Komatsu PC78MR-6 Shop Manual SEBM030604 – PDF DOWNLOAD

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Komatsu PC78MR-6 Shop Manual SEBM030604 – PDF DOWNLOAD

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Komatsu PC78MR-6 Shop Manual SEBM030604 – PDF DOWNLOAD

Language : English
Pages : 589
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC78MR-6 Shop Manual SEBM030604 – PDF DOWNLOAD

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 6
SAFETY NOTICE 6
FOREWARD 8
GENERAL 8
HOW TO READ THE SHOP MANUAL 9
HOISTING INSTRUCTIONS 10
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 11
COATING MATERIALS 13
STANDARD TIGHTENING TORQUE 15
ELECTRIC WIRE CODE 18
CONVERSION TABLE 19
UNITS 25
01 GENERAL 27
SPECIFICATION DIMENSIONS DRAWING 28
WORKING RANGE DRAWING 30
SPECIFICATIONS 31
WEIGHT TABLE 34
LIST OF LUBRICANTS AND COOLANT 36
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 38
PTO 39
COOLING SYSTEM 40
POWER TRAIN SYSTEM 41
SWING CIRCLE 42
SWING MACHINERY 43
TRACK FRAME AND IDLER CUSHION 45
IDLER 47
TRACK ROLLER 48
CARRIER ROLLER 50
SPROCKET 51
TRACK SHOE 52
ARRANGEMENT OF HYDRAULIC COMPONENTS 57
HYDRAULIC TANK AND OIL FILTER 58
CENTER SWIVEL JOINT 59
TRAVEL MOTOR 60
WORK EQUIPMENT CYLINDER 68
SOLENOID VALVE 72
SOLENOID VALVE (FOR EU SPEC ) 80
ACCUMULATOR FOR PPC 84
MULTI-CONTROL VALVE 85
ACCUMULATOR FOR BRAKER 86
HYDRAULIC PUMP 87
CONTROL VALVE 101
CLSS 113
SWING MOTOR 145
WORK EQUIPMENT AND SWING PPC VALVE 153
TRAVEL PPC VALVE 159
BOOM SWING PPC VALVE, BLADE PPC VALVE 163
BOOM HYDRAULIC ANTI-BURST VALVE (FOR EU SPEC) 167
WORK EQUIPMENT 173
DIMENSIONS OF EACH PART OF WORK EQUIPMENT 175
AIR CONDITIONER PIPING (OPTIONAL) 179
ELECTRIC CONTROL SYSTEM 180
SYSTEM COMPONENTS 200
MONITOR SYSTEM 209
SENSORS 214
20 TESTING AND ADJUSTING 217
STANDARD VALUE TABLE FOR ENGINE 218
STANARD VALUE TABLE FOR CHASSIS 219
STANDARD VALUE TABLE FOR ELECTRIC PARTS 227
TESTING AND ADJUSTING 233
LIST OF DEVICES FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 234
MEASURING ENGINE SPEED 235
MEASURING EXHAUST GAS COLOR 236
ADJUSTING VALVE CLEARANCE 237
MEASURING COMPRESSION PRESSURE 238
MEASURING BLOW-BY PRESSURE 239
TESTING AND ADJUSTING FUEL INJECTION TIMING 240
MEASURING ENGINE OIL PRESSURE 244
ADJUSTING ENGINE STOP SOLENOID 245
ADJUSTING FUEL CONTROL LINKAGE 247
ADJUSTING ENGINE SPEED SENSOR 249
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 250
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE 253
ADJUSTING PC VALVE 255
TESTING TVC-EPC SOLENOID OUTPUT PRESSURE 255
MEASURING CONTROL CIRCUIT PRESSURE 256
MEASURING PPC VALVE OUTPUT PRESSURE 257
TESTING SOLENOID VALVE OUTPUT PRESSURE 258
ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE 260
TESTING TRAVEL DEVIATION 261
TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT 263
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTORS 264
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT 265
TESTING CLEARANCE OF SWING CIRCLE BEARING 266
TESTING AND ADJUSTING TRACK SHOE TENSION 267
BLEEDING AIR FROM HYDRAULIC CIRCUIT 268
REPLACEMENT PROCEDURE OF POTENTIOMETERS 270
PROCEDURE FOR TESTING DIODE 271
TROUBLESHOOTING 273
POINTS TO REMEMBER WHEN TROUBLESHOOTING 274
SEQUENCE OF EVENTS IN TROUBLESHOOTING 275
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 276
CHECKS BEFORE TROUBLESHOOTING 284
TYPE AND LOCATION OF CONNECTORS 286
CONNECTOR ARRANGEMENT DIAGRAM 288
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 291
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL MECHANISM 314
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL 315
TVC VALVE CURRENT ADJUSTMENT TABLE 326
METHOD OF USING JUDGEMENT TABLE 327
HOW TO READ FLOW OF TROUBLESHOOTING 329
CONTENTS AND PROCEDURE OF TROUBLESHOOTING 331
TROUBLESHOOTING OF ENGINE (S MODE) 332
METHOD OF USING TROUBLESHOOTING CHART 333
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 337
S-2 ENGINE DOES NOT START 339
1) ENGINE DOES NOT TURN 339
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 340
3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 341
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR) 342
S-4 ENGINE STOPS DURING OPERATIONS 343
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 344
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 345
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 346
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 347
S-9 OIL BECOMES CONTAMINATED QUICKLY 348
S-10 FUEL CONSUMPTION IS EXCESSIVE 349
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 350
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 351
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 352
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 353
S-15 ABNORMAL NOISE IS MADE 354
S-16 VIBRATION IS EXCESSIVE 355
TROUBLESHOOTING OF COMMUNICATION SYSTEM (N MODE) 356
N-1 DEFECTIVE COMMUNICATION 357
TROUBLESHOOTING FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE) 358
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) 359
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE 361
JUDGEMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE 363
E-1 CONTROLLER POWER SUPPLY IS DEFECTIVE (LED OF CONTROLLER IS TURNED OFF) 365
E-2 [E323] (SHORT CIRCUIT IN ACCELERATOR RELAY SYSTEM) IS DISPLAYED 366
E-3 [E325] (SHORT CIRCUIT IN DECELERATOR RELAY SYSTEM) IS DISPLAYED 367
E-4 [E328] (STALL OF MOTOR) IS DISPLAYED 368
E-5 [E227] (TROUBLE IN ENGINE SPEED SENSOR) IS DISPLAYED 370
E-6 ONE TOUCH SLOW DOWN MECHANISM DOES NOT WORK 371
E-7 ENGINE DOES NOT START 372
a) [E304] SHORT CIRCUIT IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED 372
b) [E314] DISCONNECTION IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED 372
c) ENGINE STOP SOLENOID SYSTEM 373
d) STARTING SYSTEM 375
E-8 ENGINE DOES NOT STOP 379
TROUBLESHOOTING FOR CONTROLLER PUMP CONTROL SYSTEM (C MODE) 380
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (PUMP CONTROL SYSTEM) 381
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE 383
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC EQUIPMENT 387
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM (FOR STD SPEC) 389
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM (FOR EU SPEC) 391
C-1 [E232], C-2 [E233] TROUBLE IN TVC-EPC SOLENOID SYSTEM 393
C-3 [E203], C-4 [E213] TROUBLE IN SWING HOLDING BRAKE SOLENOID SYSTEM 394
C-5 [E206], C-6 [E216] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENOID SYSTEM 395
C-7 [E411] TROUBLE IN BOOM SWING ANGLE SENSOR CORRECTION 396
C-8 [E251] TROUBLE IN BOOM BOTTOM PRESSURE SENSOR (OVERLOAD SENSOR) SYSTEM (FOR EU SPEC) 397
C-9 [E258] SHORT CIRCUIT IN 5V SYSTEM OF SENSOR POWER SUPPLY (FOR EU SPEC) 397
C-9 [E258] SHORT CIRCUIT IN 5V SYSTEM OF SENSOR POWER SUPPLY (FOR STD SPEC) 398
C-10 [E412], C-11 [E413] TROUBLE IN BOOM SWING ANGLE SENSOR SYSTEM 399
C-12 [E451] SHORT CIRCUIT IN BOOM SWING LEFT STOP EPC SOLENOID SYSTEM IS DISPLAYED 400
C-13 [E452] DISCONNECTION IN BOOM SWING LEFT STOP EPC SOLENOID SYSTEM IS DISPLAYED 401
C-14 [E453] SHORT CIRCUIT IN BOOM SWING RIGHT STOP EPC SOLENOID SYSTEM IS DISPLAYED 402
C-15 [E454] DISCONNECTION IN BOOM SWING RIGHT STOP EPC SOLENOID SYSTEM IS DISPLAYED 403
C-16 BOOM SWING LEFTT END CUSHION DOES NOT WORK AT ALL OR NORMALLY 404
C-17 BOOM SWING RIGHT END CUSHION DOES NOT WORK AT ALL OR NORMALLY 406
C-18 WORK EQUIPMENT STILL MOVES AFTER WORK EQUIPMENT LOCK LEVER IS SET TO LOCK 408
C-19 MACHINE DOES NOT SWING 409
C-20 TRAVEL SPEED DOES NOT RISE 410
C-21 TROUBLE IN CONTROLLER POWER SUPPLY (LED OF CONTROLLER IS TURNED OFF) 410
TROUBLESHOOTING FOR CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE) 411
F-1 BIT PATTERN 1023-(4) SWING PRESSURE SWITCH DOES NOT LIGHT UP 412
F-2 BIT PATTERN 1023-(3) TRAVEL PRESSURE SWITCH DOES NOT LIGHT UP 413
F-3 BIT PATTERN 1023-(6) BOOM RAISE PRESSURE SWITCH DOES NOT LIGHT UP 414
F-4 BIT PATTERN 1023-(5) ARM IN PRESSURE SWITCH DOES NOT LIGHT UP 415
F-5 BIT PATTERN 1026-(1) DECELERATION SWITCH OF LEFT KNOB DOES NOT LIGHT UP 416
F-6 BIT PATTERN 1026-(4) 2ND TRAVEL SPEED SELECTION SWITCH (PEDAL) DOES NOT LIGHT UP 417
F-7 BIT PATTERN 1021-(3) COMPRESSOR SIGNAL DOES NOT LIGHT UP 418
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 419
TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES 422
H-1 SPEED OR POWER OF 2 OR MORE SYSTEMS OF WORK EQUIPMENT (BOOM, ARM, BUCKET) TRAVEL, SWING, AND BLADE IS LOW 424
a) SPEED OR POWER OF WORK EQUIPMENT (INCLUDING BLADE), TRAVEL, AND SWING SYSTEMS IS LOW 424
b) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE) AND TRAVEL IS LOW 425
c) SPEED OR POWER OF SWING AND BLADE IS LOW 425
d) SPEED OR POWER OF TRAVEL AND BLADE IS LOW 426
e) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE) IS LOW 426
f) SPEED OR POWER OF TRAVEL AND SWING IS LOW 426
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS 427
H-3 2 OR MORE SYSTEMS OF WORK EQUIPMENT (BOOM, ARM, BUCKET), TRAVEL, SWING, AND BLADE DO NOT MOVE 429
a) ALL WORK EQUIPMENT (INCLUDING BLADE), TRAVEL, AND SWING SYSTEMS DO NOT MOVE 429
b) ALL WORK EQUIPMENT (EXCLUDING BLADE) AND TRAVEL SYSTEMS DO NOT MOVE 430
c) SWING AND BLADE SYSTEMS DO NOT MOVE 430
d) TRAVEL AND BLADE SYSTEMS DO NOT MOVE 431
e) ALL WORK EQUIPMENT (EXCLUDING BLADE) DOES NOT MOVE 431
H-4 ABNORMAL SOUND COMES OUT (FROM AROUND PUMP) 432
H-5 FINE CONTROLLABILITY OR RESPONSE IS LOW 433
H-6 HYDRAULIC DRIFT IS LARGE (ALL WORK EQUIPMENT AND BLADE) 434
H-7 BOOM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL) 435
a) BOOM RAISE SPEED OR POWER IS LOW 435
b) BOOM LOWER SPEED OR POWER IS LOW 436
H-8 ARM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL) 437
a) ARM IN SPEED OR POWER IS LOW 437
b) ARM OUT SPEED OR POWER IS LOW 438
H-9 BUCKET SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL) 439
a) BUCKET CURL SPEED OR POWER IS LOW 439
b) BUCKET DUMP SPEED OR POWER IS LOW 440
H-10 BOOM SWING SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL) 441
a) SWING LEFT SPEED OR POWER IS LOW 441
b) SWING RIGHT SPEED OR POWER IS LOW 442
H-11 BOOM DOES NOT MOVE 443
a) BOOM DOES NOT RISE 443
b) BOOM DOES NOT LOWER 444
H-12 ARM DOES NOT MOVE 445
a) ARM DOES NOT MOVE IN 445
b) ARM DOES NOT MOVE OUT 446
H-13 BUCKET DOES NOT MOVE 447
a) BUCKET DOES NOT CURL 447
b) BUCKET DOES NOT DUMP 448
H-14 BOOM SWING DOES NOT MOVE 449
a) BOOM SWING LEFT DOES NOT MOVE 449
b) BOOM SWING RIGHT DOES NOT MOVE 450
H-15 HYDRAULIC DRIFT OF BOOM IS LARGE 451
H-16 HYDRAULIC DRIFT OF ARM IS LARGE 451
H-17 HYDRAULIC DRIFT OF BUCKET IS LARGE 452
H-18 HYDRAULIC DRIFT OF SWING IS LARGE 452
a) HYDRAULIC DRIFT OF SWING TO LEFT IS LARGE 452
b) HYDRAULIC DRIFT OF SWING TO RIGHT IS LARGE 452
H-19 TIME LAG IS LARGE (WHEN ENGINE SPEED IS LOW) 453
H-20 PART LOADED MORE MOVES SLOWER IN COMPOUND OPERATION OF WORK EQUIPMENT 453
H-21 BOOM RAISE SPEED IS LOW IN COMPOUND OPERATION OF SWING AND BOOM RAISE 454
H-22 TRAVEL SPEED LOWERS EXTREMELY IN COMPOUND OPERATION OF TRAVEL AND BOOM RAISE 454
H-23 SPEED IS LOW IN COMPOUND OPERATION OF WORK EQUIPMENT RELIEF AND SWING, WORK EQUIPMENT RELIEF AND OTHER WORK EQUIPMENT 454
H-24 TRAVEL DEVIATION IS LARGE 455
a) TRAVEL DEVIATION IS LARGE DURING ORDINARY TRAVEL 455
b) TRAVEL DEVIATION IS LARGE WHEN MACHINE STARTS (BUT NORMAL DURING ORDINARY TRAVEL) 456
H-25 TRAVEL DEVIATION IS LARGE IN COMPOUND OERATION OF TRAVEL AND SWING, TRAVEL AND WORK EQUIPMENT 457
H-26 TRAVEL SPEED OR POWER IS LOW (WORK EQUIPMENT, SWING, AND BLADE OPERATIONS ARE NORMAL) 458
H-27 MACHINE CANNOT BE STEERED SHARPLY OR STEERING FORCE IS INSUFFICIENT 460
H-28 TRAVEL SPEED DOES NOT CHANGE AT ALL OR DOES NOT CHANGE QUICKLY 461
H-29 MACHINE DOES NOT TRAVEL 462
H-29 SUPPLEMENT 463
H-30 OVERRUN OF TRAVEL IS LARGE 464
H-31 TRAVEL HYDRAULIC DRIFT IS LARGE 464
H-32 FINE CONTROLLABILITY OR RESPONSE IS LOW 465
H-33 SWING SPEED OR POWER IS LOW (WORK EQUIPMENT, TRAVEL, AND BLADE OPERATIONS ARE NORMAL) 466
H-34 MACHINE DOES NOT SWING (WORK EQUIPMENT, TRAVEL, AND BLADE OPERATIONS ARE NORMAL) 468
a) SWING SPEED OR POWER IS LOW IN BOTH DIRECTIONS 468
b) SWING SPEED OR POWER IS LOW IN EITHER DIRECTION 469
H-35 SWING ACCELERATION IS LOW 470
a) SWING ACCELERATION IS LOW IN BOTH DIRECTIONS 470
b) SWING ACCELERATION IS LOW IN EITHER DIRECTION 470
H-36 OVERRUN OF SWING IS LARGE 471
a) OVERRUN OF SWING IS LARGE IN BOTH DIRECTIONS 471
b) OVERRUN OF SWING IS LARGE IN EITHER DIRECTION 471
H-37 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING 472
H-38 LARGE ABNORMAL SOUND IS MADE WHEN MACHINE STOPS SWINGING 472
H-39 SWING HYDRAULIC DRIFT IS LARGE 473
H-40 FINE CONTROLLABILITY OR RESPONSE OF SWING IS LOW 474
H-41 BLADE SPEED OR POWER IS LOW (WORK EQUIPMENT, TRAVEL, AND SWING OPERATIONS ARE NORMAL) 475
H-42 BLADE DOES NOT MOVE (WORK EQUIPMENT, TRAVEL, AND SWING OPERATIONS ARE NORMAL) 476
a) BLADE DOES NOT RISE 476
b) BLADE DOES NOT LOWER 477
H-43 HYDRAULIC DRIFT OF BLADE IS LARGE 478
H-44 FINE CONTROLLABILITY OR RESPONSE OF BLADE IS LOW 479
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M MODE) 481
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE 482
ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM 484
M-1 [E101] (ERROR HISTORY DATA ARE ABNORMAL) IS DISPLAYED 486
M-2 [E108] (ENGINE COOLANT TEMPERATURE IS 105 DEGREES C) IS DISPLAYED 487
M-3 [E112] (WIPER FORWARD OUTPUT IS SHORTED) IS DISPLAYED 487
M-4 [E113] (WIPER REVERSE OUTPUT IS SHORTED) IS DISPLAYED 487
M-5 [E114] (CONTACT WITH WASHER OUTPUT OF 24V) IS DISPLAYED 487
M-6 [E115] (WIPER DOES NOT START WIPING IN 10 SECONDS) IS DISPLAYED 487
M-7 [E116] (WIPER IS NOT RETRACTED IN 10 SECONDS) IS DISPLAYED 487
M-8 MONITOR PANEL SEGMENTS DO NOT LIGHT UP AT ALL FOR 3 SECONDS AFTER STARTING SWITCH IS TURNED ON 488
a) MONITOR PANEL SEGMENTS DO NOT LIGHT UP AT ALL 488
b) SOME MONITOR PANEL SEGMENTS DO NOT LIGHT UP 488
M-9 WHEN STARTING SWITCH IS SET TO ON POSITION, ALL MONITOR PANEL SEGMENTS LIGHT UP BUT DO NOT GO OFF 490
M-10 WHILE PREHEATING IS NOT EXECUTED, “PREHEATER MONITOR” LIGHTS UP 490
M-11 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH 491
a) ALTERNATOR SYSTEM 491
b) ENGINE OIL SYSTEM 492
M-12 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED), CAUTION ITEMS (EXCLUDING BATTERY AND ENGINE OIL) FLASH 493
a) ALTERNATOR SYSTEM 493
b) ENGINE OIL PRESSURE SENSOR SYSTEM 494
M-13 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH (WHEN THERE IS NOT ABNORMALITY IN INSPECTION ITEMS AND ENGINE BEFORE TROUBLESHOOTING, HOWEVER) 495
a) “ENGINE OIL” FLASHES 495
b) “CHARGE LEVEL” FLASHES 495
c) “COOLANT TEMPERATURE” FLASHES 496
d) “FUEL LEVEL” FLASHES 497
M-14 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND WHILE CAUTION ITEM IS FLASHING, BUZZER DOES NOT SOUND 498
M-15 MONITOR PLANE LAMP FOR NIGHTTIME IS NOT TURNED ON (LC DISPLAY IS NORMAL) 499
M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE 500
M-17 COOLANT TEMPERATURE GAUGE IS NOT DISPLAYED (GAUGE DOES NOT RISE TO 1ST LINE DURING OPERATION) 500
M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL 501
M-19 FUEL LEVEL GAUGE IS NOT DISPLAYED 501
M-20 WHILE ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE 502
M-21 TROUBLE IN FUEL LEVEL SENSOR 503
M-22 TROUBLE IN COOLANT TEMPERATURE SENSOR 504
M-23 WIPER DOES NOT OPERATE OR OPERATES WHILE WIPER SWITCH IS TURNED OFF 505
a) WIPER DOES NOT OPERATE 505
b) WIPER OPERATES WHILE WIPER SWITCH IS TURNED OFF 505
M-24 WASHER MOTOR DOES NOT OPERATE OR OPERATES WHILE WASHER SWITCH IS TURNED OFF 508
a) WASHER MOTOR DOES NOT OPERATE 508
b) WASHER OPERATES WHILE WIPER SWITCH IS TURNED OFF 508
30 DISASSEMBLY AND ASSEMBLY 511
METHOD OF USING MANUAL 512
PRECAUTIONS WHEN CARRYING OUT OPERATION 513
SPECIAL TOOL LIST 517
COUNTERWEIGHT 523
REMOVAL AND INSTALLATION 523
INJECTION PUMP 524
REMOVAL 524
INSTALLATION 525
CYLINDER HEAD 526
REMOVAL 526
INSTALLATION 529
MAIN PUMP 530
REMOVAL 530
INSTALLATION 531
CONTROL PUMP 531
REMOVAL AND INSTALLATION 531
ENGINE AND MAIN PUMP 532
REMOVAL 532
INSTALLATION 534
HYDRAULIC OIL COOLER 535
REMOVAL AND INSTALLATION 535
RADIATOR 535
REMOVAL 535
INSTALLATION 536
SWING MOTOR AND SWING MACHINERY 537
REMOVAL AND INSTALLATION 537
SWING MACHINERY 538
DISASSEMBLY 538
ASSEMBLY 540
SWING MOTOR 544
REMOVAL AND INSTALLATION 544
CENTER SWIVEL JOINT 544
REMOVAL 544
INSTALLATION 545
DISASSEMBLY AND ASSEMBLY 546
CONTROL VALVE 547
REMOVAL AND INSTALLATION 547
ASSEMBLY 548
WORK EQUIPMENT PPC VALVE 549
ASSEMBLY 549
TRAVEL PPC VALVE 550
ASSEMBLY 550
HYDRAULIC TANK 552
REMOVAL AND INSTALLATION 552
FUEL TANK 553
REMOVAL 553
INSTALLATION 554
CONTROLLER 556
REMOVAL AND INSTALLATION 556
MONITOR PANEL 557
REMOVAL AND INSTALLATION 557
AIR CONDITIONER UNIT 557
REMOVAL 557
INSTALLATION 558
OPERATOR’S CAB 559
REMOVAL AND INSTALLATION 559
FLOOR FRAME 560
REMOVAL 560
INSTALLATION 561
REVOLVING FRAME 562
REMOVAL AND INSTALLATION 562
SWING CIRCLE 563
REMOVAL AND INSTALLATION 563
WORK EQUIPMENT 564
REMOVAL 564
INSTALLATION 565
SWING BRACKET 566
REMOVAL 566
INSTALLATION 567
STEEL SHOE, RUBBER PAD SHOE, ROAD LINER 568
EXPANSION AND INSTALLATION 568
RUBBER SHOE 569
REMOVAL AND INSTALLATION 569
FINAL DRIVE 569
REMOVAL 569
INSTALLATION 570
IDLER 570
ASSEMBLY 570
RECOIL SPRING 572
DISASSEMBLY 572
ASSEMBLY 573
TRACK ROLLER 574
DISASSEMBLY 574
ASSEMBLY 575
HYDRAULIC CYLINDER 577
DISASSEMBLY 577
ASSEMBLY 579
90 OTHERS 581
HYDRAULIC CIRCUIT DIAGRAM (FOR STD SPEC) 582
HYDRAULIC CIRCUIT DIAGRAM (FOR EU SPEC) 583
ELECTRICAL CIRCUIT DIAGRAM (FOR STD SPEC) (1/2) 584
ELECTRICAL CIRCUIT DIAGRAM (FOR STD SPEC) (2/2) 585
ELECTRICAL CIRCUIT DIAGRAM (FOR EU SPEC) (1/2) 586
ELECTRICAL CIRCUIT DIAGRAM (FOR EU SPEC) (2/2) 587
ELECTRICAL CIRCUIT DIAGRAM (FOR NORWAY SPEC ) (1/2) 588
ELECTRICAL CIRCUIT DIAGRAM (FOR NORWAY SPEC ) (2/2) 589

DESCRIPTION:

Komatsu PC78MR-6 Shop Manual SEBM030604 – PDF DOWNLOAD

GENERAL PRECAUTIONS:
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, al- ways wear welding gloves, apron, hand shield, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always in- form your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK:
7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the ma- chine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

G.B 13/12/24