Komatsu PC78US-6 Manual

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FOREWORD
FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions in this manual must be followed at all times when performing operation and maintenance. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing
operation and maintenance.
Operators
and
maintenance
personnel
must
always
do
as
follows
before
beginning
operation
or
maintenance.
Always
be
sure
to
read
and
understand
this
manual
thoroughly
before
performing
operation
and
maintenance.
Read
the
safety
messages
given
in
this
manual
and
the
safety
labels
affixed
to
the
machine
thoroughly
and
be
sure
that
you
understand
them
fully.
Keep
this
manual
at
the
storage
location
for
the
Operation
and
aintenance
anual
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.
Storage location for the Operation and Maintenance Manual:
Amagazine bo provided on the left side of operator's seat
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FOREWORD
FOREWORD
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FOREWORD
FOREWORD
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FOREWORD
SAFETY INFOR ATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affi ed to the
machine to give e planations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal
words
The following signal words are used to inform you that there is apotential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to e press the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates apotentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates apotentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
Example
of
safety
message
using
signal
word
When
standing
up
from
the
operator's
seat,
always
place
the
safety
lock
lever
in
the
LOCK
position.
If
you
accidentally
touch
the
control
levers
when
they
are
not
locked,
this
may
cause
a
serious
injury
or
death.
Other
signal
words
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
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FOREWORD
SAFETY INFOR ATION
Safety
labels
Safety labels are affi ed to the machine to inform the operator or maintenance worker on the spot when carrying out
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example
of
safety
label
using
words
Safety
labels
using
pictogram
Safety pictograms use apicture to e press alevel of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the top
or left side, and the method of avoiding the hazardous condition at
the bottom or right side. In addition, the type of hazardous
condition is displayed inside atriangle and the method of avoiding
the hazardous condition is shown inside acircle.
Komatsu cannot predict every circumstance that might involve apotential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The e planations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( )in the te t. (For e ample: j -> (1))
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FOREWORD
INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
Digging work
Leveling work
Ditching work
Loading work
Demolition work
See the section "RECOMMENDED APPLICATIONS (PAGE 3-97)" for further details.
DIRECTIONS OF MACHINE
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when
the operator's seat is facing the front and the sprocket is at the rear of the machine.
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FOREWORD
PRODUCT INFOR ATION
PRODUCT INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION
On the bottom right of the operator's cab
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION
On the upper side of the engine cylinder head cover
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FOREWORD
PRODUCT INFOR ATION
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION
This is on the side face of the intake air mount bracket.
EPA: Environmental Protection Agency, U.S.A.
SERVICE METER LOCATION
On top of the machine monitor
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FOREWORD
PRODUCT INFOR ATION
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Distributor name
Address
Service Personnel
Phone/Fax
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FOREWORD
CONTENTS
CONTENTS
FOREWORD 1- 1
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
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION 1- 9
SERVICE METER LOCATION 1- 9
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1- 10
SAFETY 2- 1
SAFETY INFORMATION 2- 2
SAFETY LABELS 2- 4
LOCATION OF SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
SAFETY INFORMATION 2- 12
SAFETY MACHINE OPERATION 2- 20
STARTING ENGINE 2- 20
OPERATION 2- 22
TRANSPORTATION 2- 28
BATTERY 2- 29
TOWING 2- 31
LIFTING OBJECTS WITH BUCKET 2- 32
SAFETY MAINTENANCE INFORMATION 2- 33
OPERATION 3- 1
MACHINE VIEW ILLUSTRATIONS 3- 2
OVERALL MACHINE VIEW 3- 2
CONTROLS AND GAUGES 3- 3
DETAILED CONTROLS AND GAUGES 3- 4
MONITORING SYSTEM 3- 4
SWITCHES 3- 15
CONTROL LEVERS AND PEDALS 3- 20
SUN ROOF 3- 24
WINDSHIELD 3- 25
SLIDING DOOR 3- 30
EMERGENCY ESCAPE HAMMER 3- 30
CAP WITH LOCK 3- 32
ENGINE HOOD 3- 33
MUD COVER 3- 34
BATTERY INSPECTION COVER 3- 35
FUSE 3- 36
FUSIBLELINK 3- 37
AUXILIARY ELECTRIC POWER 3- 37
CONTROLLERS 3- 37
HEATER AND DEFROSTAR CONTROLS 3- 38
AIR CONDITIONER CONTROLS 3- 43
RADIO 3- 49
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FOREWORD
CONTENTS
OPERATION MANUAL STORAGE 3- 54
TOOL BOX 3- 54
GREASE PUMP HOLDER 3- 54
ASHTRAY 3- 54
FIRE EXTINGUISHER 3- 55
MACHINE OPERATIONS AND CONTROLS 3- 56
BEFORE STARTING ENGINE 3- 56
STARTING ENGINE 3- 72
AFTER STARTING ENGINE 3- 77
STOPPING THE ENGINE 3- 80
CHECK AFTER SHUT OFF ENGINE 3- 80
MACHINE OPERATION 3- 81
STEERING THE MACHINE 3- 85
SWINGING 3- 87
WORK EQUIPMENT CONTROLS AND OPERATIONS 3- 88
WORKING MODE 3- 89
PROHIBITED OPERATIONS 3- 90
GENERAL OPERATION INFORMATION 3- 92
TRAVELING ON SLOPES 3- 94
ESCAPE FROM MUD 3- 96
RECOMMENDED APPLICATIONS 3- 97
BUCKET REPLACEMENT AND INVERSION 3- 99
PARKING MACHINE 3-101
MACHINE INSPECTION AFTER DAILY WORK 3-102
LOCKING 3-102
ROAD LINERS AND RUBBER SHOES 3-103
TRANSPORTATION 3-108
TRANSPORTATION PROCEDURE 3-108
LOADING AND UNLOADING WITH TRAILER 3-108
LIFTING MACHINE 3-114
COLD WEATHER OPERATION 3-116
COLD WEATHER OPERATION INFORMATION 3-116
AFTER DAILY WORK COMPLETION 3-118
AFTER COLD WEATHER SEASON 3-118
LONG TERM STORAGE 3-119
BEFORE STORAGE 3-119
DURING STORAGE 3-119
AFTER STORAGE 3-119
TROUBLES AND ACTIONS 3-120
RUNNING OUT OF FUEL 3-120
PHENOMENA THAT ARE NOT FAILURES 3-120
TOWING THE MACHINE 3-120
SEVERE JOB CONDITION 3-121
DISCHARGED BATTERY 3-122
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY 3-127
OTHER TROUBLE 3-128
MAINTENANCE 4- 1
MAINTENANCE INFORMATION 4- 2
LUBRICANTS, COOLANT AND FILTERS 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
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FOREWORD
CONTENTS
ELECTRIC SYSTEM MAINTENANCE 4- 6
WEAR PARTS 4- 7
WEAR PARTS LIST 4- 7
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS 4- 8
PROPER SELECTION 4- 8
TIGHTENING TORQUE SPECIFICATIONS 4- 12
TIGHTENING TORQUE LIST 4- 12
SAFETY CRITICAL PARTS 4- 13
SAFETY CRITICAL PARTS LIST 4- 13
MAINTENANCE SCHEDULE 4- 14
MAINTENANCE SCHEDULE CHART 4- 14
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4- 15
MAINTENANCE PROCEDURE 4- 16
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) 4- 16
WHEN REQUIRED 4- 17
CHECK BEFORE STARTING 4- 48
EVERY 50 HOURS MAINTENANCE 4- 49
EVERY 100 HOURS MAINTENANCE 4- 50
EVERY 250 HOURS MAINTENANCE 4- 51
EVERY 500 HOURS MAINTENANCE 4- 59
EVERY 1000 HOURS MAINTENANCE 4- 66
EVERY 2000 HOURS MAINTENANCE 4- 70
EVERY 4000 HOURS MAINTENENCE 4- 71
EVERY 5000 HOURS MAINTENANCE 4- 72
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS AND OPTIONS 6- 1
ATTACHMENTS AND OPTIONS -GENERAL INFORAMTION 6- 2
SAFETY FIRST 6- 2
ATTACHMENT INSTALLATION 6- 3
BUCKET WITH HOOK 6- 4
HOOK CONDITION 6- 4
PROHIBITED OPERATIONS 6- 4
MACHINE READY FOR ATTACHMENT 6- 5
LOCATIONS 6- 5
HYDRAULIC CIRCUIT 6- 7
ATTACHMENT OPERATIONS 6- 8
LONG TERM STORAGE 6- 10
SPECIFICATIONS 6- 10
METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT 6- 11
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) 6- 13
CONTROL PATTERN CHANGE PROCEDURE 6- 13
MACHINE CONTROL PATTERNS 6- 14
ATTACHMENT GUIDE 6- 15
OTHER ATTACHMENTS 6- 15
ATTACHMENT COMBINATIONS 6- 16
RECOMMENDED ATTACHMENT OPERATIONS 6- 17
HYDRAULIC BREAKER 6- 17
INDEX 7- 1
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SAFETY
SAFETY INFOR ATION
SAFETY INFORMATION
SAFETY LABELS 2- 4
LOCATION OF SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
SAFETY INFORMATION
Safety rules 2- 12
If abnormalities are found 2- 12
Working wear and personal protective items 2- 12
Fire e tinguisher and first aid kit 2- 12
Safety equipment 2- 12
Keep machine clean 2- 13
Keep operator's compartment clean 2- 13
Leaving operator's seat with lock 2- 13
Handrails and steps 2- 14
Mounting and dismounting 2- 14
No persons on attachments 2- 14
Do not get caught in articulated portion 2- 14
Burn prevention 2- 15
Fire prevention and e plosion prevention 2- 15
Action if fire occurs 2- 16
Windshield Washer Fluid 2- 16
Falling objects, flying objects and intruding objects prevention 2- 16
Attachment installation 2- 17
Attachment combinations 2- 17
Cab widow glasses 2- 17
Unauthorized modifications 2- 17
Safety at jobsite 2- 17
Working on loose ground 2- 17
Distance to high voltage cables 2- 18
Ensure good visibility 2- 18
Ventilation for enclosed area 2- 19
Signalman's signal and signs 2- 19
Emergency e it from operator's cab 2- 19
Asbestos dust hazard prevention 2- 19
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SAFETY
SAFETY INFOR ATION
SAFETY MACHINE OPERATION 2- 20
STARTING ENGINE 2- 20
Checks before starting engine 2- 20
Safety rules for starting engine 2- 21
Starting engine in cold weather 2- 21
OPERATION 2- 22
Checks before operation 2- 22
Safety rules for changing machine directions 2- 22
Safety rules for traveling 2- 23
Traveling on slopes 2- 24
Operations on slopes 2- 25
Prohibited operations 2- 25
Operations on snow 2- 26
Parking machine 2- 27
TRANSPORTATION 2- 28
Loading and unloading 2- 28
Shipping the machine 2- 28
BATTERY 2- 29
Battery hazard prevention 2- 29
Starting engine with booster cables 2- 30
TOWING 2- 31
Safety rules for towing 2- 31
LIFTING OBJECTS WITH BUCKET 2- 32
Safety rules for lifting objects 2- 32
SAFETY MAINTENANCE INFORMATION 2- 33
Warning Tag 2- 33
Keep Work Place Clean and Tidy 2- 33
Appoint Leader when Working with Others 2- 33
Stop Engine Before Carrying Out Maintenance 2- 33
Two Workers for Maintenance when Engine is Running 2- 34
Proper Tools 2- 35
Personnel 2- 35
Attachments 2- 35
Work Under the Machine 2- 35
Noise 2- 35
When Using Hammer 2- 36
Welding Works 2- 36
Removing Battery Terminals 2- 36
Safety First when Using High-pressure Grease to Adjust Track Tension 2- 36
Do Not Disassemble Recoil Springs 2- 36
Safety Rules for High-pressure Oil 2- 37
Safety Handling High-pressure Hoses 2- 37
Waste Materials 2- 37
Air Conditioner Maintenance 2- 37
Compressed Air 2- 38
Periodic Replacement of Safety Critical Parts 2- 38
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SAFETY
SAFETY LABELS
SAFETY LABELS
The following warning signes and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to
peel off.
There are also other labels in addition to the warning signes and safety labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
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SAFETY
SAFETY LABELS
LOCATION OF SAFETY LABELS
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SAFETY
SAFETY LABELS
SAFETY LABELS
(1) Precautions for operation, inspection and
maintenance (09651-03001)
(2) Precautions for before operation (09802-03000)
(3) Warning for leaving operator's seat
(09654-03001)
(4) Warnings for high voltage (09801-03001)
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