Komatsu PC78US-6 PC78UU-6 Hydraulic Excavator Shop Manual SEBD025113 PDF

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Komatsu PC78US-6 PC78UU-6 Hydraulic Excavator Shop Manual SEBD025113 – PDF DOWNLOAD

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Komatsu PC78US-6 PC78UU-6 Hydraulic Excavator Shop Manual SEBD025113 – PDF DOWNLOAD 

Language : English
Pages : 983
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC78US-6 PC78UU-6 Hydraulic Excavator Shop Manual SEBD025113 – PDF DOWNLOAD 

MACHINE MODEL   SERIAL NUMBER
PC78US-6                   4001 and up
PC78US-6                   4809 and up (For Norway & EU)
PC78UU-6                   22832 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

TABLE OF CONTENTS:

Komatsu PC78US-6 PC78UU-6 Hydraulic Excavator Shop Manual SEBD025113 – PDF DOWNLOAD 

MACHINE MODEL   SERIAL NUMBER
PC78US-6                   4001 and up
PC78US-6                   4809 and up (For Norway & EU)
PC78UU-6                   22832 and up

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 7
FOREWORD 9
01 GENERAL 27
SPECIFICATION DIMENSIONS DRAWING 28
WORKING RANGE DRAWING 30
SPECIFICATIONS 31
WEIGHT TABLE 43
LIST OF LUBRICANTS AND COOLANT 47
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 49
PTO 50
COOLING SYSTEM 52
POWER TRAIN SYSTEM 54
SWING CIRCLE 56
SWING MACHINERY 58
TRACK FRAME AND IDLER CUSHION 62
IDLER 64
TRACK ROLLER 65
CARRIER ROLLER 67
SPROCKET 68
TRACK SHOE 69
ARRANGEMENT OF HYDRULIC COMPONENTS 74
HYDRAULIC TANK AND OIL FILTER 77
CENTER SWIVEL JOINT 79
TRAVEL MOTOR 81
WORK EQUIPMENT CYLINDER 89
SOLENOID VALVE 94
MULTI-CONTROL VALVE 101
ACCUMULATOR FOR BRAKE 102
HYDRAULIC PUMP 103
CONTROL VALVE 128
CLSS 168
SWING MOTOR 206
WORK EQUIPMENT AND SWING PPC VALVE 214
TRAVEL PPC VALVE 220
OFFSET PPC VALVE, ATTACHMENT PPC VALVE, BLADE PPC VALVE 224
WORK EQUIPMENT 228
DIMENSIONS OF EACH PART OF WORK EQUIPMENT 234
AIR CONDITIONER (OPTIONAL) 240
ELECTRIC CONTROL SYSTEM 243
SYSTEM COMPONENTS 300
MONITOR SYSTEM 313
SENSORS 319
20 TESTING AND ADJUSTING 323
STANDARD VALUE TABLE 324
STANDARD VALUE TABLE FOR ENGINE 324
STANDARD VALUE TABLE FOR CHASSIS 326
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 335
TESTING AND ADJUSTING 346
LIST OF DEVICES FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 347
MEASURING ENGINE SPEED 348
MEASURING EXHAUST GAS COLOR 349
ADJUSTING VALVE CLEARANCE 350
MEASURING COMPRESSION PRESSURE 351
MEASURING BLOW-BY PRESSURE 353
TESTING AND ADJUSTING FUEL INJECTION TIMING 355
MEASURING ENGINE OIL PRESSURE 359
ADJUSTING FUEL STOP SOLENOID 360
ADJUSTING FUEL CONTROL LINKAGE 362
ADJUSTING ENGINE SPEED SENSOR 364
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 365
MEASURING LS DIFFERENTIAL PRESSURE ANDADJUSTING LS VALVE 368
ADJUSTING PC VALVE 370
TESTING TVC-EPC SOLENOID OUTPUT PRESSURE 370
MEASURING CONTROL CIRCUIT PRESSURE 372
MEASURING PPC VALVE OUTPUT PRESSURE 373
TESTING SOLENOID VALVE OUTPUT PRESSURE 374
ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE 376
TESTING TRAVEL DEVIATION 377
TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT 379
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTORS 380
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT 381
TESTING CLEARANCE OF SWING CIRCLE BEARING 382
TESTING AND ADJUSTING TRACK SHOE TENSION 383
BLEEDING AIR FROM HYDRAULIC CIRCUIT 384
PROCEDURE FOR ADJUSTING INSTALLATION OF LONG ARM 386
REPLACEMENT PROCEDURE OF POTENTIOMETERS 387
PROCEDURE FOR TESTING DIODE 388
TROUBLESHOOTING 389
POINTS TO REMEMBER WHEN TROUBLESHOOTING 390
SEQUENCE OF EVENTS IN TROUBLESHOOTING 391
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 392
CHECKS BEFORE TROUBLESHOOTING 400
CONNECTOR TYPES AND MOUNTING LOCATIONS (PC78US-6 SERIAL NO 4001-5500) 401
CONNECTOR ARRANGEMENT DIAGRAM PC78US-6 SERIAL NO 4001-5500 403
CONNECTOR TYPES AND MOUNTING LOCATIONS (PC78US-6 SERIAL NO 5501-6500) 406
CONNECTOR ARRANGEMENT DIAGRAM (PC78US-6 SERIAL NO 5501-6500) 408
CONNECTOR TYPES AND MOUNTING LOCATONS (PC78US-6 SERIAL NO : 6501 AND UP) 411
CONNECTOR ARRANGEMENT DIAGRAM (PC78UU-6 SERIAL NO : 6501 AND UP) 414
CONNECTOR TYPES AND MOUNTING LOCATIONS PC78UU-6 SERIAL NO 22832-23500 417
CONNECTOR ARRANGEMENT DIAGRAM PC78UU-6 SERIAL NO 22832-23500 420
CONNECTOR TYPES AND MOUNTING LOCATIONS PC78UU-6 SERIAL NO 23501 and up 423
CONNECTOR ARRANGEMENT DIAGRAM PC78UU-6 SERIAL NO 23501 and up 426
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 429
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL MECHANISM 453
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL 457
TVC VALVE CURRENT ADJUSTMENT TABLE 474
HOW TO READ FLOW OF TROUBLESHOOTING 477
CONTENTS AND PROCEDURE OF TROUBLESHOOTING 479
TROUBLESHOOTING FOR COMMUNICATION SYSTEM (N MODE) 480
N-1 DEFECTIVE COMMUNICATION 481
TROUBLESHOOTING FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE) 483
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (PUMP CONTROL SYSTEM) 484
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE 486
JUDGEMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE 491
E-1 CONTROLLER POWER SUPPLY IS DEFECTIVE (LED OF CONTROLLER IS TURNED OFF) 495
E-2 [E321] (SHORT CIRCUIT IN MOTOR DRIVE RELAY) IS DISPLAYED 497
E-3 [E323] (SHORT CIRCUIT IN ACCELERATOR RELAY) IS DISPLAYED 498
E-4 [E325] (SHORT CIRCUIT IN DECELERATOR RELAY) IS DISPLAYED 500
E-5 [E328] (STALL OF MOTOR) IS DISPLAYED 504
E-6 [E227] (TROUBLE IN ENGINE SPEED SENSOR) IS DISPLAYED 509
E-7 [E306] TROUBLE IN GOVERNOR MOTOR FEEDBACK POTENTIOMETER IS DISPLAYED 511
E-8 [E308] TROUBLE IN FUEL CONTROL DIAL SYSTEM IS DISPLAYED 512
E-9 ONE-TOUCH SLOW-DOWN MECHANISM DOES NOT WORK 513
E-10 ENGINE DOES NOT START 515
A) [E304] SHORT CIRCUIT IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED 515
B) [E314] DISCONNECTION IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED 515
C) ENGINE STOP SOLENOID SYSTEM 517
D) STARTING SYSTEM 522
E-11 ENGINE DOES NOT STOP 529
TROUBLESHOOTING FOR CONTROLLER (PUMP CONTROL SYSTEM) (C MODE) 533
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (PUMP CONTROL SYSTEM) 534
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE 536
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC EQUIPMENT 542
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM 546
C-1 [E232] TROUBLE IN TVC-EPC SOLENOID SYSTEM 556
C-2 [E233] TROUBLE IN TVC-EPC SOLENOID SYSTEM 556
C-3 [E203] TROUBLE IN SWING HOLDING BRAKE SOLENIOD SYSTEM 558
C-4 [E213] TROUBLE IN SWING HOLDING BRAKE SOLENIOD SYSTEM 558
C-5 [E206] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENIOD SYSTEM 560
C-6 [E216] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENIOD SYSTEM 560
C-7 [E403] TROUBLE IN BOOM ANGLE SENSOR CORRECTION 562
C-8 [E406] TROUBLE IN ARM ANGLE SENSOR CORRECTION 562
C-9 [E411] TROUBLE IN OFFSET BOOM ANGLE SENSOR CORRECTION 562
C-10 [E441] TROUBLE IN INTERFERENCE PREVENTION (FRONT) CORRECTION 564
C-11 [E442] TROUBLE IN INTERFERENCE PREVENTION (SIDE) CORRECTION (ONLY PC78UU-6) 564
C-12 [E443] TROUBLE IN DEPTH INDICATION CORRECTION (ONLY PC78UU-6) 565
C-13 [E258] SHORT CIRCUIT IN 5V SYSTEM OF SENSOR POWER SUPPLY (ONLY PC78UU-6) 566
C-14 [E224] TROUBLE IN PUMP PRESSURE SENSOR IS DISPLAYED (PC78US-6 SERIAL NO : 6501 AND UP) 569
C-15 [E401] TROUBLE IN BOOM ANGLE SENSOR SYSTEM (ONLY PC78UU-6) 570
C-16 [E402] TROUBLE IN BOOM ANGLE SENSOR SYSTEM (ONLY PC78UU-6) 570
C-17 [E404] TROUBLE IN ARM ANGLE SENSOR SYSTEM (ONLY PC78UU-6) 571
C-18 [E405] TROUBLE IN ARM ANGLE SENSOR SYSTEM (ONLY PC78UU-6) 571
C-19 [E407] TROUBLE IN OFFSET ANGLE SENSOR SYSTEM (ONLY PC78UU-6) 572
C-20 [E408] TROUBLE IN OFFSET ANGLE SENSOR SYSTEM (ONLY PC78UU-6) 572
C-21 [E421] SHORT CIRCUIT IN BOOM RAISE EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6) 573
C-22 [E422] DISCONNECTION IN BOOM RAISE EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6) 574
C-23 [E423] SHORT CIRCUIT OR GROUNDING FAULT IN ARM-IN EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6) 575
C-24 [E424] DISCONNECTION IN ARM IN EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6) 576
C-25 [E425] SHORT CIRCUIT OR GROUNDING FAULT IN OFFSET LEFT EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6) 577
C-26 [E426] DISCONNECTION IN OFFSET LEFT EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6) 578
C-27 [E431] SHORT CIRCUIT OR GROUNDING FAULT IN PPC BASIC PRESSURE LOCK SOLENOID SYSTEM IS DISPLAYED (ONLY PC78UU-6) 579
C-28 BOOM DOES NOT STOP AUTOMATICALLY AT NORMAL POSITION BUT INTERFERES WHEN IT IS RAISED (ONLY PC78UU-6) 582
C-29 ARM DOES NOT STOP AUTOMATICALLY AT NORMAL POSITION BUT INTERFERES WHEN IT IS MOVED IN (ONLY PC78UU-6) 583
C-30 OFFSET DOES NOT STOP AUTOMATICALLY AT NORMAL POSITION BUT INTERFERES WHEN IT IS MOVED TO LEFT (ONLY PC78UU-6) 584
C-31 WORK EQUIPMENT STOPS FAR OR NEAR (ONLY PC78UU-6) 585
C-32 BUZZER SOUNDS FOR 7 SECONDS WHILE EMERGENCY WORK EQUIPMENT OPERATION SWITCH IS NOT TURNED ON (ONLY PC78UU-6) 586
C-33 BOOM RAISE END CUSHION DOES NOT WORK AT ALL OR NORMALLY (ONLY PC78UU-6) 589
C-34 ARM-IN END CUSHION DOES NOT WORK AT ALL OR NORMALLY (ONLY PC78UU-6) 590
C-35 OFFSET SEND CUSHION DOES NOT WORK AT ALL OR NORMALLY (ONLY PC78UU-6) 591
C-36 WORK EQUIPMENT STOPS AFTER OR BEFORE SET HEIGHT (ONLY PC78UU-6) 592
C-37 WHEN DEPTH DISPLAY IS RESET, 0 0 M IS NOT INDICATED AT GL (ONLY PC78UU-6) 593
C-38 WORK EQUIPMENT STILL MOVES AFTER WORK EQUIPMENT LOCK LEVER IS SET TO LOCK 594
C-39 MACHINE DOES NOT SWING 598
C-40 TRAVEL SPEED DOES NOT RISE (PC78US-6: 4001-6500, PC78UU-6:22832 AND UP 600
C-41 GEAR SPEED DOES NOT CHANGE AUTOMATICALLY (PC78US-6: 6501 AND UP) 601
C-42 TROUBLE IN CONTROLLER POWER SUPPLY SYSTEM (LED OF CONTROLLER IS TURNED OFF) 601
TROUBLESHOOTING FOR CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE) 602
F-1 BIT PATTERN 1023-4 SWING PRESSURE SWITCH DOES NOT LIGHT UP 603
F-2 BIT PATTERN 1023-3 TRAVEL PRESSURE SWITCH DOES NOT LIGHT UP 605
F-3 BIT PATTERN 1023-6 BOOM RAISE PRESSURE SWITCH DOES NOT LIGHT UP 607
F-4 BIT PATTERN 1023-5 ARM IN PRESSURE SWITCH DOES NOT LIGHT UP 609
F-5 BIT PATTERN 1026-1 DECELERATION SWITCH OF LEFT KNOB DOES NOT LIGHT UP 611
F-6 BIT PATTERN 1021-4 2ND TRAVEL SPEED SELECTION SWITCH (PEDAL) DOES NOT LIGHT UP (US WITH BLADE) 613
F-7 BIT PATTERN 1021-3 COMPRESSOR SIGNAL DOES NOT LIGHT UP 614
F-8 BIT PATTERN 1026-(3) EMERGENCY WORK EQUIPMENT OPERATION SWITCH DOES NOT LIGHT UP (ONLY PC78UU-6) 616
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 617
TABLE OF HYRAULIC FAILURE MODES AND CAUSES 620
H-1 SPEED OR POWER OF 2 OR MORE SYSTEMS OF WORK EQUIPMENT (BOOM, ARM, BUCKET, OFFSET), TRAVEL, SWING, AND BLADE IS LOW 622
A) SPEED OR POWER OF ALL WORK EQUIPMENT (INCLUDING BLADE), TRAVEL AND SWING IS LOW 622
B) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE), AND TRAVEL IS LOW 623
C) SPEED OR POWER OF SWING AND BLADE IS LOW 623
D) SPEED OR POWER OF TRAVEL AND BLADE IS LOW 624
E) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE) IS LOW 624
F) SPEED OR POWER OF TRAVEL AND SWING IS LOW 625
G) SPEED OR POWER OF ALL WORK EQUIPMENT AND SWING IS LOW 625
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS 626
H-3 2 OR MORE SYSTEMS (INCLUDING BLADE), TRAVEL, AND SWING SYSTEMS DO NOT MOVE 628
A) ALL WORK EQUIPMENT (INCLUDING BLADE), TRAVEL, AND SWING SYSTEMS DO NOT MOVE 628
B) ALL WORK (EXCLUDING BLADE) AND TRAVEL SYSTEMS DO MOVE 629
C) SWING AND BLADE SYSTEMS DO NOT MOVE 629
D) TRAVEL AND BLADE SYSTEMS DO NOT MOVE 630
E) ALL WORK EQUIPMENT (EXCLUDING BLADE) DOES NOT MOVE 630
H-4 ABNORMAL SOUND COMES OUT (FROM AROUND PUMP) 631
H-5 FINE CONTROLLABILITY OR RESPONSE IS LOW 632
H-6 HYDRAULIC DRIFT IS LARGE (ALL WORK EQUIPMENT AND BLADE) 633
H-7 BOOM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL) 634
A) BOOM RAISE SPEED OR POWER IS LOW 634
B) BOOM LOWER SPEED OR POWER IS LOW 635
H-8 ARM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL) 636
A) ARM IN SPEED OR POWER IS LOW 636
B) ARM OUT SPEED OR POWER IS LOW 638
H-9 BUCKET SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL) 639
A) BUCKET CURL SPEED OR POWER IS LOW 639
B) BUCKET DUMP SPEED OR POWER IS LOW 640
H-10 OFFSET SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL) (ONLY PC78UU-6) 641
A) OFFSET LEFT SPEED OR POWER IS LOW 641
B) OFFSET RIGHT SPEED OR POWER IS LOW 642
H-11 BOOM DOES NOT MOVE 643
A) BOOM DOES NOT RISE 643
B) BOOM DOES NOT LOWER 644
H-12 ARM DOES NOT MOVE 645
A) ARM DOES NOT MOVE IN 645
B) ARM DOES NOT MOVE OUT 646
H-13 BUCKET DOES NOT MOVE 647
A) BUCKET DOES NOT CURL 647
B) BUCKET DOES NOT DUMP 648
H-14 OFFSET BOOM DOES NOT MOVE (ONLY PC78UU-6) 649
A) OFFSET BOOM LEFT DOES NOT MOVE 649
B) OFFSET BOOM RIGHT DOES NOT MOVE 650
H-15 HYDRAULIC DRIFT OF BOOM IS LARGE 651
H-16 HYDRAULIC DRIFT OF ARM IS LARGE 651
H-17 HYDRAULIC DRIFT OF BUCKET IS LARGE 652
H-18 HYDRAULIC DRIFT OF OFFSET IS LARGE (ONLY PC78UU-6) 652
A) HYDRAULIC DRIFT OF OFFSET TO LEFT IS LARGE 652
B) HYDRAULIC DRIFT OF OFFSET TO RIGHT IS LARGE 652
H-19 TIME LAG IS LARGE (WHEN ENGINE SPEED IS LOW) 653
H-20 PART LOADED MORE MOVES SLOWER IN COMPOUND OPERATION OF WORK EQUIPMENT 653
H-21 BOOM RAISE SPEED IS LOW IN COMPOUND OPERATION OF SWING AND BOOM RAISE 654
H-22 TRAVEL SPEED LOWERS EXTREMELY IN COMPOUND OPERATION OF TRAVEL AND BOOM RAISE 654
H-23 SPEED IS LOW IN COMPOUND OPERATION OF WORK EQUIPMENT RELIEF AND SWING, WORK EQUIPMENT RELIEF AND OTHER WORK EQUIPMENT 654
H-24 WORK EQUIPMENT DOES NOT MOVE OR ITS SPEED IS LOW IN COMPOUND OPERAITON OF TRAVEL AND WORK EQUIPMENT 655
H-25 TRAVEL DEVIATION IS LARGE 656
A) TRAVEL DEVIATION DEVIATION IS LARGE DURING ORDINARY TRAVEL 656
B) TRAVEL DEVIATION IS LARGE WHEN MACHINE STARTS (BUT DURING NORMAL ORDINARY TRAVEL) 657
H-26 TRAVEL DEVIATION IS LARGE IN COMPOUND OPERATION OF TRAVEL AND SWING, TRAVEL AND WORK EQUIPMENT 658
H-27 TRAVEL SPEED OR POWER IS LOW (WORK EQUIPMENT, SWING AND BLADE OPERATIONS ARE NORMAL) 659
H-28 MACHINE CANNOT BE STEERED SHARPLY OR STEERING FORCE IS INSUFFICIENT 661
H-29 TRAVEL SPEED DOES NOT CHANGE AT ALL OR DOES NOT CHANGE QUICKLY 662
H-30 MACHINE DOES NOT TRAVEL 663
H-30 SUPPLEMENT 664
H-31 OVERRUN OF TRAVEL IS LARGE 665
H-32 TRAVEL HYDRAULIC DRIFT IS LARGE 665
H-33 FINE CONTROLLABILITY OR RESPONSE IS LOW 666
H-34 SWING SPEED OR POWER IS LOW (WORK EQUIPMENT, SWING, AND BLADE OPERATIONS ARE NORMAL) 667
H-35 MACHINE DOES NOT SWING (WORK EQUIPMENT, TRAVEL, AND BLADE OPERATIONS ARE NORMAL) 670
A) SWING SPEED OR POWER IS LOW IN BOTH DIRECTIONS 670
B) SWING SPEED OR POWER IS LOW IN EITHER DIRECTION 671
H-36 SWING ACCLERATION IS LOW 672
A) SWING ACCELERATION IS LOW IN BOTH DIRECTIONS 672
B) SWING ACCELERATION IS LOW IN EITHER DIRECTION 672
H-37 OVERRUN OF SWING IS LARGE 673
A) OVERRUN OF SWING IS LARGE IN BOTH DIRECTIONS 673
B) OVERRUN OF SWING IS LARGE IN EITHER DIRECTION 673
H-38 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING 674
H-39 LARGE ABNORMAL SOUND IS MADE WHEN MACHINE STOPS SWINGING 674
H-40 SWING HYDRAULIC DRIFT IS LARGE 675
H-41 FINE CONTROLLABILTY MORE RESPONSE OF SWING IS LOW 676
H-42 BLADE SPEED OR POWER IS LOW (WORK EQUIPMENT, TRAVEL, AND BLADE OPERATIONS ARE NORMAL) 677
H-43 BLADE DOES NOT MOVE (WORK EQUIPMENT, TRAVEL, AND SWING OPERATIONS ARE NORMAL) 678
A) BLADE DOES NOT RISE 678
B) BLADE DOES NOT LOWER 679
H-44 HYDRAULIC DRIFT OF BLADE IS LARGE 680
H-45 FINE CONTROLLABILITY OR REPSONSE OF BLADE IS LOW 681
H-46 MONITOR PANEL DISPLAYS ERROR CODE AND BOOM RAISE, ARM IN, AND OFFSET LEFT OPERATIONS STOP JUST BEFORE INTERFERENCE (ONLY 682
H-47 MACHINE DOES NOT STOP BOOM RAISE, ARM IN, AND OFFSET LEFT OPERATIONS AUTOMATICALLY BUT INTERFERES (ONLY PC78UU-6) 682
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M MODE) 683
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE 684
ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM 686
M-1 [E101] (ERROR HISTORY DATA ARE ABNORMAL) IS DISPLAYED 692
M-2 [E108] (ENGINE COOLANT TEMPERATURE IS 105°C ) IS DISPLAYED 694
M-3 [E114] (WIPER FORWARD OUTPUT IS SHORTED) IS DISPLAYED 694
M-4 [E115] (WIPER REVERSE OUTPUT OF 24 V) IS DISPLAYED 694
M-5 [E116] (CONTACT WITH WASHER OUTPUT OF 24 V) IS DISPLAYED 694
M-6 [E117] (WIPER DOES NOT START WIPING IN 10 SECONDS) IS DISPLAYED 694
M-7 [E118] (WIPER IS NOT RETRACTED IN 10 SECONDS) IS DISPLAYED 694
M-8 WHEN STARTING SWITCH IS TURNED ON POSITION, MONITOR PANEL SEGMENTS DO NOT LIGHT UP FOR 3 SECONDS 695
A) MONITOR PANEL SEGMENTS DO NOT LIGHT UP AT ALL 695
B) SOME MONITOR PANEL SEGMENTS DO NOT LIGHHT UP AT ALL 695
M-9 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL SEGMENTS LIGHT UP BUT DO NOT GO OFF 697
M-10 WHILE PREHEATING IS NOT EXECUTED, “PREHEATER MONITOR” LIGHTS UP 697
M-11 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH 698
A) ALTERNATOR SYSTEM 698
B) ENGINE OIL SYSTEM 700
M-12 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED), CAUTION ITEMS AND EMERGENCY STOP ITEMS (EXCLUDING BA 702
A) ALTERNATOR SYSTEM 702
B) ENGINE OIL SYSTEM 704
M-13 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH (WHEN THE 706
A) “ENGINE OIL” FLASHES 706
B) “CHARGE LEVEL” FLASHES 706
C) “COOLANT TEMPERATURE” FLASHES 707
D) “FUEL LEVEL” FLASHES 709
M-14 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND 711
M-15 MONITOR PLANE LAMP FOR NIGHTTIME IS NOT TURNED ON (LC DISPLAY IS NORMAL) 713
M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE 715
M-17 COOLANT TEMPERATURE GAUGE IS NOT DISPLAYED (GAUGE DOES NOT RISE TO 1ST LINE DURING OPERATION) 717
M-18 FUEL LEVEL GAUGE ALWAYS DISPALYS FULL 719
M-19 FUEL LEVEL GAUGE IS NOT DISPLAYED 721
M-20 WHILE ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE 723
M-21 TROUBLE IN FUEL LEVEL SENSOR 724
M-22 TROUBLE IN COOLANT TEMPERATURE SENSOR 726
M-23 WIPER DOES NOT OPERATE OR OPERATES WHILE WIPER SWITCH IS TURNED OFF 727
A) WIPER DOES NOT OPERATE 727
B) WIPER OPERATES WHILE WIPER SWITCH IS TURNED OFF 727
M-24 WASHER MOTOR DOES NOT OPERATE OR OPERATES WHILE WASHER SWITCH IS TURNED OFF 732
A) WASHER MOTOR DOES NOT OPERATE 732
B) WASHER OPERATES WHILE WIPER SWITCH IS TURNED OFF 732
M-25 DEPTH SET 0 MODE AND HEIGHT MODE CANNOT BE SELECTED AND SET (ONLY PC78UU-6) 735
30 DISASSEMBLY AND ASSEMBLY 736
METHOD OF USING MANUAL 737
PRECAUTIONS WHEN CARRYING OUT OPERATION 738
SPECIAL TOOL LIST 742
COUNTERWEIGHT 750
REMOVAL AND INSTALLATION 750
INJECTION PUMP 752
REMOVAL AND INSTALLATION 752
CYLINDER HEAD 756
REMOVAL AND INSTALLATION 756
MAIN PUMP 764
REMOVAL AND INSTALLATION 764
CONTROL PUMP 766
REMOVAL AND INSTALLATION 766
ENGINE AND MAIN PUMP 767
REMOVAL AND INSTALLATION 767
HYDRAULIC OIL COOLER 770
REMOVAL AND INSTALLATION 770
RADIATOR 772
REMOVAL AND INSTALLATION 772
SWING MOTOR AND SWING MACHINERY 774
REMOVAL AND INSTALLATION 774
SWING MACHINERY 775
DISASSEMBLY AND ASSEMBLY 775
SWING MOTOR 785
REMOVAL AND INSTALLATION 785
CENTER SWIVEL JOINT 786
DISASSEMBLY AND ASSEMBLY 787
REMOVAL AND INSTALLATION 786
CONTROL VALVE 788
ASSEMBLY 789
REMOVAL AND INSTALLATION 788
WORK EQUIPMENT PPC VALVE 790
ASSEMBLY 790
TRAVEL PPC VALVE 792
ASSEMBLY 792
HYDRAULIC TANK 793
REMOVAL AND INSTALLATION 793
FUEL TANK 796
REMOVAL AND INSTALLATION 796
CONTROLLER 800
REMOVAL AND INSTALLATION 800
MONITOR PANEL 801
REMOVAL AND INSTALLATION 801
AIR CONDITIONER UNIT 802
REMOVAL AND INSTALLATION 802
OPERATOR’S CAB 804
REMOVAL AND INSTALLATION 804
FLOOR FRAME 806
REMOVAL AND INSTALLATION 806
OPERATOR’S CAB GLASS (STUCK GLASS) 808
REMOVAL AND INSTALLATION 808
FRONT WINDOW ASSEMBLY 818
REMOVAL AND INSTALLATION 818
REVOLVING FRAME 819
REMOVAL AND INSTALLATION 819
SWING CIRCLE 822
REMOVAL AND INSTALLATION 822
WORK EQUIPMENT 823
REMOVAL AND INSTALLATION 823
FIRST BOOM 829
REMOVAL AND INSTALLATION 829
SECOND BOOM 832
REMOVAL AND INSTALLATION 832
OFFSET BRACKET 833
REMOVAL AND INSTALLATION 833
STEEL SHOE, RUBBER PAD SHOE, ROAD LINER 835
EXPANSION AND INSTALLATION 835
RUBBER SHOE 836
REMOVAL AND INSTALLATION 836
FINAL DRIVE 836
REMOVAL AND INSTALLATION 836
IDLER 837
ASSEMBLY 837
RECOIL SPRING 839
DISASSEMBLY AND ASSEMBLY 839
TRACK ROLLER 841
DISASSEMBLY AND ASSEMBLY 841
HYDRAULIC CYLINDER 844
DISASSEMBLY AND ASSEMBLY 844
50 OTHER SPECIFICATIONS 849
PC78US-6 (FOR NORWAY) 851
CONTENTS 852
GENERAL 853
SPECIFICATION DIMENSIONS DRAWING (FOR NORWAY) 853
WORKING RANGE DRAWING (FOR NORWAY) 854
SPECIFICATIONS (FOR NORWAY) 856
WEIGHT TABLE (FOR NORWAY) 862
STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD 864
ARRANGEMENT OF HYDRAULIC COMPONENTS (FOR NORWAY) 864
DIMENSIONS OF EACH PART OF WORK EQUIPMENT 866
BOOM HYDRAULIC ANTI-BURST VALVE 868
ELECTRIC CONTROL SYSTEM (FOR NORWAY) 874
GENERAL SYSTEM DIAGRAM (FOR NORWAY) 875
OVERLOAD ALARM FUNCTION (FOR NORWAY) 881
OVERLOAD ALARM PRESSURE SWITCH (FOR NORWAY) 882
METER DISPLAY UNIT (FOR NORWAY) 883
TROUBLESHOOTING 884
CONNECTION TYPES AND MOUNTING LOCATIONS 887
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL MECHANISM 902
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL 904
TROUBLESHOOTING FOR CONTROLLER PUMP CONTROL SYSTEM (C MODE) 912
PRECAUTIONS FOR TROUBLESHOOTING CONTROLLER (PUMP CONTROL SYSTEM) 913
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE 915
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC EQUIPMENT 919
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM 923
C-1 [E232] TROUBLE IN TVC-EPC SOLENOID SYSTEM 926
C-2 [E233] TROUBLE IN TVC-EPC SOLENOID SYSTEM 926
C-3 [E203] TROUBLE IN SWING HOLDING BRAKE SOLENOID SYSTEM 928
C-4 [E213] TROUBLE IN SWING HOLDING BRAKE SOLNOID SYSTEM 928
C-5 [E206] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENOID SYSTEM 930
C-6 [E216] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENOID SYSTEM 930
C-7 [E251] TROUBLE IN BOOM PRESSURE SENSOR (OVERLOAD SENSOR) SYSTEM 932
C-8 [E258] SHORT CIRCUIT IN 5 V SYSTEM OF SENSOR POWER SUPPLY 934
C-9 WORK EQUIPMENT STILL MOVES AFTER WORK EQUIPMENT LOCK LEVER IS SET TO LOCK 937
C-10 MACHINE DOES NOT SWING 940
C-11 TRAVEL SPEED DOES NOT RISE 942
C-12 GEAR SPEED DOES NOT CHAGE AUTOMATICALLY 943
C-13 TROUBLE IN CONTROLLER POWER SUPPLY (LED OF CONTROLLER IS TURNED OFF) 943
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M MODE) 944
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLESM ON MACHINE 684
ELECTRIC CIRCUIT DIAGRAM 945
M-1 [E101] (ERROR HISTORY DATA ARE ABNORMAL) IS DISPLAYED 688
M-2 [E108] (ENGINE COOLANT TEMPERATURE IS 105°C) IS DISPLAYED 689
M-3 [E114] (WIPER FORWARD OUTPOUT IS HSORTED) IS DISPLAYED 689
M-4 [E115] (WIPER REVERSE OUTPUT IS SHORTED) IS DISPLAYED 689
M-5 [E-116] (CONTACT WITH WASHER OUTPUT OF 24 V) IS DISPLAYED 689
M-6 [E117] (WIPER DOES NOT START WIPING IN 10 SECONDS) IS DISPLAYED 689
M-7 [E118] (WIPER IS NOT RETRACTED IN 10 SECONDS) IS DISPLAYED 689
M-8 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL SEGMENTS DO NOT LIGHT UP FOR 3 SECONDS 690
A) MONITOR PANEL SEGEMENTS DO NOT LIGHT UP AT ALL 690
B) SOME MONITOR PANEL SEGMENTS DO NOT LIGHT UP 690
M-9 WHEN STARTING SWITHC IS SET TO ON POSITION, ALL MONITOR PANEL SEGMENTS LIGHT UP BUT DO NOT GO OFF 691
M-10 WHILE PREHEATING IS EXECUTED, “PREHEATER MONITOR” LIGHT UP 691
M-11 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH 951
A) ALTERNATOR SYSTEM 951
B) ENGINE OIL PRESSURE SYSTEM 952
M-12 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED),CAUTION ITEMS AND EMERGENCY STOP ITEMS (EXCLUDING BATTERY AND ENGINE OIL) FLASH 955
A) ALTERNATOR SYSTEM 955
B) ENGINE OIL PRESSURE SENSOR SYSTEM 956
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 ISPECTION ITEMS AND ENGINE BEFORE TROUBLESHOOTING) 696
A) “ENGINE OIL” FLASHES 696
B) “CHARGE LEVEL” FLASHES 696
C) “FUEL LEVEL” FLASHES 697
D) “FUEL LEVEL” FLASHES 698
M-14 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGIN EIS STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND WHILE CATION ITEM IS FLASHING, BUZZER DOES NOT SOUND 699
M-15 MONITOR PANEL LAMP FOR NIGHTTIME IS NOT TURNED ON (LC DISPLAYED IS NORMAL) 700
M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE 701
M-17 COOLANT TEMPERATURE GAUGE IS NOT DISPLAYED (GAUGE DOES NOT RISE TO 1ST LINE DURING OPERATION) 701
M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL 702
M-19 FUEL LEVEL GAUGE IS NOT DISPLAYED 702
M-20 WHILE ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE 703
M-21 TROUBLE IN FUEL LEVEL SENSOR 704
M-22 TROUBLE IN COOLANT TEMPERATURE SENSOR 705
M-23 WIPER DOES NOT OPERATOR OR OPERATES WHILE WIPER SWITCH IS TURNED OFF 706
A) WIPER DOES NOT OPERATE 706
B) WIPER OPERATES WHILE WIPER SWICH IS TURNED OFF 706
M-24 WASHER MOTOR DOES NOT OPERATE OR OPERATES WHILE WASHER SWITCH IS TURNED OFF 709
A) WASHER MOTOR DOES NOT OPERATE 709
B) WASHER OPERATES WHILE WIPER SWITCH IS TURNED OFF 709
90 OTHERS 959
HYDRAULIC CIRCUIT DIAGRAM 960
PC78US-6 SERIAL NO : 4001-6500 (BLADE-LESS SPECIFICATION) 960
PC78US-6 SERIAL NO : 6501 AND UP (BLADE-LESS SPECIFICATION) 961
PC78US-6 (ADDITIONAL ATTACHMENT CIRCUIT) 962
PC78US-6 SERIAL NO : 4001-6500 (BLADE SPECIFICATION) 963
PC78US-6 SERIAL NO : 6501 AND UP (BLADE SPECIFICATION) 964
PC78US-6 SERIAL NO : 4809-6500 (NORWAY & EU SPECIFICATION) 965
PC78US-6 SERIAL NO : 65001 AND UP (NORWAY & EU SPECIFICATION) 966
PC78US-6 967
ELECTRICAL CIRCUIT DIAGRAM 968
PC78US-6 SERIAL NO : 4001-5500 (1/2) 968
PC78US-6 SERIAL NO : 4001-5500 (2/2) 969
PC78US-6 SERIAL NO : 5501-6500 (1/2) 970
PC78US-6 SERIAL NO : 5501-6500 (2/2) 971
PC78US-6 SERIAL NO : 6501AND UP (1/2) 972
PC78US-6 SERIAL NO : 6501 AND UP (2/2) 973
PC78US-6 SERIAL NO :4809-5500 (NORWAY & EU SPECIFICATION)(1/2) 974
PC78US-6 SERIAL NO : 4809-5500 (NORWAY & EU SPECIFICATION) (2/2) 975
PC78US-6 SERIAL NO : 5501-6500 (NORWAY & EU SPECIFICATION) (1/2) 976
PC78US-6 SERIAL NO : 5501-6500 (NORWAY & EU SPECIFICATION) (2/2) 977
PC78US-6 SERIAL NO : 6501 AND UP (NORWAY & EU SPECIFICATION) (1/2) 978
PC78US-6 SERIAL NO : 6501 AND UP (NORWAY & EU SPECIFICATION) (2/2) 979
PC78UU-6 SERIAL NO : 22832-23500 (1/2) 980
PC78UU-6 SERIAL NO : 22832-23500 (2/2) 981
PC78UU-6 SERIAL NO : 23501 AND UP (1/2) 982
PC78UU-6 SERIAL NO : 23501 AND UP (2/2) 983

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24