Komatsu PC78UU-10 Series Hydraulic Excavator Shop Manual SEN06659-01 – PDF DOWNLOAD

Komatsu PC78UU-10 Series Hydraulic Excavator Shop Manual SEN06659-01 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC78UU-10 Series Hydraulic Excavator Shop Manual SEN06659-01 – PDF DOWNLOAD

Language : English
Pages : 1988
Downloadable : Yes
File Type : PDF
Size: 48.8 MB

TABLE OF CONTENTS:

Komatsu PC78UU-10 Series Hydraulic Excavator Shop Manual SEN06659-01 – 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
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 00-35
PRECAUTIONS FOR DEF 00-36
STORE AdBlue/DEF 00-37
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00-38
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 00-41
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00-48
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 00-50
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00-51
PRACTICAL USE OF KOMTRAX 00-52
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00-53
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 00-57
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 00-61
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 00-62
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 00-64
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00-65
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
00-67
HOW TO READ ELECTRICAL WIRE CODE 00-68
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00-72
STANDARD TIGHTENING TORQUE TABLE 00-75
CONVERSION TABLE 00-82
01 SPECIFICATIONS 01-1
CONTENTS 01-2
ABBREVIATION LIST 01-3
SPECIFICATIONS 01-9
SPECIFICATION DRAWING 01-9
WORKING RANGE DRAWINGS 01-10
SPECIFICATIONS 01-12
WEIGHT TABLE 01-16
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
INDEX 00 INDEX AND FOREWORD
00-2 PC78UU-10
LAYOUT DRAWING OF CONTROL SYSTEM 10-47
MACHINE MONITOR SYSTEM 10-49
KOMTRAX SYSTEM 10-50
COMPONENT PARTS OF CONTROL SYSTEM 10-51
HYDRAULIC SYSTEM 10-81
LAYOUT DRAWING OF HYDRAULIC SYSTEM 10-81
CLSS 10-85
ENGINE AND PUMP COMBINED CONTROL SYSTEM 10-88
COMPONENT PARTS OF HYDRAULIC SYSTEM 10-92
WORK EQUIPMENT SYSTEM 10-159
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10-159
STRUCTURE OF VALVE CONTROL 10-163
PPC LOCK SYSTEM 10-164
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 10-165
INTERFERENCE PREVENTION DEVICE 10-168
AUTOMATIC CONTROL DEVICE (UU MODE) 10-176
END CUSHION FUNCTION 10-180
RESETTING FUNCTION 10-181
BUCKET DUMP CONTROL LOCK SYSTEM 10-183
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10-184
SWING SYSTEM 10-215
LAYOUT DRAWING OF SWING SYSTEM 10-215
SWING CONTROL SYSTEM DIAGRAM 10-218
COMPONENT PARTS OF SWING SYSTEM 10-220
TRAVEL SYSTEM 10-232
LAYOUT DRAWING OF TRAVEL SYSTEM 10-232
TRAVEL CONTROL SYSTEM DIAGRAM 10-234
COMPONENT PARTS OF TRAVEL SYSTEM 10-236
UNDERCARRIAGE AND FRAME 10-252
LAYOUT DRAWING OF UNDERCARRIAGE 10-252
IDLER CUSHION 10-254
WORK EQUIPMENT 10-255
STRUCTURE OF WORK EQUIPMENT 10-255
FUNCTION OF WORK EQUIPMENT 10-257
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 10-258
BUCKET CLEARANCE ADJUSTMENT SHIM 10-259
CAB AND ITS ATTACHMENTS 10-260
ROPS CAB 10-260
CAB MOUNT 10-261
TAKE WIRING HARNESS OUT OF CAB 10-263
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: PC78UU-10 20-9
STANDARD VALUE TABLE FOR MACHINE 20-12
STANDARD VALUE TABLE FOR MACHINE: PC78UU-10 20-12
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 20-26
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 30-21
TEST AND ADJUST VALVE CLEARANCE 30-23
00 INDEX AND FOREWORD INDEX
PC78UU-10 00-3
TEST COMPRESSION PRESSURE 30-25
TEST BLOWBY PRESSURE 30-28
TEST ENGINE OIL PRESSURE 30-30
TEST FUEL PRESSURE 30-32
TEST FUEL RETURN RATE AND LEAKAGE 30-34
BLEED AIR FROM FUEL SYSTEM 30-38
TEST FUEL CIRCUIT FOR LEAKAGE 30-40
HANDLE CYLINDER CUT-OUT MODE OPERATION 30-42
HANDLE NO-INJECTION CRANKING OPERATION 30-43
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 30-44
TEST ALTERNATOR BELT 30-45
TEST AUTOMATIC TENSIONER 30-46
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 30-48
POWER TRAIN 30-54
TEST SWING CIRCLE BEARING CLEARANCE 30-54
UNDERCARRIAGE AND FRAME 30-55
TEST AND ADJUST TRACK TENSION 30-55
HYDRAULIC SYSTEM 30-57
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30-57
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, AND TRAVEL CIRCUITS 30-59
TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE 30-65
TEST OIL PRESSURE OF CONTROL CIRCUIT 30-69
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 30-71
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 30-76
TEST OUTLET PRESSURE OF SOLENOID VALVE 30-80
TEST PPC VALVE OUTLET PRESSURE 30-85
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 30-87
TEST AND ADJUST TRAVEL DEVIATION 30-88
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 30-91
TEST OIL LEAKAGE 30-93
BLEED AIR FROM HYDRAULIC CIRCUIT 30-98
CAB AND ITS ATTACHMENTS 30-103
METHOD FOR ADJUSTING MIRRORS 30-103
TEST AND ADJUST ENGINE HOOD CATCHER 30-105
ELECTRICAL SYSTEM 30-108
SET AND OPERATE MACHINE MONITOR 30-108
METHOD FOR STARTING UP KOMTRAX TERMINAL 30-175
ADJUST REARVIEW CAMERA ANGLE 30-180
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 30-181
HANDLE BATTERY DISCONNECT SWITCH 30-182
TEST DIODES 30-183
Pm CLINIC 30-184
Pm CLINIC SERVICE 30-184
40 TROUBLESHOOTING 40-1
CONTENTS 40-2
ABBREVIATION LIST 40-9
RELATED INFORMATION ON TROUBLESHOOTING 40-15
GENERAL TROUBLESHOOTING POINTS 40-15
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40-16
CHECKS BEFORE TROUBLESHOOTING 40-18
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40-20
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40-22
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 40-46
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40-53
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 40-56
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40-60
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR
SYSTEM 40-62
INDEX 00 INDEX AND FOREWORD
00-4 PC78UU-10
CONNECTORS LIST AND LAYOUT 40-64
CONNECTOR CONTACT IDENTIFICATION 40-75
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40-114
FUSE LOCATION TABLE 40-120
FAILURE CODES TABLE 40-122
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 [989H00] 40-146
FAILURE CODE [989HKM] 40-147
FAILURE CODE [989L00] 40-148
FAILURE CODE [989M00] 40-149
FAILURE CODE [989N00] 40-150
FAILURE CODE [A900FR] 40-151
FAILURE CODE [A900N6] 40-152
FAILURE CODE [A900NY] 40-153
FAILURE CODE [AB00KE] 40-154
FAILURE CODE [B@BAZG] 40-156
FAILURE CODE [B@BCNS] 40-157
FAILURE CODE [CA115] 40-158
FAILURE CODE [CA122] 40-159
FAILURE CODE [CA123] 40-161
FAILURE CODE [CA131] 40-163
FAILURE CODE [CA132] 40-165
FAILURE CODE [CA144] 40-167
FAILURE CODE [CA145] 40-169
FAILURE CODE [CA153] 40-171
FAILURE CODE [CA154] 40-173
FAILURE CODE [CA187] 40-175
FAILURE CODE [CA221] 40-177
FAILURE CODE [CA222] 40-179
FAILURE CODE [CA227] 40-181
FAILURE CODE [CA234] 40-182
FAILURE CODE [CA238] 40-183
FAILURE CODE [CA239] 40-185
FAILURE CODE [CA271] 40-187
FAILURE CODE [CA272] 40-189
FAILURE CODE [CA322] 40-190
FAILURE CODE [CA324] 40-192
FAILURE CODE [CA331] 40-194
FAILURE CODE [CA332] 40-196
FAILURE CODE [CA343] 40-198
FAILURE CODE [CA351] 40-199
FAILURE CODE [CA352] 40-200
FAILURE CODE [CA356] 40-202
FAILURE CODE [CA357] 40-204
FAILURE CODE [CA386] 40-206
FAILURE CODE [CA435] 40-207
FAILURE CODE [CA441] 40-209
FAILURE CODE [CA442] 40-211
00 INDEX AND FOREWORD INDEX
PC78UU-10 00-5
FAILURE CODE [CA449] 40-212
FAILURE CODE [CA451] 40-213
FAILURE CODE [CA452] 40-215
FAILURE CODE [CA466] 40-217
FAILURE CODE [CA515] 40-219
FAILURE CODE [CA516] 40-221
FAILURE CODE [CA553] 40-223
FAILURE CODE [CA555] 40-224
FAILURE CODE [CA556] 40-225
FAILURE CODE [CA559] 40-226
FAILURE CODE [CA689] 40-230
FAILURE CODE [CA691] 40-232
FAILURE CODE [CA692] 40-234
FAILURE CODE [CA697] 40-236
FAILURE CODE [CA698] 40-237
FAILURE CODE [CA731] 40-238
FAILURE CODE [CA778] 40-240
FAILURE CODE [CA1117] 40-242
FAILURE CODE [CA1695] 40-243
FAILURE CODE [CA1696] 40-244
FAILURE CODE [CA1843] 40-245
FAILURE CODE [CA1844] 40-247
FAILURE CODE [CA1896] 40-249
FAILURE CODE [CA1942] 40-250
FAILURE CODE [CA1961] 40-251
FAILURE CODE [CA2185] 40-252
FAILURE CODE [CA2186] 40-253
FAILURE CODE [CA2249] 40-255
FAILURE CODE [CA2272] 40-256
FAILURE CODE [CA2311] 40-259
FAILURE CODE [CA2349] 40-260
FAILURE CODE [CA2353] 40-262
FAILURE CODE [CA2357] 40-264
FAILURE CODE [CA2765] 40-265
FAILURE CODE [CA3419] 40-266
FAILURE CODE [CA3421] 40-268
FAILURE CODE [CA3724] 40-270
FAILURE CODE [CA3918] 40-272
FAILURE CODE [CA3919] 40-273
FAILURE CODE [CA3921] 40-274
FAILURE CODE [CA3922] 40-275
FAILURE CODE [CA3923] 40-277
FAILURE CODE [D110KB] 40-279
FAILURE CODE [D19JKZ] 40-281
FAILURE CODE [D811MC] 40-284
FAILURE CODE [D862KA] 40-285
FAILURE CODE [D8ALKA] 40-286
FAILURE CODE [D8ALKB] 40-288
FAILURE CODE [D8AQKR] 40-290
FAILURE CODE [DA20MC] 40-292
FAILURE CODE [DA22KK] 40-293
FAILURE CODE [DA25KP] 40-296
FAILURE CODE [DA26KP] 40-299
FAILURE CODE [DA29KQ] 40-302
FAILURE CODE [DA2LKA] 40-304
FAILURE CODE [DA2LKB] 40-306
FAILURE CODE [DA2QKR] 40-308
FAILURE CODE [DA2RKR] 40-311
INDEX 00 INDEX AND FOREWORD
00-6 PC78UU-10
FAILURE CODE [DAF0MB] 40-312
FAILURE CODE [DAF0MC] 40-313
FAILURE CODE [DAF8KB] 40-314
FAILURE CODE [DAF9KQ] 40-316
FAILURE CODE [DAFGMC] 40-317
FAILURE CODE [DAFLKA] 40-318
FAILURE CODE [DAFLKB] 40-320
FAILURE CODE [DAFQKR] 40-321
FAILURE CODE [DAZ9KQ] 40-322
FAILURE CODE [DAZQKR] 40-323
FAILURE CODE [DB2QKR] 40-325
FAILURE CODE [DB2RKR] 40-330
FAILURE CODE [DDNRKA] 40-335
FAILURE CODE [DDNRKY] 40-337
FAILURE CODE [DDNS00] 40-339
FAILURE CODE [DGH2KB] 40-341
FAILURE CODE [DHPAMA] 40-343
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 [DHSRMA] 40-372
FAILURE CODE [DHSSMA] 40-375
FAILURE CODE [DKA0KA] 40-378
FAILURE CODE [DKA0KB] 40-381
FAILURE CODE [DKA0PH] 40-384
FAILURE CODE [DKC0KA] 40-385
FAILURE CODE [DKC0KB] 40-388
FAILURE CODE [DKC0PH] 40-391
FAILURE CODE [DKP0KA] 40-392
FAILURE CODE [DKP0KB] 40-395
FAILURE CODE [DKP0PH] 40-398
FAILURE CODE [DKULKA] 40-399
FAILURE CODE [DKULKB] 40-401
FAILURE CODE [DKULKY] 40-403
FAILURE CODE [DV20KB] 40-405
FAILURE CODE [DW43KA] 40-407
FAILURE CODE [DW43KB] 40-409
FAILURE CODE [DW43KY] 40-411
FAILURE CODE [DW45KA] 40-413
FAILURE CODE [DW45KB] 40-416
FAILURE CODE [DW45KY] 40-419
FAILURE CODE [DW4CKY] 40-421
FAILURE CODE [DW4FKA] 40-423
FAILURE CODE [DW4FKB] 40-425
FAILURE CODE [DW4FKY] 40-427
FAILURE CODE [DW4GKA] 40-429
FAILURE CODE [DW4GKB] 40-431
FAILURE CODE [DW4GKY] 40-433
FAILURE CODE [DW4HKA] 40-435
FAILURE CODE [DW4HKB] 40-437
FAILURE CODE [DW4HKY] 40-439
FAILURE CODE [DWJ0KA] 40-441
00 INDEX AND FOREWORD INDEX
PC78UU-10 00-7
FAILURE CODE [DWJ0KB] 40-443
FAILURE CODE [DWJ0KY] 40-445
FAILURE CODE [DXA8KA] 40-447
FAILURE CODE [DXA8KB] 40-449
FAILURE CODE [DXEBKA] 40-451
FAILURE CODE [DXEBKB] 40-453
FAILURE CODE [DXEBKY] 40-455
FAILURE CODE [DY20KA] 40-457
FAILURE CODE [DY20MA] 40-459
FAILURE CODE [DY2CKB] 40-461
FAILURE CODE [DY2DKB] 40-464
FAILURE CODE [DY2EKB] 40-466
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 40-468
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40-468
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 40-474
E-3 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 40-477
E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING 40-479
E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING
40-482
E-6 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING
40-483
E-7 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-484
E-8 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-485
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-486
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-487
E-11 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-488
E-12 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 40-489
E-13 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 40-491
E-14 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
OR MAXIMUM 40-492
E-15 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT
TEMPERATURE 40-493
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM 40-494
E-17 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE
40-496
E-18 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 40-497
E-19 FUNCTION SWITCH DOES NOT OPERATE 40-498
E-20 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 40-499
E-21 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR
DOES NOT LIGHT UP OR DOES NOT GO OFF 40-500
E-22 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 40-501
E-23 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS
NOT DISPLAYED 40-502
E-24 BOOM RAISING DOES NOT AUTOMATICALLY STOP PROPERLY AND IT INTERFERES (CAB
SIDE) 40-503
E-25 ARM IN DOES NOT AUTOMATICALLY STOP PROPERLY AND IT INTERFERES (CAB SIDE)
40-505
E-26 OFFSET LEFT DOES NOT AUTOMATICALLY STOP PROPERLY AND IT INTERFERES (CAB
SIDE) 40-507
E-27 BOOM LOWERING DOES NOT AUTOMATICALLY STOP PROPERLY AND IT INTERFERES
(RIGHT EXTERIOR SIDE) 40-509
E-28 ARM IN DOES NOT AUTOMATICALLY STOP PROPERLY AND IT INTERFERES (RIGHT EXTERIOR
SIDE) 40-511
INDEX 00 INDEX AND FOREWORD
00-8 PC78UU-10
E-29 OFFSET RIGHT DOES NOT AUTOMATICALLY STOP PROPERLY AND IT INTERFERES
(RIGHT EXTERIOR SIDE) 40-513
E-30 WORK EQUIPMENT STOP POSITION IS TOO FAR OR NEAR 40-515
E-31 CUSHION FOR BOOM RAISE END DOES NOT WORK OR IS WEAK 40-517
E-32 CUSHION FOR ARM IN END DOES NOT WORK OR IS WEAK 40-519
E-33 AT THE HEIGHT RESTRICTION, MACHINE STOPS PAST EXCESSIVE THE RESTRICTION
OR STOPS SHORT OF IT 40-521
E-34 DEPTH INDICATION DEVIATES OR DOES NOT DISPLAY 40-523
E-35 BUZZER SOUNDS FOR 7 SECONDS EVEN IF THE WORK EQUIPMENT LOCK RELEASE
SWITCH IS NOT TURNED ON 40-525
E-36 WHEN THE WORK EQUIPMENT LOCK RELEASE SWITCH IS TURNED ON, THE WORK
EQUIPMENT LOCK PILOT LAMP DOES NOT LIGHT UP 40-526
E-37 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS
NOT CHANGED 40-528
E-38 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT
CHANGE 40-529
E-39 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE 40-530
E-40 ALARM BUZZER CANNOT BE CANCELED 40-531
E-41 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION
40-532
E-42 SERVICE MODE CANNOT BE SELECTED 40-533
E-43 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 40-534
E-44 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 40-537
E-45 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT
SWING 40-539
E-46 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING
BRAKE DOES NOT OPERATE 40-541
E-47 ALARM DOES NOT SOUND DURING TRAVEL 40-543
E-48 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 40-545
E-49 HORN DOES NOT SOUND 40-546
E-50 HORN DOES NOT STOP SOUNDING 40-548
E-51 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF
40-549
E-52 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 40-550
E-53 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE
40-552
E-54 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-553
E-55 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-554
E-56 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-555
E-57 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-556
E-58 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-557
E-59 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-558
E-60 OFFSET LEFT IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION 40-559
E-61 OFFSET RIGHT IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION 40-560
E-62 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-561
E-63 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-562
E-64 BLADE RAISE ON IS NOT DISPLAYED CORRECTLY WITH MONITORING 40-563
E-65 BLADE LOWER ON IS NOT DISPLAYED CORRECTLY WITH MONITORING 40-565
E-66 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 40-567
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 40-568
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 40-568
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 40-569
00 INDEX AND FOREWORD INDEX
PC78UU-10 00-9
FAILURE MODE AND CAUSE TABLE 40-571
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 40-579
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 40-580
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 40-582
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 40-583
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 40-584
H-6 SPEED OR POWER OF BOOM IS LOW 40-586
H-7 ARM SPEED OR POWER IS LOW 40-590
H-8 BUCKET SPEED OR POWER IS LOW 40-593
H-9 BLADE SPEED OR POWER IS LOW 40-596
H-10 OFFSET SPEED OR POWER IS LOW 40-598
H-11 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 40-600
H-12 HYDRAULIC DRIFT OF BOOM IS LARGE 40-602
H-13 HYDRAULIC DRIFT OF ARM IS LARGE 40-603
H-14 HYDRAULIC DRIFT OF BUCKET IS LARGE 40-604
H-15 HYDRAULIC DRIFT OF OFFSET IS LARGE 40-605
H-16 HYDRAULIC DRIFT OF BLADE IS LARGE 40-606
H-17 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT
MOVES 40-608
H-18 BOOM RAISING AND LOWERING,ARM IN,OR OFFSET RIGHT AND LEFT DOES NOT AUTOMATICALLY
STOP AND IT INTERFERE 40-609
H-19 TIME LAG OF WORK EQUIPMENT IS LARGE 40-610
H-20 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD
MOVES SLOWER 40-611
H-21 IN COMBINED OPERATION OF WORK EQUIPMENT AND TRAVEL, TRAVEL SPEED DROPS
LARGELY 40-612
H-22 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW
40-613
H-23 MACHINE DOES NOT TRAVEL STRAIGHT 40-614
H-24 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 40-616
H-25 TRAVEL SPEED IS LOW 40-619
H-26 ONE OF TRACKS DOES NOT RUN 40-622
H-27 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 40-624
H-28 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 40-625
H-29 SWINGS ONLY IN ONE DIRECTION 40-627
H-30 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND
LEFT) 40-628
H-31 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY
ONE DIRECTION 40-630
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH
RIGHT AND LEFT) 40-631
H-33 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE
DIRECTION EITHER RIGHT OR LEFT) 40-632
H-34 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 40-633
H-35 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 40-634
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 40-635
H-37 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)
40-636
TROUBLESHOOTING OF ENGINE (S-MODE) 40-637
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 40-637
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION
40-638
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 40-639
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) 40-640
S-4 ENGINE STARTABILITY IS POOR 40-641
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 40-643
S-6 ENGINE STOPS DURING OPERATION 40-645
INDEX 00 INDEX AND FOREWORD
00-10 PC78UU-10
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 40-647
S-8 ENGINE LACKS POWER 40-648
S-9 EXHAUST SMOKE IS BLACK 40-650
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 40-652
S-11 OIL BECOMES CONTAMINATED QUICKLY 40-653
S-12 FUEL CONSUMPTION IS EXCESSIVE 40-654
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
40-655
S-14 OIL PRESSURE DROPS 40-656
S-15 FUEL MIXES INTO ENGINE OIL 40-658
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 40-659
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 40-660
S-18 UNUSUAL NOISE IS HEARD 40-661
S-19 VIBRATION IS EXCESSIVE 40-662
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 40-663
50 DISASSEMBLY AND ASSEMBLY 50-1
CONTENTS 50-2
ABBREVIATION LIST 50-7
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 50-13
HOW TO READ THIS MANUAL 50-13
COATING MATERIALS LIST 50-15
SPECIAL TOOLS LIST 50-19
SKETCHES OF SPECIAL TOOLS 50-28
ENGINE AND COOLING SYSTEM 50-32
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 50-32
REMOVE AND INSTALL INJECTOR ASSEMBLY 50-41
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 50-139
REMOVE AND INSTALL ENGINE REAR OIL SEAL 50-142
REMOVE AND INSTALL FUEL COOLER ASSEMBLY 50-145
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 50-148
REMOVE AND INSTALL KDOC MUFFLER 50-151
REMOVE AND INSTALL FUEL TANK ASSEMBLY 50-159
REMOVE AND INSTALL KCCV VENTILATOR ASSEMBLY 50-165
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 50-169
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 50-172
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 50-177
POWER TRAIN 50-179
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 50-179
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE
MACHINE: #30001 to 35917) 50-182
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE
MACHINE: #35918 AND UP) 50-229
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 50-278
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 50-281
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 50-290
UNDERCARRIAGE AND FRAME 50-292
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 50-292
00 INDEX AND FOREWORD INDEX
PC78UU-10 00-11
REMOVE AND INSTALL SPROCKET 50-294
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 50-296
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 50-298
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 50-302
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 50-305
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 50-309
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 50-314
HYDRAULIC SYSTEM 50-320
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 50-320
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 50-323
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 50-326
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 50-334
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 50-344
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 50-354
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 50-356
WORK EQUIPMENT 50-359
REMOVE AND INSTALL BLADE ASSEMBLY 50-359
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 50-362
REMOVE AND INSTALL 1ST BOOM ASSEMBLY 50-371
REMOVE AND INSTALL 2ND BOOM ASSEMBLY 50-381
REMOVE AND INSTALL 3RD BRACKET ASSEMBLY 50-385
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 50-393
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM (HEAD SIDE) 50-397
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM (BOTTOM SIDE) 50-400
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY 50-404
REMOVE AND INSTALL BOOM POTENTIOMETER ASSEMBLY 50-405
REMOVE AND INSTALL ARM POTENTIOMETER ASSEMBLY 50-406
REMOVE AND INSTALL OFFSET POTENTIOMETER ASSEMBLY 50-409
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 50-410
CAB AND ITS ATTACHMENTS 50-417
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 50-417
REMOVE AND INSTALL OPERATOR’S CAB DOOR 50-428
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 50-431
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 50-442
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 50-445
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 50-461
REMOVE AND INSTALL OPERATOR’S SEAT 50-475
REMOVE AND INSTALL SEAT BELT 50-477
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 50-479
ELECTRICAL SYSTEM 50-493
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 50-493
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 50-496
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 50-498
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 50-504
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 50-506
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 50-508
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
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
INDEX 00 INDEX AND FOREWORD
00-12 PC78UU-10
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 OFFSET PPC VALVE (WITH EPC VALVE) 60-58
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 60-61
MAINTENANCE STANDARD OF SOLENOID VALVE 60-64
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 60-65
WORK EQUIPMENT 60-66
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60-66
MAINTENANCE STANDARD OF BOOM CYLINDER 60-77
MAINTENANCE STANDARD OF ARM CYLINDER 60-78
MAINTENANCE STANDARD OF BOOM OFFSET CYLINDER 60-79
MAINTENANCE STANDARD OF BUCKET CYLINDER 60-80
MAINTENANCE STANDARD OF BLADE CYLINDER 60-81
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
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
00 INDEX AND FOREWORD INDEX
PC78UU-10 00-13
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 90-13
ELECTRICAL CIRCUIT DIAGRAM 90-15
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 90-15
ELECTRICAL CIRCUIT DIAGRAM (1/6) 90-19
ELECTRICAL CIRCUIT DIAGRAM (2/6) 90-21
ELECTRICAL CIRCUIT DIAGRAM (3/6) 90-23
ELECTRICAL CIRCUIT DIAGRAM (4/6) 90-25
ELECTRICAL CIRCUIT DIAGRAM (5/6) 90-27
ELECTRICAL CIRCUIT DIAGRAM (6/6) 90-29
INDEX 1

DESCRIPTION:

Komatsu PC78UU-10 Series Hydraulic Excavator Shop Manual SEN06659-01 – 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: