PDF Operation & Maintenance Manual Komatsu PC78US-6 Hydraulic Excavator - 1 MB
This is the official Operation & Maintenance Manual for the Komatsu PC78US-6 Hydraulic Excavator (serial numbers 5501 and up).
It provides operators with detailed instructions on proper machine handling and safety procedures.
The maintenance section outlines service schedules and fluid specifications to ensure your excavator's longevity.
This manual is a critical resource for both owners and operators.
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SEAM046100T
Operation & Maintenance
Manual
PC78US-5
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PC78US-5 β1001 and up
This material is proprietary to Komatsu Utility Division and is not to be reproduced, used, or disclosed
except in accordance with written authorization from Komatsu America International Company.
It is out policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on
products sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It
is recommended that customers contact their distributor for information on the latest revision.
Copyright 2001 Komatsu
DataKom Publishing Corporation
November 2001
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CONTENTS FOREWORD
CONTENTS
FOREWORD
FOREWORD......................................................................................................................................................... 1-2
SAFETY INFORMATION...................................................................................................................................... 1-5
INTRODUCTION................................................................................................................................................... 1-7
DIRECTIONS OF MACHINE ...................................................................................................................... 1-7
PRODUCT INFORMATION .................................................................................................................................. 1-8
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION ...................................................................... 1-8
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION ......................................................................... 1-8
SERVICE METER LOCATION ................................................................................................................... 1-9
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ..................................................................... 1-9
SAFETY
SAFETY INFORMATION...................................................................................................................................... 2-2
POSITION FOR ATTACHING SAFETY LABELS................................................................................................ 2-4
POSITION FOR ATTACHING SAFETY LABELS ....................................................................................... 2-5
SAFETY LABELS ....................................................................................................................................... 2-6
SAFETY INFORMATION.................................................................................................................................... 2-10
SAFETY MACHINE OPERATION ...................................................................................................................... 2-19
STARTING ENGINE ................................................................................................................................. 2-19
OPERATION............................................................................................................................................. 2-21
TRANSPORTATION................................................................................................................................. 2-27
BATTERY ................................................................................................................................................. 2-29
TOWING ................................................................................................................................................... 2-31
LIFTING OBJECTS WITH BUCKET ......................................................................................................... 2-32
SAFETY MAINTENANCE INFORMATION ........................................................................................................ 2-33
OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE ................................................................................................................. 3-2
GENERAL VIEW CONTROLS AND GAUGES........................................................................................... 3-3
EXPLANATION OF COMPONENTS.................................................................................................................... 3-4
MACHINE MONITOR ................................................................................................................................. 3-4
SWITCHES ............................................................................................................................................... 3-10
1-10
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POSITION FOR ATTACHING SAFETY LABELS SAFETY
SAFETY LABELS
(1) Precautions for operation, inspection and mainte- (2) Precautions for before operation (09802-03000)
nance (09651-03001)
(3) Precautions for leaving the operatorβs seat (4) Precautions for going close to electric cables
(09654-03001) (09801-03001)
2-6
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SAFETY INFORMATION SAFETY
ATTACHMENT COMBINATIONS
Depending on the type or combination of work equipment, there is a hazard that the work equipment may hit the
cab or other parts of the machine. Before using unfamiliar work equipment, check if there is any hazard of interfer-
ence, and operate with caution.
CAB WIDOW GLASSES
If the cab glass on the work equipment side is broken, there is a hazard that the work equipment may contact the
operator's body directly. Stop operation immediately and replace the glass.
UNAUTHORIZED MODIFICATIONS
Any modification mode without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
β Komatsu will not be responsible for any injuries, accidents, or product failures resulting from modifications
made without authorization from Komatsu.
SAFETY AT JOBSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
β When carrying out operations near combustable materials such as thatched roofs, dry leaves or dry grass,
there is a hazard of fire, so be careful when operating.
β Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Do not carry out operations at places where there is a hazard of landslides or falling rocks.
β If water lines, gas lines, or high-voltage electrical lines may
be buried under the worksite, contact each utility and iden-
tify their locations. Be careful not to sever or damage any
of these lines.
β Take necessary measures to prevent any unauthorized
person from entering the operating area.
β When traveling or operating in shallow water or on soft
ground, check the shape and condition of the bedrock, and
the depth and speed of flow of the water before starting
operations.
WORKING ON LOOSE GROUND
β Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or
after earthquakes is weak in these areas.
β When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of
the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is
safe and to prevent the machine from rolling over or falling.
2-16
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SAFETY MACHINE OPERATION SAFETY
OPERATIONS ON SNOW
β Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the
machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be
particularly careful when working on slopes.
β With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.
β If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be care-
ful not to leave the road shoulder or to get trapped in a snow drift.
β When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot
be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out opera-
tions carefully.
PARKING MACHINE
β Park the machine on firm, level ground.
β Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
β Lower the work equipment completely to the ground.
β When leaving the machine, set safety lock lever (1) to the
LOCK position, then stop the engine.
β Always close the operator's cab door, and use the key to
lock all the equipment in order to prevent any unauthorized
person from moving the machine. Always remove the key,
take it with you, and leave it in the specified place.
β If it is necessary to park the machine on a slope, always do
as follows.
β Set the bucket on the downhill side, then dig it into the
ground.
β Put blocks under the tracks to prevent the machine
from moving.
2-26
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SAFETY MAINTENANCE INFORMATION SAFETY
ATTACHMENTS
β Appoint a leader before starting removal or installation
operations for attachments.
β Place attachments that have been removed from the
machine in a stable condition so that they do not fall. And
take steps to prevent unauthorized persons from entering
the storage area.
WORK UNDER THE MACHINE
β If it is necessary to go under the work equipment or the
machine to carry out service and maintenance, support the
work equipment and machine securely with blocks and
stands strong enough to support the weight of the work
equipment and machine.
β It is extremely dangerous to work under the machine if the
track shoes are off the ground and the machine is sup-
ported only by the work equipment. If the control levers are
touched by mistake, or there is a hazard to the hydrauli-
cline, the work equipment or the machine may suddenly
descend. This is extremely dangerous. Never work under
the machine if the machine is not properly supported by
blocks or stands.
NOISE
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear cov-
ers or ear plugs while working.
WHEN USING HAMMER
When using a hammer, pins may fly out or metal particles may
be scattered. This may lead to serious injury. Always do as fol-
lows.
β If hard metal parts such as pins, bucket teeth, cutting
edges, or bearings are hit with a hammer, there is a hazard
that pieces might be scattered and cause injury. Always
wear safety goggles and gloves.
β When hitting pins or bucket teeth, there is a hazard that
broken pieces might be sent flying and injure people in the
surrounding area. Always check that there is no one in the
surrounding area.
β If pins are hit with strong force, there is a hazard that the pin may fly out and injure people in the surrounding
area.
2-36
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EXPLANATION OF COMPONENTS OPERATION
EMERGENCY STOP ITEMS
CAUTION
If the monitor flashes, stop the engine immediately or run at low idling, then inspect the problem point
immediately and repair the problem.
These are items which need to be observed when the engine is running. If there is any abnormality, the abnormal
location on the monitor will flash and the buzzer will sound. Carry out the necessary repairs immediately.
(1) Engine oil pressure monitor
ENGINE OIL PRESSURE MONITOR
If the engine lubricating pressure is below the normal value,
this monitor (1) lights up and the buzzer sounds. If it lights up,
stop the engine, and check the oil level in the oil pan and lubri-
cating system.
REMARK
β While the starting switch is ON, the lamp will remain lit and
will go off once the engine is started.
β When the engine is started or stopped with the starting
switch at the ON position, the lamp may light up and the
buzzer may sound momentarily, but this does not indicate
any abnormality.
3-6
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EXPLANATION OF COMPONENTS OPERATION
WORK EQUIPMENT CONTROL LEVER
This Left work equipment control lever (2) is used to operate
the arm and upper structure.
Arm operation Swing operation
(a) Swing to right
(b) Swing to left
(c) Arm IN
(d) Arm OUT
N (Neutral): The upper structure and arm are held in position
and do not move.
This Right work equipment control lever(3) is used to operate
the arm and upper structure.
Boom operation Bucket operation
(e) RAISE
(f) LOWER
(g) DUMP
(h) CURL
N (Neutral): The boom and bucket are held in position and do
not move.
BLADE CONTROL LEVER
(Only machines with blade specification)
This lever (4) is used to control the blade.
(a): LOWER
(b): RAISE
3-16
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EXPLANATION OF COMPONENTS OPERATION
RIGHT SIDE INSPECTION COVER
CAUTION
When carrying out inspection and maintenance inside the cover, always use the support lever to hold the
cover open.
NOTICE
Always keep the cover locked except when opening it.
1. Release lock (1) of the cover.
For details, see "CAP, COVER WITH LOCK (PAGE 3-
24)".
2. Hook your finger in catch (2) and open cover (3).
3. Remove stopper (4) from spring catcher (5).
4. Lower stopper (4) so that the cushion of stopper (4) con-
tacts the outside circumference of the machine.
5. When closing cover (3), fix stopper (4) to the spring
catcher (5) and close cover (3), and lower the cover
slowly.
6. Lock the cover.
3-26
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EXPLANATION OF COMPONENTS OPERATION
ANTENNA
If the receiving wave is weak or generates noise, extend the
antenna. If the wave is too strong, adjust the sensitivity by
retracting the antenna.
NOTICE
When transporting the machine or parking it in a garage,
always fully retract the antenna to avoid the possibility of
breakage.
PRECAUTIONS WHEN USING
β To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during opera-
tion.
β If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water
on the equipment.
β Do not wipe the scales or buttons with benzene, thinner, or any other solvent. Wipe with a soft dry cloth. Use a
cloth soaked in alcohol if the equipment is extremely dirty.
β When the battery is replaced, the settings for the preset buttons are all cleared, so set them again.
3-36
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MACHINE OPERATIONS AND CONTROLS OPERATION
ADJUST BEFORE OPERATION
WARNING
β Adjust the seat position before starting operations or after changing the operator.
β Adjust the seat so that the brake pedal can be depressed fully with the operatorβs back against the
backrest.
OPERATORβS SEAT
The seat and console box can move forward and backward.
Move lever (1) to the right, set the seat in a position that is easy
to operate, then release the lever.
Fore-and-aft adjustment: 160 mm (6.3 in) (8 stages)
Adjust the position of the operatorβs seat to match the opera-
tion. For example, when carrying out deep digging operations,
the view below the front of the machine is improved if you slide
it to the front.
REARVIEW MIRRORS
Adjust the mirror so that it is possible to see clearly the area to
the bottom rear of the machine (the area hidden by the engine
hood).
3-46
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MACHINE OPERATIONS AND CONTROLS OPERATION
5. After carrying out the warming-up operation, check that
each gauge and monitor lamp is in the following condi-
tion.
β Engine water temperature gauge (6): Inside green
range
β Fuel gauge (7): Inside green range
β Engine oil pressure monitor (8): OUT
β Charge level monitor (9): OUT
6. Check that there is no abnormal exhaust gas color, noise,
or vibration. If any abnormality is found, repair it.
7. Set lock lever (2) to the LOCK position and check that it is
impossible to operate the swing and work equipment with
the left and right work equipment control levers.
3-56
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MACHINE OPERATIONS AND CONTROLS OPERATION
β Bucket control
Move the right work equipment control lever to the left or
right to operate the bucket.
β Blade control (blade specification)
Move the lever on the right side of the operatorβs seat to
the front or rear to operate the blade.
3-66
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MACHINE OPERATIONS AND CONTROLS OPERATION
LOADING WORK
In places where the swing angle is small, work efficiency can
be enhanced by locating the dump truck in a place easily visi-
ble to the operator.
Loading is easier and capacity greater if you begin from the
front of the dump truck body than if loading is done from the
side.
SMOOTHING WORK
(Only machines with blade specification)
When refilling after excavation and when smoothing the ground
surface, use the blade.
3-76
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MACHINE OPERATIONS AND CONTROLS OPERATION
β Always maintain the rubber shoes at the proper tension to prevent them from coming off.
If the tension is low, the rubber shoes will come off under the following conditions.
Even if the tension is correct, be extremely careful when carrying out operations.
1. Avoid operating the steering when traveling over curbs,
rocks, or places where there is a big difference in height
(more than approx. 20 cm (8 in)). When traveling over
such objects, always travel at right angles to the object.
2. When traveling in reverse up a slope, do not turn when
moving from flat ground onto the slope.
If it is necessary to turn on slopes, be sure to turn gradu-
ally.
3. Avoid traveling along the edge of slopes or on rough
ground with the track on one side raised (with the
machine tilting at an angel of more than approx. 10ΒΊ) and
with the track on the other side on flat ground. To avoid
damage to the road liners and rubber shoes, travel with
the tracks on both sides on flat ground.
4. If the machine is operated as explained in 1 to 3 above,
the rubber shoes is slackened. Do not steer the machine
in the positions shown in the figure.
3-86
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TRANSPORTATION OPERATION
LIFTING MACHINE
WARNING
β Never raise the machine with any worker on it.
β Always make sure that the wire rope used for lifting the machine is of ample strength for the weight of
the machine.
β Never try to lift the machine in any posture other than the posture given in the procedure below.
There is a hazard that the machine may lose its balance.
β Never lift the machine with the upper structure swung to the side. Swing the work equipment so that it
is at the sprocket end and set the undercarriage and upper structure parallel before lifting.
β When lifting, keep the machine horizontal.
β It is dangerous to go under the machine when it is raised.
Never go under the machine in such cases.
STANDARD SPECIFICATION MACHINE
NOTICE
The lifting procedure applies to machines with standard specifications.
The method of lifting differs according to the attachments and options actually installed. In such cases,
please contact your Komatsu distributor for information.
When lifting the machine, carry out the operation on flat ground as follows.
For details of the weight, see SPECIFICATIONS (PAGE 5-2).
3-96
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TROUBLESHOOTING OPERATION
DISCHARGED BATTERY
WARNING
β It is dangerous to charge the battery while it is still
mounted on the machine. Always remove the battery
before charging it.
β When checking or handling the battery, stop the
engine and turn the starting switch key to the OFF
position.
β The battery generates hydrogen gas, so there is a haz-
ard of explosion.
Do not bring lighted cigarettes near the battery, or do
anything that will cause sparks.
β Battery electrolyte is dilute sulphuric acid, and it will
attack your clothes and skin. If it gets on your clothes
or on your skin, wash it immediately off with large
amounts of water. If it gets in your eyes, wash it out
with fresh water, and consult a doctor.
β When handling batteries, always wear protective gog-
gles and rubber gloves.
β When removing the battery, first disconnect the cable
from the ground (normally the negative (-) terminal).
When installing, install the positive (+) terminal first.
If a tool touches the positive terminal and the chassis,
there is danger that it will cause a spark, so be
extremely careful.
β If the terminals are loose, there is danger that the
defective contact may generate sparks that will cause
an explosion.
β When installing the terminals, install them tightly.
When removing or installing the terminals, check
which is the positive (+) terminal and which is the neg-
ative (-) terminal.
β Green rust around the terminals is a cause of self-dis-
charge of the battery. Polish the terminals with sand-
paper. After removing the rust, coat the terminals
thinly with grease before installing.
3-106
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MAINTENANCE INFORMATION MAINTENANCE
MAINTENANCE INFORMATION
Do not carry out any inspection and maintenance operation that is not found in this manual.
SERVICE METER READING
Check the service meter reading every day to see if the time has come for any necessary maintenance to be car-
ried out.
KOMATSU GENUINE REPLACEMENT PARTS
Use Komatsu genuine parts specified in the Parts Book as replacement parts.
KOMATSU GENUINE LUBRICANTS
Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient tem-
perature.
WINDSHIELD WASHER FLUID
Use automobile windshield washer fluid, and be sure not to let any dirt get into it.
FRESH AND CLEAN LUBRICANTS
Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away from
oil and grease.
CHECK DRAINED OIL AND USED FILTER
After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If
large quantities of metal particles or foreign materials are found, always report to the person in charge, and carry
out suitable action.
FUEL STRAINER
If your machine is equipped with a fuel strainer, do not remove it while fueling.
WELDING INSTRUCTIONS
β Turn off the engine starting switch.
β Do not apply more than 200V continuously.
β Connect grounding cable within 1m (3.3 ft) from the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may have troubles.
β Avoid seals or bearings from being between the area to be welded and the position of grounding point.
β Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
4-2
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USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE
Engine Oil
[CD or CE] Anti-freeze Coolant
Gear Oil Grease
SAE10W, 30, 40 [Ethylene Glycol
No. Supplier [GL-4 or GL-5] [Lithium-Base]
10W30, 15W40 Base]
SAE80, 90, 140 NLGI No.2
(The 15W40 oil Permanent Type
marked * is CE.)
EO10-CD AF-ACL
EO30-CD GO90 G2-LI AF-PTL
1 KOMATSU
EO10-30CD GO140 G2-LI-S AF-PT(Winter, one
EO15-40CD season type)
Diesel sigma S super
2 AGIP dieselmulti- grade Rotra MP GR MU/EP -
*Sigma turbo
Multi-purpose gear PYKON premium
3 AMOCO *Amoco 300 -
oil grease
Litholine HEP 2
4 ARCO *Arcofleet S3 pius Arco HD gear oil -
Arco EP moly D
Gear oil EP
5 BP Vanellus C3 Energrease LS-EP2 Antifreeze
Hypogear EP
*RPM delo 400 Universal thuban Marfak all purpose 2
6 CALTEX AF engine coolant
RPM delo 450 Universal thuban EP Ultra-duty grease 2
EP
*Turbomax EPX
MS3
7 CASTROL *RX super Hypoy Anti-freeze
Spheerol EPL2
CRD Hypoy B
Hypoy C
8 CHEVRON *Delo 400 Universal gear Ultra-duty grease 2 -
Universal gear
9 CONOCO *Fleet motor oil Super-sta grease -
lubricant
Multiperformance 3C Tranself EP
10 ELF - Glacelf
Performance 3C Tranself EP type 2
Essolube D3
*Essolube XD-3
EXXON Gear oil GP
11 *Essolube XD-3 Extra Beacon EP2 All season coolant
(ESSO) Gear oil GX
*Esso heavy duty
Exxon heavy duty
Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifeeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolant
Delvac 1300 Mobilux EP2
Mobilube GX
13 MOBIL *Delvac super Mobilgrease 77 -
Mobilube HD
10W-30, 15W-40 Mobilgrease special
Multi-purpose white
*Superme duty fleet Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
motor oil Multi-purpose 4140 707L White-bearing summer coolant
grease
FINA potonic N
15 PETROFINA FINA kappa TD FINA marson EPL2 FINA tamidor
FINA potonic NE
4-12
--- Page 22 ---
MAINTENANCE PROCEDURE MAINTENANCE
CLEAN INSIDE OF COOLING SYSTEM
WARNING
β Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under
high internal pressure.
If the cap is removed to drain the coolant in this condition, there is a hazard of burns. Wait for the tem-
perature to go down, then turn the cap slowly to release the pressure before removing it.
β Cleaning is carried out with the engine running. When standing up or leaving the operator's seat, set
the safety lock lever to the LOCK position.
β For details of starting the engine, see "BEFORE STARTING ENGINE (PAGE 3-38)" and "STARTING
ENGINE (PAGE 3-51)" in the OPERATION section.
β There is danger of touching the fan if the undercover is left removed.
Never enter behind the machine when the engine is running.
Clean the inside of the cooling system, change the coolant and replace the corrosion resistor agent KI according to
the table below.
Cleaning inside of cooling system
Kind of coolant Adding corrosion resistor agent KI
and changing coolant
Permanent type anti- Every year (autumn)or every 2000
freeze (All season type) hours whichever comes first
Every 1000 hours and when
Non permanent type
Every 6 months (spring, autumn) cleaning the inside of the cooling
antifreeze containing
(Drain antifreeze in spring, add system and when changing cool-
ethylene glycol (winter,
antifreeze in autumn) ant.
one season type)
When not using anti- Every 6 months or every 1000
freeze hours whichever comes first
Stop the machine on level ground when cleaning or changing the coolant.
Use a permanent type of antifreeze.
If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene glycol.
Super Coolant (AF-ACL) has an anti-corrosion effect as well as an antifreeze effect.
The ratio of antifreeze to water depends on the ambient temperature, but to obtain the corrosion resistance effect,
a minimum ratio of 30% by volume is necessary.
In areas where the water is hard, always add Komatsu genuine corrosion resistor agent KI. One packet of corro-
sion resistor agent contains 100g (0.22 lb). The standard density of the mixture should be 7g/liters (0.065 oz/US
gal).
When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mix-
ing rate table given below.
It is actually better to estimate a temperature about 10Β°C (50Β°F) lower when deciding the mixing rate.
4-22
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MAINTENANCE PROCEDURE MAINTENANCE
CHECK AND ADJUST RUBBER SHOES TENSION
(Machine equipped with rubber shoes)
WARNING
β The rubber shoes tension is checked with the machine raised, so it is extremely dangerous if the
machine comes down by mistake during the inspection. Stop the engine and set the safety lock lever
to the LOCK position to prevent the machine from moving.
Never put any part of your body under the track or track frame while measuring, and be extremely
careful when taking the measurements.