIELD WASHER FLUID....1511
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION....1511
ATTACHMENT INSTALLATION....1512
ATTACHMENT COMBINATIONS....1512
CAB WINDOW GLASSES....1512
UNAUTHORIZED MODIFICATIONS....1512
SAFETY AT JOBSITE....1512
WORKING ON LOOSE GROUND....1513
DISTANCE TO HIGH VOLTAGE CABLES....1513
ENSURE GOOD VISIBILITY....1513
VENTILATION FOR ENCLOSED AREA....1514
SIGNALMAN'S SIGNAL AND SIGNS....1514
EMERGENCY EXIT FROM OPERATOR'S CAB....1514
ASBESTOS DUST HAZARD PREVENTION....1514
SAFETY MACHINE OPERATION....1515
STARTING ENGINE....1515
CHECKS BEFORE STARTING ENGINE....1515
SAFETY RULES FOR STARTING ENGINE....1516
STARTING ENGINE IN COLD WEATHER....1516
OPERATION....1517
CHECKS BEFORE OPERATION....1517
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS....1517
SAFETY RULES FOR TRAVELING....1518
TRAVELING ON SLOPES....1519
OPERATIONS ON SLOPES....1520
PROHIBITED OPERATIONS....1520
OPERATIONS ON SNOW....1521
PARKING MACHINE....1522
TRANSPORTATION....1523
LOADING AND UNLOADING....1523
SHIPPING THE MACHINE....1523
BATTERY....1524
BATTERY HAZARD PREVENTION....1524
STARTING ENGINE WITH BOOSTER CABLES....1525
TOWING....1526
SAFETY RULES FOR TOWING....1526
LIFTING OBJECTS WITH BUCKET....1527
SAFETY RULES FOR LIFTING OBJECTS....1527
SAFETY MAINTENANCE INFORMATION....1528
WARNING TAG....1528
KEEP WORK PLACE CLEAN AND TIDY....1528
APPOINT LEADER WHEN WORKING WITH OTHERS....1528
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE....1528
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....1529
PROPER TOOLS....1530
ACCUMULATOR....1530
PERSONNEL....1530
ATTACHMENTS....1530
WORK UNDER THE MACHINE....1531
NOISE....1531
WHEN USING HAMMER....1531
WELDING WORKS....1531
REMOVING BATTERY TERMINALS....1531
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION....1532
DO NOT DISASSEMBLE RECOIL SPRINGS....1532
SAFETY RULES FOR HIGH-PRESSURE OIL....1532
SAFETY HANDLING HIGH-PRESSURE HOSES....1532
WASTE MATERIALS....1533
AIR CONDITIONER MAINTENANCE....1533
COMPRESSED AIR....1533
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....1533
OPERATION....1535
MACHINE VIEW ILLUSTRATIONS....1536
OVERALL MACHINE VIEW....1536
CONTROLS AND GAUGES....1537
DETAILED CONTROLS AND GAUGES....1538
MONITORING SYSTEM....1538
SWITCHES....1548
CONTROL LEVERS AND PEDALS....1553
SUN ROOF....1558
WINDSHIELD....1559
SLIDING DOOR....1564
EMERGENCY ESCAPE HAMMER....1564
CAP WITH LOCK....1566
ENGINE HOOD....1567
MUD COVER....1568
BATTERY INSPECTION COVER....1569
FUSE....1570
FUSIBLE LINK....1571
AUXILIARY ELECTRIC POWER....1571
CONTROLLERS....1571
AIR CONDITIONER CONTROLS....1572
HEATER AND DEFROSTER CONTROLS....1578
RADIO....1583
OPERATION MANUAL STORAGE....1588
TOOL BOX....1588
GREASE PUMP HOLDER....1588
ASHTRAY....1588
FIRE EXTINGUISHER....1589
MACHINE OPERATIONS AND CONTROLS....1590
BEFORE STARTING ENGINE....1590
STARTING ENGINE....1606
AFTER STARTING ENGINE....1611
STOPPING THE ENGINE....1614
CHECK AFTER SHUT OFF ENGINE....1614
MACHINE OPERATION....1615
STEERING THE MACHINE....1619
SWINGING....1621
WORK EQUIPMENT CONTROLS AND OPERATIONS....1622
WORKING MODE....1624
PROHIBITED OPERATIONS....1625
GENERAL OPERATION INFORMATION....1627
TRAVELING ON SLOPES....1629
ESCAPE FROM MUD....1631
RECOMMENDED APPLICATIONS....1632
MACHINE READY FOR ATTACHMENT....1634
BUCKET REPLACEMENT AND INVERSION....1640
PARKING MACHINE....1642
MACHINE INSPECTION AFTER DAILY WORK....1643
LOCKING....1643
ROAD LINERS AND RUBBER SHOES....1644
TRANSPORTATION....1649
TRANSPORTATION PROCEDURE....1649
LOADING AND UNLOADING WITH TRAILER....1649
LIFTING MACHINE....1655
COLD WEATHER OPERATION....1657
COLD WEATHER OPERATION INFORMATION....1657
AFTER DAILY WORK COMPLETION....1659
AFTER COLD WEATHER SEASON....1659
LONG TERM STORAGE....1660
BEFORE STORAGE....1660
DURING STORAGE....1660
AFTER STORAGE....1660
TROUBLES AND ACTIONS....1661
RUNNING OUT OF FUEL....1661
PHENOMENA THAT ARE NOT FAILURES....1661
TOWING THE MACHINE....1662
SEVERE JOB CONDITION....1662
DISCHARGED BATTERY....1663
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY....1668
OTHER TROUBLE....1669
MAINTENANCE....1675
MAINTENANCE INFORMATION....1676
OUTLINE OF SERVICE....1678
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....1678
ELECTRIC SYSTEM MAINTENANCE....1681
WEAR PARTS....1682
WEAR PARTS LIST....1682
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....1683
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....1684
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....1685
TIGHTENING TORQUE SPECIFICATIONS....1686
TIGHTENING TORQUE LIST....1686
SAFETY CRITICAL PARTS....1687
SAFETY CRITICAL PARTS LIST....1687
MAINTENANCE SCHEDULE....1688
MAINTENANCE SCHEDULE CHART....1688
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....1689
MAINTENANCE PROCEDURE....1690
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)....1690
REPLACE FUEL FILTER CARTRIDGE....1735
CHANGE OIL IN ENGINE OIL PAN, REPLACE OIL FILTER CARTRIDGE....1736
WHEN REQUIRED....1691
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT....1691
CLEAN INSIDE OF COOLING SYSTEM....1695
REPLACE WATER SEPARATOR ELEMENT....1698
CLEAN FUEL TANK....1699
CHECK AND TIGHTEN TRACK SHOE BOLTS....1700
CHECK AND ADJUST TRACK TENSION....1701
CHECK ROAD LINERS OR RUBBER SHOES....1703
CHECK AND ADJUST RUBBER SHOE TENSION....1705
REPLACE ROAD LINERS....1706
REPLACE RUBBER SHOES....1707
CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES....1709
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)....1710
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)....1713
ADJUST BUCKET CLEARANCE....1714
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID....1715
CHECK AND ADJUST AIR CONDITIONER....1716
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER....1717
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT....1718
WASH WASHABLE FLOOR....1719
BLEEDING AIR FROM HYDRAULIC SYSTEM....1721
CHECK BEFORE STARTING....1724
EVERY 50 HOURS MAINTENANCE....1725
DRAIN WATER FROM FUEL TANK....1725
EVERY 100 HOURS MAINTENANCE....1726
LUBRICATING....1726
EVERY 250 HOURS MAINTENANCE....1727
LUBRICATING....1727
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL....1729
CHECK LEVEL OF BATTERY ELECTROLYTE....1730
CHECK AND ADJUST COOLING FAN BELT TENSION....1732
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....1734
EVERY 500 HOURS MAINTENANCE....1735
REPLACE FUEL FILTER CARTRIDGE....1735
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....1736
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS....1737
CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS....1739
LUBRICATE SWING CIRCLE....1741
CHECK SWING PINION GREASE LEVEL, ADD GREASE....1741
EVERY 1000 HOURS MAINTENANCE....1742
REPLACE HYDRAULIC OIL FILTER ELEMENT....1742
CHANGE OIL IN SWING MACHINERY CASE....1744
CHANGE OIL IN FINAL DRIVE CASE....1745
EVERY 2000 HOURS MAINTENANCE....1746
CHECK PTO GEAR CASE, ADD OIL....1746
CLEAN, CHECK TURBOCHARGER....1746
CHECK ALTERNATOR, STARTING MOTOR....1746
EVERY 4000 HOURS MAINTENANCE....1747
CHECK WATER PUMP....1747
EVERY 5000 HOURS MAINTENANCE....1748
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER....1748
SPECIFICATIONS....1751
SPECIFICATIONS....1752
ATTACHMENTS, OPTIONS....1755
ATTACHMENTS AND OPTIONS - GENERAL INFORMATION....1756
SAFETY FIRST....1756
ATTACHMENT INSTALLATION....1757
BUCKET WITH HOOK....1758
HOOK CONDITION....1758
PROHIBITED OPERATIONS....1758
METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT....1759
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)....1761
CONTROL PATTERN CHANGE PROCEDURE....1761
MACHINE CONTROL PATTERNS....1762
ATTACHMENT GUIDE....1763
OTHER ATTACHMENTS....1763
ATTACHMENT COMBINATIONS....1764
SELECTION OF TRACK SHOES....1765
RECOMMENDED ATTACHMENT OPERATIONS....1766
HYDRAULIC BREAKER....1766
INDEX....1771
TEN00202-00 - Hydraulic Excavator GALEO PC78MR-6 Operation & Maintenance Manual....1775
COVER....1775
FOREWORD....1776
FOREWORD....1777
SAFETY INFORMATION....1780
INTRODUCTION....1782
DIRECTIONS OF MACHINE....1782
PRODUCT INFORMATION....1783
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....1783
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION....1783
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION....1784
SERVICE METER LOCATION....1784
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....1785
CONTENTS....1786
SAFETY....1789
SAFETY INFORMATION....1790
SAFETY LABELS....1792
LOCATION OF SAFETY LABELS....1793
SAFETY LABELS....1794
SAFETY INFORMATION....1801
SAFETY RULES....1801
IF PROBLEMS ARE FOUND....1801
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS....1801
FIRE EXTINGUISHER AND FIRST AID KIT....1801
SAFETY EQUIPMENT....1801
KEEP MACHINE CLEAN....1802
KEEP OPERATOR'S COMPARTMENT CLEAN....1802
LEAVING OPERATOR'S SEAT WITH LOCK....1802
HANDRAILS AND STEPS....1803
MOUNTING AND DISMOUNTING....1803
NO PERSONS ON ATTACHMENTS....1803
DO NOT GET CAUGHT IN ARTICULATED PORTION....1803
BURN PREVENTION....1804
FIRE PREVENTION AND EXPLOSION PREVENTION....1804
ACTION IF FIRE OCCURS....1805
WINDSHIELD WASHER FLUID....1805
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION....1805
ATTACHMENT INSTALLATION....1806
ATTACHMENT COMBINATIONS....1806
CAB WINDOW GLASSES....1806
UNAUTHORIZED MODIFICATIONS....1806
SAFETY AT JOBSITE....1806
WORKING ON LOOSE GROUND....1807
DISTANCE TO HIGH VOLTAGE CABLES....1807
ENSURE GOOD VISIBILITY....1807
VENTILATION FOR ENCLOSED AREA....1808
SIGNALMAN'S SIGNAL AND SIGNS....1808
EMERGENCY EXIT FROM OPERATOR'S CAB....1808
ASBESTOS DUST HAZARD PREVENTION....1808
SAFETY MACHINE OPERATION....1809
STARTING ENGINE....1809
CHECKS BEFORE STARTING ENGINE....1809
SAFETY RULES FOR STARTING ENGINE....1810
STARTING ENGINE IN COLD WEATHER....1810
OPERATION....1811
CHECKS BEFORE OPERATION....1811
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS....1811
SAFETY RULES FOR TRAVELING....1812
TRAVELING ON SLOPES....1813
OPERATIONS ON SLOPES....1814
PROHIBITED OPERATIONS....1814
OPERATIONS ON SNOW....1815
PARKING MACHINE....1816
TRANSPORTATION....1817
LOADING AND UNLOADING....1817
SHIPPING THE MACHINE....1817
BATTERY....1818
BATTERY HAZARD PREVENTION....1818
STARTING ENGINE WITH BOOSTER CABLES....1819
TOWING....1820
SAFETY RULES FOR TOWING....1820
LIFTING OBJECTS WITH BUCKET....1821
SAFETY RULES FOR LIFTING OBJECTS....1821
SAFETY MAINTENANCE INFORMATION....1822
WARNING TAG....1822
KEEP WORK PLACE CLEAN AND TIDY....1822
APPOINT LEADER WHEN WORKING WITH OTHERS....1822
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE....1822
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....1823
PROPER TOOLS....1824
ACCUMULATOR....1824
PERSONNEL....1824
ATTACHMENTS....1824
WORK UNDER THE MACHINE....1825
NOISE....1825
WHEN USING HAMMER....1825
WELDING WORKS....1825
REMOVING BATTERY TERMINALS....1825
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION....1826
DO NOT DISASSEMBLE RECOIL SPRINGS....1826
SAFETY RULES FOR HIGH-PRESSURE OIL....1826
SAFETY HANDLING HIGH-PRESSURE HOSES....1826
WASTE MATERIALS....1827
AIR CONDITIONER MAINTENANCE....1827
COMPRESSED AIR....1827
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....1827
OPERATION....1828
MACHINE VIEW ILLUSTRATIONS....1829
OVERALL MACHINE VIEW....1829
CONTROLS AND GAUGES....1830
DETAILED CONTROLS AND GAUGES....1831
MONITORING SYSTEM....1831
SWITCHES....1841
CONTROL LEVERS AND PEDALS....1846
SUN ROOF....1851
WINDSHIELD....1852
SLIDING DOOR....1857
EMERGENCY ESCAPE HAMMER....1857
CAP WITH LOCK....1859
ENGINE HOOD....1860
MUD COVER....1861
BATTERY INSPECTION COVER....1862
FUSE....1863
FUSIBLE LINK....1864
AUXILIARY ELECTRIC POWER....1864
CONTROLLERS....1864
AIR CONDITIONER CONTROLS....1865
HEATER AND DEFROSTER CONTROLS....1871
RADIO....1876
OPERATION MANUAL STORAGE....1881
TOOL BOX....1881
GREASE PUMP HOLDER....1881
ASHTRAY....1881
FIRE EXTINGUISHER....1882
MACHINE OPERATIONS AND CONTROLS....1883
BEFORE STARTING ENGINE....1883
STARTING ENGINE....1899
AFTER STARTING ENGINE....1904
STOPPING THE ENGINE....1907
CHECK AFTER SHUT OFF ENGINE....1907
MACHINE OPERATION....1908
STEERING THE MACHINE....1912
SWINGING....1914
WORK EQUIPMENT CONTROLS AND OPERATIONS....1915
WORKING MODE....1917
PROHIBITED OPERATIONS....1918
GENERAL OPERATION INFORMATION....1920
TRAVELING ON SLOPES....1922
ESCAPE FROM MUD....1924
RECOMMENDED APPLICATIONS....1925
MACHINE READY FOR ATTACHMENT....1927
BUCKET REPLACEMENT AND INVERSION....1933
PARKING MACHINE....1936
MACHINE INSPECTION AFTER DAILY WORK....1937
LOCKING....1937
ROAD LINERS AND RUBBER SHOES....1938
TRANSPORTATION....1943
TRANSPORTATION PROCEDURE....1943
LOADING AND UNLOADING WITH TRAILER....1943
LIFTING MACHINE....1949
COLD WEATHER OPERATION....1951
COLD WEATHER OPERATION INFORMATION....1951
AFTER DAILY WORK COMPLETION....1953
AFTER COLD WEATHER SEASON....1953
LONG TERM STORAGE....1954
BEFORE STORAGE....1954
DURING STORAGE....1954
AFTER STORAGE....1954
TROUBLES AND ACTIONS....1955
RUNNING OUT OF FUEL....1955
PHENOMENA THAT ARE NOT FAILURES....1955
TOWING THE MACHINE....1956
SEVERE JOB CONDITION....1956
DISCHARGED BATTERY....1957
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY....1962
OTHER TROUBLE....1963
MAINTENANCE....1968
MAINTENANCE INFORMATION....1969
OUTLINE OF SERVICE....1971
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....1971
ELECTRIC SYSTEM MAINTENANCE....1975
WEAR PARTS....1976
WEAR PARTS LIST....1976
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....1977
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....1978
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....1979
TIGHTENING TORQUE SPECIFICATIONS....1980
TIGHTENING TORQUE LIST....1980
SAFETY CRITICAL PARTS....1981
SAFETY CRITICAL PARTS LIST....1981
MAINTENANCE SCHEDULE....1982
MAINTENANCE SCHEDULE CHART....1982
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....1983
MAINTENANCE PROCEDURE....1984
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)....1984
WHEN REQUIRED....1985
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT....1985
CLEAN INSIDE OF COOLING SYSTEM....1989
REPLACE WATER SEPARATOR ELEMENT....1992
CLEAN FUEL TANK....1993
CHECK AND TIGHTEN TRACK SHOE BOLTS....1994
CHECK AND ADJUST TRACK TENSION....1995
CHECK ROAD LINERS OR RUBBER SHOES....1997
CHECK AND ADJUST RUBBER SHOE TENSION....1999
REPLACE ROAD LINERS....2000
REPLACE RUBBER SHOES....2001
CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES....2003
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)....2004
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)....2007
ADJUST BUCKET CLEARANCE....2008
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID....2009
CHECK AND MAINTENANCE AIR CONDITIONER....2010
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER....2011
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT....2012
WASH WASHABLE FLOOR....2013
BLEEDING AIR FROM HYDRAULIC SYSTEM....2015
CHECK BEFORE STARTING....2018
EVERY 50 HOURS MAINTENANCE....2019
DRAIN WATER FROM FUEL TANK....2019
EVERY 100 HOURS MAINTENANCE....2020
LUBRICATING....2020
CHECK SWING MACHINERY CASE OIL, ADD OIL....2021
EVERY 250 HOURS MAINTENANCE....2022
LUBRICATING....2022
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL....2024
CHECK LEVEL OF BATTERY ELECTROLYTE....2025
CHECK AND ADJUST COOLING FAN BELT TENSION....2027
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....2029
EVERY 500 HOURS MAINTENANCE....2030
REPLACE FUEL FILTER CARTRIDGE....2030
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....2031
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS....2032
CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS....2034
LUBRICATE SWING CIRCLE....2036
CHECK SWING PINION GREASE LEVEL, ADD GREASE....2036
EVERY 1000 HOURS MAINTENANCE....2037
REPLACE HYDRAULIC OIL FILTER ELEMENT....2037
CHANGE OIL IN SWING MACHINERY CASE....2039
GREASE SWING MACHINERY BEARING....2040
CHANGE OIL IN FINAL DRIVE CASE....2041
EVERY 2000 HOURS MAINTENANCE....2042
CHECK PTO GEAR CASE, ADD OIL....2042
CLEAN, CHECK TURBOCHARGER....2042
CHECK ALTERNATOR, STARTING MOTOR....2042
CHECK ENGINE VALVE CLEARANCE, ADJUST....2042
EVERY 4000 HOURS MAINTENANCE....2043
CHECK WATER PUMP....2043
EVERY 5000 HOURS MAINTENANCE....2044
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER....2044
SPECIFICATIONS....2046
SPECIFICATIONS....2047
ATTACHMENTS, OPTIONS....2049
ATTACHMENTS AND OPTIONS - GENERAL INFORMATION....2050
SAFETY FIRST....2050
ATTACHMENT INSTALLATION....2051
BUCKET WITH HOOK....2052
HOOK CONDITION....2052
PROHIBITED OPERATIONS....2052
METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT....2053
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)....2055
CONTROL PATTERN CHANGE PROCEDURE....2055
MACHINE CONTROL PATTERNS....2056
ATTACHMENT GUIDE....2057
OTHER ATTACHMENTS....2057
ATTACHMENT COMBINATIONS....2058
SELECTION OF TRACK SHOES....2059
RECOMMENDED ATTACHMENT OPERATIONS....2060
HYDRAULIC BREAKER....2060
INDEX....2065
TEN00288-00 - Hydraulic Excavator PC78MR-6 Operation & Maintenance Manual....2069
COVER....2070
FOREWORD....2070
FOREWORD....2071
SAFETY INFORMATION....2072
INTRODUCTION....2074
DIRECTIONS OF MACHINE....2074
PRODUCT INFORMATION....2075
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....2075
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION....2075
ADDITIONAL ENGINE SERIAL NO. PLATE....2076
SERVICE METER LOCATION....2076
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....2076
CONTENTS....2077
SAFETY....2080
SAFETY....2081
SAFETY LABELS....2083
LOCATION OF SAFETY LABELS....2084
SAFETY LABELS....2085
GENERAL PRECAUTIONS....2092
SAFETY MACHINE OPERATION....2100
STARTING ENGINE....2100
OPERATION....2102
TRANSPORTATION....2108
BATTERY....2109
TOWING....2111
LIFTING OBJECTS WITH BUCKET....2112
SAFETY MAINTENANCE INFORMATION....2113
OPERATION....2120
MACHINE VIEW ILLUSTRATIONS....2121
OVERALL MACHINE VIEW....2121
CONTROLS AND GAUGES....2122
DETAILED CONTROLS AND GAUGES....2123
MONITORING SYSTEM....2123
SWITCHES....2133
CONTROL LEVERS AND PEDALS....2138
SUN ROOF....2143
WINDSHIELD....2144
SLIDING DOOR....2149
EMERGENCY ESCAPE HAMMER....2149
CAP WITH LOCK....2151
ENGINE HOOD....2152
MUD COVER....2153
BATTERY INSPECTION COVER....2154
FUSE....2155
FUSIBLE LINK....2156
AUXILIARY ELECTRIC POWER....2156
CONTROLLERS....2156
AIR CONDITIONER CONTROLS....2157
HEATER AND DEFROSTER CONTROLS....2163
RADIO....2168
OPERATION MANUAL STORAGE....2173
TOOL BOX....2173
GREASE PUMP HOLDER....2173
ASHTRAY....2173
FIRE EXTINGUISHER....2174
MACHINE OPERATIONS AND CONTROLS....2175
BEFORE STARTING ENGINE....2175
STARTING ENGINE....2191
AFTER STARTING ENGINE....2196
STOPPING THE ENGINE....2199
CHECK AFTER SHUT OFF ENGINE....2199
MACHINE OPERATION....2200
STEERING THE MACHINE....2204
SWINGING....2206
WORK EQUIPMENT CONTROLS AND OPERATIONS....2207
WORKING MODE....2209
PROHIBITED OPERATIONS....2210
GENERAL OPERATION INFORMATION....2212
TRAVELING ON SLOPES....2214
ESCAPE FROM MUD....2216
RECOMMENDED APPLICATIONS....2217
MACHINE READY FOR ATTACHMENT....2219
BUCKET REPLACEMENT AND INVERSION....2225
PARKING MACHINE....2228
MACHINE INSPECTION AFTER DAILY WORK....2229
LOCKING....2229
ROAD LINERS AND RUBBER SHOES....2230
TRANSPORTATION....2235
TRANSPORTATION PROCEDURE....2235
LOADING AND UNLOADING WITH TRAILER....2235
LIFTING MACHINE....2241
COLD WEATHER OPERATION....2243
COLD WEATHER OPERATION INFORMATION....2243
AFTER DAILY WORK COMPLETION....2245
AFTER COLD WEATHER SEASON....2245
LONG TERM STORAGE....2246
BEFORE STORAGE....2246
DURING STORAGE....2246
AFTER STORAGE....2246
TROUBLES AND ACTIONS....2247
RUNNING OUT OF FUEL....2247
PHENOMENA THAT ARE NOT FAILURES....2247
TOWING THE MACHINE....2248
SEVERE JOB CONDITION....2248
DISCHARGED BATTERY....2249
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY....2254
OTHER TROUBLE....2255
MAINTENANCE....2260
MAINTENANCE INFORMATION....2261
OUTLINE OF SERVICE....2263
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....2263
ELECTRIC SYSTEM MAINTENANCE....2267
WEAR PARTS....2268
WEAR PARTS LIST....2268
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....2269
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....2270
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....2271
TIGHTENING TORQUE SPECIFICATIONS....2272
TIGHTENING TORQUE LIST....2272
SAFETY CRITICAL PARTS....2273
SAFETY CRITICAL PARTS LIST....2273
MAINTENANCE SCHEDULE....2274
MAINTENANCE SCHEDULE CHART....2274
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....2275
MAINTENANCE PROCEDURE....2276
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)....2276
WHEN REQUIRED....2277
CHECK BEFORE STARTING....2310
EVERY 50 HOURS MAINTENANCE....2311
EVERY 100 HOURS MAINTENANCE....2312
EVERY 250 HOURS MAINTENANCE....2314
EVERY 500 HOURS MAINTENANCE....2322
EVERY 1000 HOURS MAINTENANCE....2329
EVERY 2000 HOURS MAINTENANCE....2334
EVERY 4000 HOURS MAINTENANCE....2335
EVERY 5000 HOURS MAINTENANCE....2336
SPECIFICATIONS....2338
SPECIFICATIONS....2339
ATTACHMENTS, OPTIONS....2342
ATTACHMENTS AND OPTIONS - GENERAL INFORMATION....2343
SAFETY FIRST....2343
ATTACHMENT INSTALLATION....2344
BUCKET WITH HOOK....2345
HOOK CONDITION....2345
PROHIBITED OPERATIONS....2345
METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT....2346
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)....2348
CONTROL PATTERN CHANGE PROCEDURE....2348
MACHINE CONTROL PATTERNS....2349
ATTACHMENT GUIDE....2350
OTHER ATTACHMENTS....2350
ATTACHMENT COMBINATIONS....2351
SELECTION OF TRACK SHOES....2352
RECOMMENDED ATTACHMENT OPERATIONS....2353
HYDRAULIC BREAKER....2353
INDEX....2358
Komatsu Hydraulic Excavators PC78MR Repair Service Manuals
