Komatsu PC78US-10 Series Hydraulic Excavator Shop Manual SEN06518-06 – PDF DOWNLOAD

Komatsu PC78US-10 Series Hydraulic Excavator Shop Manual SEN06518-06 – PDF DOWNLOAD

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Komatsu PC78US-10 Series Hydraulic Excavator Shop Manual SEN06518-06 – PDF DOWNLOAD

Language : English
Pages : 1878
Downloadable : Yes
File Type : PDF
Size: 49 MB

TABLE OF CONTENTS:

Komatsu PC78US-10 Series Hydraulic Excavator Shop Manual SEN06518-06 – PDF DOWNLOAD

00 INDEX AND FOREWORD 00-1
ABBREVIATION LIST 00-15
FOREWORD, SAFETY, BASIC INFORMATION 00-21
HOW TO READ THE SHOP MANUAL 00-21
SAFETY NOTICE FOR OPERATION 00-23
PRECAUTIONS TO PREVENT FIRE 00-31
ACTIONS IF FIRE OCCURS 00-33
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 00-34
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00-35
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 00-38
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00-45
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 00-47
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00-48
PRACTICAL USE OF KOMTRAX 00-49
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00-50
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 00-54
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 00-58
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 00-59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 00-61
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00-62
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
00-64
HOW TO READ ELECTRICAL WIRE CODE 00-65
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00-69
STANDARD TIGHTENING TORQUE TABLE 00-72
CONVERSION TABLE 00-79
01 SPECIFICATIONS 01-1
CONTENTS 01-2
ABBREVIATION LIST 01-3
SPECIFICATIONS 01-9
SPECIFICATION DRAWING 01-9
WORKING RANGE DRAWINGS 01-12
SPECIFICATIONS 01-13
WEIGHT TABLE 01-17
TABLE OF FUEL, COOLANT, AND LUBRICANTS 01-19
10 STRUCTURE AND FUNCTION 10-1
CONTENTS 10-2
ABBREVIATION LIST 10-5
BOOT-UP SYSTEM 10-11
LAYOUT DRAWING OF BOOT-UP SYSTEM 10-11
SYSTEM OPERATING LAMP SYSTEM 10-12
BATTERY DISCONNECT SWITCH 10-13
ENGINE SYSTEM 10-15
LAYOUT DRAWING OF ENGINE SYSTEM 10-15
ENGINE CONTROL SYSTEM 10-17
AUTO-DECELERATION SYSTEM 10-20
ENGINE AUTOMATIC WARM-UP SYSTEM 10-22
OVERHEAT PREVENTION SYSTEM 10-24
TURBOCHARGER PROTECTION SYSTEM 10-25
AUTOMATIC IDLE STOP SYSTEM 10-26
COMPONENT PARTS OF ENGINE SYSTEM 10-29
COOLING SYSTEM 10-44
LAYOUT DRAWING OF COOLING SYSTEM 10-44
CONTROL SYSTEM 10-47
LAYOUT DRAWING OF CONTROL SYSTEM 10-47
MACHINE MONITOR SYSTEM 10-49
INDEX 00 INDEX AND FOREWORD
00-2 PC78US-10
KOMTRAX SYSTEM 10-50
COMPONENT PARTS OF CONTROL SYSTEM 10-51
HYDRAULIC SYSTEM 10-78
LAYOUT DRAWING OF HYDRAULIC SYSTEM 10-78
CLSS 10-81
ENGINE AND PUMP COMBINED CONTROL SYSTEM 10-84
COMPONENT PARTS OF HYDRAULIC SYSTEM 10-88
WORK EQUIPMENT SYSTEM 10-156
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10-156
STRUCTURE OF VALVE CONTROL 10-159
PPC LOCK SYSTEM 10-161
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 10-162
OVERLOAD CAUTION SYSTEM 10-164
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 10-166
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10-167
SWING SYSTEM 10-195
LAYOUT DRAWING OF SWING SYSTEM 10-195
SWING CONTROL SYSTEM DIAGRAM 10-198
COMPONENT PARTS OF SWING SYSTEM 10-200
TRAVEL SYSTEM 10-212
LAYOUT DRAWING OF TRAVEL SYSTEM 10-212
TRAVEL CONTROL SYSTEM DIAGRAM 10-214
COMPONENT PARTS OF TRAVEL SYSTEM 10-216
UNDERCARRIAGE AND FRAME 10-232
LAYOUT DRAWING OF UNDERCARRIAGE 10-232
IDLER CUSHION 10-234
WORK EQUIPMENT 10-235
STRUCTURE OF WORK EQUIPMENT 10-235
FUNCTION OF WORK EQUIPMENT 10-236
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 10-237
BUCKET CLEARANCE ADJUSTMENT SHIM 10-238
CAB AND ITS ATTACHMENTS 10-239
ROPS CAB 10-239
CAB MOUNT 10-240
TAKE WIRING HARNESS OUT OF CAB 10-242
20 STANDARD VALUE TABLE 20-1
CONTENTS 20-2
ABBREVIATION LIST 20-3
STANDARD VALUE TABLE FOR ENGINE 20-9
STANDARD VALUE TABLE FOR ENGINE: PC78US-10 20-9
STANDARD VALUE TABLE FOR MACHINE 20-12
STANDARD VALUE TABLE FOR MACHINE: PC78US-10 20-12
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 20-26
STANDARD VALUE TABLE FOR ELECTRICAL 20-30
STANDARD VALUE TABLE FOR ELECTRICAL 20-30
30 TESTING AND ADJUSTING 30-1
CONTENTS 30-2
ABBREVIATION LIST 30-5
RELATED INFORMATION ON TESTING AND ADJUSTING 30-11
TOOLS FOR TESTING AND ADJUSTING 30-11
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 30-16
ENGINE AND COOLING SYSTEM 30-18
TEST ENGINE SPEED 30-18
TEST EXHAUST GAS COLOR 30-22
TEST AND ADJUST VALVE CLEARANCE 30-24
TEST COMPRESSION PRESSURE 30-26
TEST BLOWBY PRESSURE 30-29
TEST ENGINE OIL PRESSURE 30-31
00 INDEX AND FOREWORD INDEX
PC78US-10 00-3
TEST FUEL PRESSURE 30-33
TEST FUEL RETURN RATE AND LEAKAGE 30-35
BLEED AIR FROM FUEL SYSTEM 30-39
TEST FUEL CIRCUIT FOR LEAKAGE 30-41
HANDLE CYLINDER CUT-OUT MODE OPERATION 30-43
HANDLE NO-INJECTION CRANKING OPERATION 30-44
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 30-45
TEST ALTERNATOR BELT 30-46
TEST AUTOMATIC TENSIONER 30-47
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 30-49
POWER TRAIN 30-55
TEST SWING CIRCLE BEARING CLEARANCE 30-55
UNDERCARRIAGE AND FRAME 30-56
TEST AND ADJUST TRACK TENSION 30-56
HYDRAULIC SYSTEM 30-58
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30-58
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, AND TRAVEL CIRCUITS 30-62
TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE 30-71
TEST OIL PRESSURE OF CONTROL CIRCUIT 30-75
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 30-77
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 30-82
TEST OUTLET PRESSURE OF SOLENOID VALVE 30-86
TEST PPC VALVE OUTLET PRESSURE 30-89
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 30-91
TEST AND ADJUST TRAVEL DEVIATION 30-92
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 30-95
TEST OIL LEAKAGE 30-97
BLEED AIR FROM HYDRAULIC CIRCUIT 30-101
CAB AND ITS ATTACHMENTS 30-106
METHOD FOR ADJUSTING MIRRORS 30-106
TEST AND ADJUST ENGINE HOOD CATCHER 30-108
ELECTRICAL SYSTEM 30-111
SET AND OPERATE MACHINE MONITOR 30-111
METHOD FOR STARTING UP KOMTRAX TERMINAL 30-156
ADJUST REARVIEW CAMERA ANGLE 30-161
ADJUST RIGHTVIEW CAMERA ANGLE 30-164
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 30-167
HANDLE BATTERY DISCONNECT SWITCH 30-168
TEST DIODES 30-169
Pm CLINIC 30-170
Pm CLINIC SERVICE 30-170
40 TROUBLESHOOTING 40-1
CONTENTS 40-2
ABBREVIATION LIST 40-8
RELATED INFORMATION ON TROUBLESHOOTING 40-14
GENERAL TROUBLESHOOTING POINTS 40-14
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40-15
CHECKS BEFORE TROUBLESHOOTING 40-17
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40-19
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40-21
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 40-45
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40-52
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 40-55
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40-59
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR
SYSTEM 40-61
CONNECTORS LIST AND LAYOUT 40-63
CONNECTOR CONTACT IDENTIFICATION 40-75
INDEX 00 INDEX AND FOREWORD
00-4 PC78US-10
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40-115
FUSE LOCATION TABLE 40-121
FAILURE CODES TABLE 40-123
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 40-131
FAILURE CODE [879AKA] 40-131
FAILURE CODE [879AKB] 40-133
FAILURE CODE [879BKA] 40-134
FAILURE CODE [879BKB] 40-136
FAILURE CODE [879CKA] 40-138
FAILURE CODE [879CKB] 40-139
FAILURE CODE [879DKZ] 40-140
FAILURE CODE [879EMC] 40-142
FAILURE CODE [879FMC] 40-143
FAILURE CODE [879GKX] 40-144
FAILURE CODE [989L00] 40-146
FAILURE CODE [989M00] 40-147
FAILURE CODE [989N00] 40-148
FAILURE CODE [A900FR] 40-149
FAILURE CODE [A900N6] 40-150
FAILURE CODE [A900NY] 40-151
FAILURE CODE [AB00KE] 40-152
FAILURE CODE [B@BAZG] 40-154
FAILURE CODE [B@BCNS] 40-155
FAILURE CODE [CA115] 40-156
FAILURE CODE [CA122] 40-157
FAILURE CODE [CA123] 40-159
FAILURE CODE [CA131] 40-161
FAILURE CODE [CA132] 40-163
FAILURE CODE [CA144] 40-165
FAILURE CODE [CA145] 40-167
FAILURE CODE [CA153] 40-169
FAILURE CODE [CA154] 40-171
FAILURE CODE [CA187] 40-173
FAILURE CODE [CA221] 40-175
FAILURE CODE [CA222] 40-177
FAILURE CODE [CA227] 40-179
FAILURE CODE [CA234] 40-180
FAILURE CODE [CA238] 40-181
FAILURE CODE [CA239] 40-183
FAILURE CODE [CA271] 40-185
FAILURE CODE [CA272] 40-187
FAILURE CODE [CA322] 40-188
FAILURE CODE [CA324] 40-190
FAILURE CODE [CA331] 40-192
FAILURE CODE [CA332] 40-194
FAILURE CODE [CA343] 40-196
FAILURE CODE [CA351] 40-197
FAILURE CODE [CA352] 40-198
FAILURE CODE [CA356] 40-200
FAILURE CODE [CA357] 40-202
FAILURE CODE [CA386] 40-204
FAILURE CODE [CA435] 40-205
FAILURE CODE [CA441] 40-207
FAILURE CODE [CA442] 40-209
FAILURE CODE [CA449] 40-210
FAILURE CODE [CA451] 40-211
FAILURE CODE [CA452] 40-213
FAILURE CODE [CA466] 40-215
00 INDEX AND FOREWORD INDEX
PC78US-10 00-5
FAILURE CODE [CA515] 40-217
FAILURE CODE [CA516] 40-219
FAILURE CODE [CA553] 40-221
FAILURE CODE [CA555] 40-222
FAILURE CODE [CA556] 40-223
FAILURE CODE [CA559] 40-224
FAILURE CODE [CA689] 40-228
FAILURE CODE [CA691] 40-230
FAILURE CODE [CA692] 40-232
FAILURE CODE [CA697] 40-234
FAILURE CODE [CA698] 40-235
FAILURE CODE [CA731] 40-236
FAILURE CODE [CA778] 40-238
FAILURE CODE [CA1117] 40-240
FAILURE CODE [CA1695] 40-241
FAILURE CODE [CA1696] 40-242
FAILURE CODE [CA1843] 40-243
FAILURE CODE [CA1844] 40-245
FAILURE CODE [CA1896] 40-247
FAILURE CODE [CA1942] 40-248
FAILURE CODE [CA1961] 40-249
FAILURE CODE [CA2185] 40-250
FAILURE CODE [CA2186] 40-251
FAILURE CODE [CA2249] 40-253
FAILURE CODE [CA2272] 40-254
FAILURE CODE [CA2311] 40-257
FAILURE CODE [CA2349] 40-258
FAILURE CODE [CA2353] 40-260
FAILURE CODE [CA2357] 40-262
FAILURE CODE [CA2765] 40-263
FAILURE CODE [CA3419] 40-264
FAILURE CODE [CA3421] 40-266
FAILURE CODE [CA3724] 40-268
FAILURE CODE [CA3918] 40-270
FAILURE CODE [CA3919] 40-271
FAILURE CODE [CA3921] 40-272
FAILURE CODE [CA3922] 40-273
FAILURE CODE [CA3923] 40-275
FAILURE CODE [D110KB] 40-277
FAILURE CODE [D19JKZ] 40-279
FAILURE CODE [D811MC] 40-282
FAILURE CODE [D862KA] 40-283
FAILURE CODE [D8ALKA] 40-284
FAILURE CODE [D8ALKB] 40-286
FAILURE CODE [D8AQKR] 40-288
FAILURE CODE [DA20MC] 40-290
FAILURE CODE [DA22KK] 40-291
FAILURE CODE [DA25KP] 40-294
FAILURE CODE [DA26KP] 40-297
FAILURE CODE [DA29KQ] 40-299
FAILURE CODE [DA2LKA] 40-301
FAILURE CODE [DA2LKB] 40-303
FAILURE CODE [DA2QKR] 40-305
FAILURE CODE [DA2RKR] 40-307
FAILURE CODE [DAF0MB] 40-308
FAILURE CODE [DAF0MC] 40-309
FAILURE CODE [DAF8KB] 40-310
FAILURE CODE [DAF8KB] 40-312
INDEX 00 INDEX AND FOREWORD
00-6 PC78US-10
FAILURE CODE [DAF9KQ] 40-314
FAILURE CODE [DAFGMC] 40-315
FAILURE CODE [DAFLKA] 40-316
FAILURE CODE [DAFLKB] 40-318
FAILURE CODE [DAFQKR] 40-319
FAILURE CODE [DAZ9KQ] 40-320
FAILURE CODE [DAZQKR] 40-321
FAILURE CODE [DB2QKR] 40-326
FAILURE CODE [DB2RKR] 40-331
FAILURE CODE [DDNRKA] 40-336
FAILURE CODE [DDNRKY] 40-338
FAILURE CODE [DDNS00] 40-340
FAILURE CODE [DGH2KB] 40-342
FAILURE CODE [DHPAMA] 40-344
FAILURE CODE [DHS3MA] 40-346
FAILURE CODE [DHS4MA] 40-349
FAILURE CODE [DHS5MA] 40-352
FAILURE CODE [DHS8MA] 40-354
FAILURE CODE [DHS9MA] 40-357
FAILURE CODE [DHSAMA] 40-360
FAILURE CODE [DHSBMA] 40-363
FAILURE CODE [DHSCMA] 40-366
FAILURE CODE [DHSDMA] 40-369
FAILURE CODE [DKULKA] 40-372
FAILURE CODE [DKULKB] 40-374
FAILURE CODE [DKULKY] 40-376
FAILURE CODE [DR21KX] 40-378
FAILURE CODE [DV20KB] 40-380
FAILURE CODE [DW43KA] 40-382
FAILURE CODE [DW43KB] 40-384
FAILURE CODE [DW43KY] 40-386
FAILURE CODE [DW45KA] 40-387
FAILURE CODE [DW45KB] 40-390
FAILURE CODE [DW45KY] 40-393
FAILURE CODE [DW4CKY] 40-395
FAILURE CODE [DWJ0KA] 40-397
FAILURE CODE [DWJ0KB] 40-399
FAILURE CODE [DWJ0KY] 40-401
FAILURE CODE [DXA8KA] 40-402
FAILURE CODE [DXA8KB] 40-404
FAILURE CODE [DXE4KA] 40-406
FAILURE CODE [DXE4KB] 40-408
FAILURE CODE [DXE4KY] 40-410
FAILURE CODE [DY20KA] 40-412
FAILURE CODE [DY20MA] 40-414
FAILURE CODE [DY2CKB] 40-416
FAILURE CODE [DY2DKB] 40-419
FAILURE CODE [DY2EKB] 40-421
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 40-423
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40-423
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 40-429
E-3 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 40-432
E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING 40-434
E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING
40-437
E-6 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING
40-438
00 INDEX AND FOREWORD INDEX
PC78US-10 00-7
E-7 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-439
E-8 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-440
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-441
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-442
E-11 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-443
E-12 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 40-444
E-13 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 40-446
E-14 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
OR MAXIMUM 40-447
E-15 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT
TEMPERATURE 40-448
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM 40-449
E-17 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE
40-451
E-18 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 40-452
E-19 FUNCTION SWITCH DOES NOT OPERATE 40-453
E-20 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 40-454
E-21 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR
DOES NOT LIGHT UP OR DOES NOT GO OFF 40-455
E-22 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 40-456
E-23 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS
NOT DISPLAYED 40-458
E-24 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS
NOT CHANGED 40-459
E-25 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT
CHANGE 40-460
E-26 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE 40-461
E-27 ALARM BUZZER CANNOT BE CANCELED 40-462
E-28 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION
40-463
E-29 SERVICE MODE CANNOT BE SELECTED 40-464
E-30 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 40-465
E-31 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 40-468
E-32 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT
SWING 40-470
E-33 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING
BRAKE DOES NOT OPERATE 40-472
E-34 WORK EQUIPMENT DOES NOT OPERATE WHILE LOCK LEVER AUTOMATIC RELEASE
SWITCH IS IN RELEASE POSITION 40-474
E-35 ALARM DOES NOT SOUND DURING TRAVEL 40-476
E-36 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 40-478
E-37 HORN DOES NOT SOUND 40-479
E-38 HORN DOES NOT STOP SOUNDING 40-481
E-39 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF
40-482
E-40 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 40-483
E-41 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE
40-485
E-42 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-486
E-43 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-487
E-44 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-488
INDEX 00 INDEX AND FOREWORD
00-8 PC78US-10
E-45 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-489
E-46 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-490
E-47 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-491
E-48 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-492
E-49 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-493
E-50 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-494
E-51 BLADE RAISE ON IS NOT DISPLAYED CORRECTLY WITH MONITORING 40-497
E-52 BLADE LOWER ON IS NOT DISPLAYED CORRECTLY WITH MONITORING 40-499
E-53 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 40-501
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 40-502
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 40-502
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 40-503
FAILURE MODE AND CAUSE TABLE 40-505
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 40-514
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 40-515
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 40-517
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 40-518
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 40-519
H-6 SPEED OR POWER OF BOOM IS LOW 40-521
H-7 ARM SPEED OR POWER IS LOW 40-525
H-8 BUCKET SPEED OR POWER IS LOW 40-528
H-9 BLADE SPEED OR POWER IS LOW 40-531
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 40-533
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE 40-534
H-12 HYDRAULIC DRIFT OF ARM IS LARGE 40-535
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE 40-536
H-14 HYDRAULIC DRIFT OF BLADE IS LARGE 40-537
H-15 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT
MOVES 40-539
H-16 TIME LAG OF WORK EQUIPMENT IS LARGE 40-540
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 40-541
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD
MOVES SLOWER 40-542
H-19 IN COMBINED OPERATION OF TRAVEL WITH WORK EQUIPMENT OR SWING, TRAVEL
SPEED DROPS LARGELY 40-543
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW
40-544
H-21 MACHINE DOES NOT TRAVEL STRAIGHT 40-545
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 40-547
H-23 TRAVEL SPEED IS LOW 40-550
H-24 ONE OF TRACKS DOES NOT RUN 40-552
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 40-554
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 40-555
H-27 SWINGS ONLY IN ONE DIRECTION 40-557
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND
LEFT) 40-558
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY
ONE DIRECTION 40-560
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH
RIGHT AND LEFT) 40-561
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE
DIRECTION EITHER RIGHT OR LEFT) 40-562
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 40-563
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 40-564
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 40-565
00 INDEX AND FOREWORD INDEX
PC78US-10 00-9
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)
40-566
TROUBLESHOOTING OF ENGINE (S-MODE) 40-567
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 40-567
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION
40-568
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 40-569
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) 40-570
S-4 ENGINE STARTABILITY IS POOR 40-571
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 40-573
S-6 ENGINE STOPS DURING OPERATION 40-575
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 40-577
S-8 ENGINE LACKS POWER 40-578
S-9 EXHAUST SMOKE IS BLACK 40-580
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 40-582
S-11 OIL BECOMES CONTAMINATED QUICKLY 40-583
S-12 FUEL CONSUMPTION IS EXCESSIVE 40-584
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
40-585
S-14 OIL PRESSURE DROPS 40-586
S-15 FUEL MIXES INTO ENGINE OIL 40-588
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 40-589
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 40-590
S-18 UNUSUAL NOISE IS HEARD 40-591
S-19 VIBRATION IS EXCESSIVE 40-592
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 40-593
50 DISASSEMBLY AND ASSEMBLY 50-1
CONTENTS 50-2
ABBREVIATION LIST 50-6
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 50-12
HOW TO READ THIS MANUAL 50-12
COATING MATERIALS LIST 50-14
SPECIAL TOOLS LIST 50-18
SKETCHES OF SPECIAL TOOLS 50-27
ENGINE AND COOLING SYSTEM 50-31
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 50-31
REMOVE AND INSTALL INJECTOR ASSEMBLY 50-40
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 50-52
REMOVE AND INSTALL EGR VALVE ASSEMBLY 50-76
REMOVE AND INSTALL EGR COOLER ASSEMBLY 50-79
REMOVE AND INSTALL STARTER ASSEMBLY 50-83
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT 50-86
REMOVE AND INSTALL ALTERNATOR BELT 50-89
REMOVE AND INSTALL AUTOMATIC TENSIONER 50-92
REMOVE AND INSTALL RADIATOR ASSEMBLY 50-94
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 50-103
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 50-111
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 50-116
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 50-140
REMOVE AND INSTALL ENGINE REAR OIL SEAL 50-143
REMOVE AND INSTALL FUEL COOLER ASSEMBLY 50-146
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 50-149
REMOVE AND INSTALL KDOC MUFFLER 50-152
REMOVE AND INSTALL FUEL TANK ASSEMBLY 50-160
REMOVE AND INSTALL KCCV VENTILATOR ASSEMBLY 50-166
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 50-170
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 50-173
INDEX 00 INDEX AND FOREWORD
00-10 PC78US-10
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 50-178
POWER TRAIN 50-180
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 50-180
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE
MACHINE: #30001 to 35917) 50-183
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE
MACHINE: #35918 AND UP) 50-230
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 50-279
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 50-282
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 50-291
UNDERCARRIAGE AND FRAME 50-293
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 50-293
REMOVE AND INSTALL SPROCKET 50-295
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 50-297
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 50-299
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 50-303
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 50-306
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 50-311
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 50-316
HYDRAULIC SYSTEM 50-322
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 50-322
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 50-325
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 50-328
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 50-336
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 50-346
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 50-356
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 50-358
WORK EQUIPMENT 50-361
REMOVE AND INSTALL BLADE ASSEMBLY 50-361
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 50-364
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 50-370
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM 50-374
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY 50-377
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 50-378
CAB AND ITS ATTACHMENTS 50-384
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 50-384
REMOVE AND INSTALL OPERATOR’S CAB DOOR 50-396
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 50-399
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 50-410
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 50-413
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 50-425
REMOVE AND INSTALL OPERATOR’S SEAT 50-439
REMOVE AND INSTALL SEAT BELT 50-441
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 50-443
ELECTRICAL SYSTEM 50-457
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 50-457
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 50-460
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 50-462
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 50-468
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 50-470
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 50-472
60 MAINTENANCE STANDARD 60-1
CONTENTS 60-2
ABBREVIATION LIST 60-3
ENGINE AND COOLING SYSTEM 60-9
MAINTENANCE STANDARD OF ENGINE MOUNT 60-9
MAINTENANCE STANDARD FOR PTO 60-10
MAINTENANCE STANDARD OF COOLING SYSTEM 60-11
00 INDEX AND FOREWORD INDEX
PC78US-10 00-11
POWER TRAIN 60-13
MAINTENANCE STANDARD OF SWING CIRCLE 60-13
MAINTENANCE STANDARD OF SWING MACHINERY 60-15
MAINTENANCE STANDARD OF SPROCKET 60-17
UNDERCARRIAGE AND FRAME 60-18
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 60-18
MAINTENANCE STANDARD OF IDLER 60-20
MAINTENANCE STANDARD OF TRACK ROLLER 60-22
MAINTENANCE STANDARD OF CARRIER ROLLER 60-23
MAINTENANCE STANDARD OF TRACK SHOE 60-24
MAINTENANCE STANDARD OF TRIPLE SHOE 60-27
MAINTENANCE STANDARD OF ROAD LINER 60-28
MAINTENANCE STANDARD FOR RUBBER SHOE 60-29
HYDRAULIC SYSTEM 60-30
MAINTENANCE STANDARD OF HYDRAULIC TANK 60-30
MAINTENANCE STANDARD OF MAIN PUMP 60-31
MAINTENANCE STANDARD OF PC-EPC VALVE 60-34
MAINTENANCE STANDARD OF SWING MOTOR 60-35
MAINTENANCE STANDARD OF TRAVEL MOTOR 60-38
MAINTENANCE STANDARD OF CONTROL VALVE 60-39
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 60-49
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM 60-51
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 60-53
MAINTENANCE STANDARD OF BLADE PPC VALVE 60-56
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 60-58
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 60-61
MAINTENANCE STANDARD OF SOLENOID VALVE 60-64
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE
CIRCUIT) 60-65
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 60-66
WORK EQUIPMENT 60-67
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60-67
MAINTENANCE STANDARD OF BOOM CYLINDER 60-76
MAINTENANCE STANDARD OF ARM CYLINDER 60-77
MAINTENANCE STANDARD OF BUCKET CYLINDER 60-78
MAINTENANCE STANDARD OF BLADE CYLINDER 60-79
80 APPENDIX 80-1
CONTENTS 80-2
ABBREVIATION LIST 80-4
AIR CONDITIONER SYSTEM 80-10
PRECAUTIONS FOR REFRIGERANT 80-10
AIR CONDITIONER COMPONENT 80-11
SPECIFICATIONS OF AIR CONDITIONER 80-13
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 80-14
OUTLINE OF REFRIGERATION CYCLE 80-15
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 80-17
AIR CONDITIONER UNIT 80-17
COMPONENT PARTS OF AIR CONDITIONER UNIT 80-20
AIR CONDITIONER CONTROLLER 80-25
COMPRESSOR 80-26
CONDENSER 80-27
RECEIVER DRIER 80-28
SENSORS FOR AIR CONDITIONER SYSTEM 80-29
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER
80-31
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 80-33
AIR CONDITIONER SYSTEM DIAGRAM 80-35
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 80-36
INDEX 00 INDEX AND FOREWORD
00-12 PC78US-10
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS
80-38
TESTING AIR LEAKAGE (DUCT) 80-44
METHOD FOR TESTING AIR LEAKAGE (DUCT) 80-44
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 80-45
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE
OF THE MACHINE MONITOR 80-46
TEST VENT (MODE) CHANGEOVER 80-47
METHOD FOR TESTING VENT (MODE) CHANGEOVER 80-47
TESTING FRESH/RECIRC AIR CHANGEOVER 80-48
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 80-48
TEST SUNLIGHT SENSOR 80-49
METHOD FOR TESTING SUNLIGHT SENSOR 80-49
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 80-50
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 80-50
TEST RELAYS 80-52
METHOD FOR TESTING RELAYS 80-52
AIR CONDITIONER TROUBLESHOOTING CHART 1 80-53
AIR CONDITIONER TROUBLESHOOTING CHART 2 80-54
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 80-57
FAILURE CODE [879AKA] 80-59
FAILURE CODE [879AKB] 80-60
FAILURE CODE [879BKA] 80-61
FAILURE CODE [879BKB] 80-63
FAILURE CODE [879CKA] 80-65
FAILURE CODE [879CKB] 80-66
FAILURE CODE [879DKZ] 80-67
FAILURE CODE [879EMC] 80-69
FAILURE CODE [879FMC] 80-70
FAILURE CODE [879GKX] 80-71
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)
80-73
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)
80-75
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) 80-78
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 80-80
TROUBLESHOOTING USING GAUGE PRESSURE 80-82
CONNECTION OF SERVICE TOOL 80-85
METHOD FOR CONNECTING SERVICE TOOL 80-85
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER
PIPINGS 80-87
HANDLE COMPRESSOR OIL 80-89
90 CIRCUIT DIAGRAMS 90-1
CONTENTS 90-2
ABBREVIATION LIST 90-3
HYDRAULIC CIRCUIT DIAGRAM 90-9
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90-9
HYDRAULIC CIRCUIT DIAGRAM (1/2) 90-13
HYDRAULIC CIRCUIT DIAGRAM (2/2) 90-15
HYDRAULIC CIRCUIT DIAGRAM (FOR EUROPEAN UNION) 90-17
ELECTRICAL CIRCUIT DIAGRAM 90-19
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 90-19
ELECTRICAL CIRCUIT DIAGRAM (1/6) 90-23
ELECTRICAL CIRCUIT DIAGRAM (2/6) 90-25
ELECTRICAL CIRCUIT DIAGRAM (3/6) 90-27
ELECTRICAL CIRCUIT DIAGRAM (4/6) 90-29
ELECTRICAL CIRCUIT DIAGRAM (5/6) 90-31
00 INDEX AND FOREWORD INDEX
PC78US-10 00-13
ELECTRICAL CIRCUIT DIAGRAM (6/6) 90-33
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (SERIAL NUMBER: 30001 – 33927)
(1/6) 90-35
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (SERIAL NUMBER: 30001 – 33927)
(2/6) 90-37
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (SERIAL NUMBER: 30001 – 33927)
(3/6) 90-39
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (SERIAL NUMBER: 30001 – 33927)
(4/6) 90-41
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (SERIAL NUMBER: 30001 – 33927)
(5/6) 90-43
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (SERIAL NUMBER: 30001 – 33927)
(6/6) 90-45
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (SERIAL NUMBER: 33928 – ) (1/6)
90-47
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (SERIAL NUMBER: 33928 – ) (2/6)
90-49
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (SERIAL NUMBER: 33928 – ) (3/6)
90-51
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (SERIAL NUMBER: 33928 – ) (4/6)
90-53
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (SERIAL NUMBER: 33928 – ) (5/6)
90-55
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (SERIAL NUMBER: 33928 – ) (6/6)
90-57
INDEX 1

DESCRIPTION:

Komatsu PC78US-10 Series Hydraulic Excavator Shop Manual SEN06518-06 – PDF DOWNLOAD

SERIAL NUMBERS 30001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

IMAGES PREVIEW OF THE MANUAL: