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Komatsu PC78US-8 Hydraulic Excavator Shop Manual SEN04543-10 – PDF DOWNLOAD
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Komatsu PC78US-8 Hydraulic Excavator Shop Manual
SERIAL NUMBERS : 15001 and up
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Description
Komatsu PC78US-8 Hydraulic Excavator Shop Manual SEN04543-10
FILE DETAILS:
Komatsu PC78US-8 Hydraulic Excavator Shop Manual SEN04543-10
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC78US-8
Serial Number: 15001 and up
Book Code: SEN04543-10
Language: English
Pages: 1016
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC78US-8 Hydraulic Excavator Shop Manual SEN04543-10
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu PC78US-8 Hydraulic Excavator Shop Manual SEN04543-10
COVER ................................................................................................... 1 00 Index and foreword.................................................................................... 0 100 Index............................................................................................ 3 Composition of shop manual....................................................................... 4 Table of contents................................................................................ 6 200 Foreword and general information................................................................. 15 Safety notice.................................................................................... 16 How to read the shop manual...................................................................... 21 Explanation of terms for maintenance standard.................................................... 23 Handling of electric equipment and hydraulic component........................................... 25 Handling of connectors newly used for engines.................................................... 34 How to read electric wire code................................................................... 37 Precautions when carrying out operation.......................................................... 40 Method of disassembling and connecting push-pull type coupler.................................... 43 Standard tightening torque table................................................................. 46 Conversion table................................................................................. 50 01 Specification......................................................................................... 0 100 Specification and technical data................................................................. 57 Specification dimension drawing.................................................................. 58 Working range diagram............................................................................ 59 Specifications................................................................................... 60 Weight table..................................................................................... 64 Table of fuel, coolant and lubricants............................................................ 66 10 Structure, function and maintenance standard.......................................................... 0 100 Engine and cooling system........................................................................ 69 Engine mount..................................................................................... 70 PTO.............................................................................................. 71 Cooling system................................................................................... 72 200 Power train...................................................................................... 75 Power train...................................................................................... 77 Swing circle..................................................................................... 78 Swing machinery.................................................................................. 80 300 Undercarriage and frame.......................................................................... 83 Track frame...................................................................................... 84 Idler cushion.................................................................................... 85 Idler............................................................................................ 86 Track roller..................................................................................... 87 Carrier roller................................................................................... 88 Sprocket......................................................................................... 89 Track shoe....................................................................................... 90 401 Hydraulic system, Part 1......................................................................... 97 Hydraulic component layout drawing............................................................... 98 Valve control.................................................................................... 100 Hydraulic tank and filter........................................................................ 102 Hydraulic pump................................................................................... 104 402 Hydraulic system, Part 2......................................................................... 123 Control valve.................................................................................... 124 CLSS............................................................................................. 136 Functions and operation by valve................................................................. 140 403 Hydraulic system, Part 3......................................................................... 173 PPC valve........................................................................................ 175 Swing motor...................................................................................... 191 Travel motor..................................................................................... 202 Center swivel joint.............................................................................. 210 Solenoid valve................................................................................... 212 PPC accumulator.................................................................................. 215 Anti-drop valve.................................................................................. 217 Multi-control valve.............................................................................. 222 500 Work equipment................................................................................... 225 Work equipment................................................................................... 226 Dimensions of components......................................................................... 228 Work equipment cylinder.......................................................................... 234 600 Cab and its attachments.......................................................................... 237 Air conditioner.................................................................................. 238 700 Electrical system................................................................................ 251 Electronic control system........................................................................ 252 Monitor system................................................................................... 284 KOMTRAX system................................................................................... 298 Sensor........................................................................................... 300 20 Standard value table.................................................................................. 0 100 Standard service value table..................................................................... 307 Standard value table for engine related parts.................................................... 308 Standard value table for chassis................................................................. 309 30 Testing and adjusting................................................................................. 0 101 Testing and adjusting, Part 1.................................................................... 319 Tools for testing, adjusting, and troubleshooting................................................ 321 Testing engine speed............................................................................. 326 Testing exhaust temperature...................................................................... 327 Checking exhaust gas color....................................................................... 328 Adjusting valve clearance........................................................................ 329 Testing compression pressure..................................................................... 331 Testing blow-by pressure......................................................................... 333 Testing engine oil pressure...................................................................... 334 Handling fuel system parts....................................................................... 335 Releasing residual pressure from fuel system..................................................... 335 Testing fuel pressure............................................................................ 336 Testing fuel return rate and fuel leakage........................................................ 337 Bleeding air from fuel circuit................................................................... 339 Checking fuel circuit for leakage................................................................ 341 Testing and adjusting alternator belt tension.................................................... 342 Checking and adjusting air conditioner compressor belt tension................................... 344 Testing swing circle bearing clearance........................................................... 345 Checking and adjusting track shoe tension........................................................ 346 Testing and adjusting oil pressure in work equipment and travel circuits......................... 348 Testing and adjusting swing and blade circuit oil pressure (Blade specification)................. 350 Testing control circuit basic pressure........................................................... 353 Testing and adjusting oil pressure in pump PC control circuit.................................... 354 Testing PC-EPC solenoid output pressure.......................................................... 357 Testing LS differential pressure and adjusting LS valve.......................................... 358 Testing solenoid valve output pressure........................................................... 360 Testing PPC valve output pressure................................................................ 362 Adjusting play of work equipment and swing PPC valves............................................ 364 Checking parts which cause hydraulic drift of work equipment..................................... 365 Testing and adjusting travel deviation........................................................... 367 Releasing residual pressure from hydraulic circuit............................................... 369 Testing oil leakage.............................................................................. 370 Bleeding air from each part...................................................................... 373 Adjusting mirrors................................................................................ 375 Testing and adjusting hood catch................................................................. 376 102 Testing and adjusting, Part 2.................................................................... 379 Special functions of machine monitor............................................................. 380 103 Testing and adjusting, Part 3.................................................................... 431 Handling voltage circuit of engine controller.................................................... 432 Preparation work for troubleshooting of electrical system........................................ 433 Procedure for testing diodes..................................................................... 438 Pm Clinic service................................................................................ 439 40 Troubleshooting....................................................................................... 0 100 Failure code table and fuse locations............................................................ 445 Failure code table............................................................................... 446 Fuse locations................................................................................... 448 200 General information on troubleshooting........................................................... 453 Points to remember when troubleshooting.......................................................... 454 Sequence of events in troubleshooting............................................................ 455 Checks before troubleshooting.................................................................... 456 Classification and troubleshooting steps......................................................... 457 Information in troubleshooting table............................................................. 458 Phenomena looking like troubles and troubleshooting Nos.......................................... 460 Connection table for connector pin numbers....................................................... 463 T- branch box and T- branch adapter table........................................................ 499 301 Troubleshooting by failure code, Part 1.......................................................... 503 Failure code [989L00] Engine controller lock caution 1........................................... 505 Failure code [989M00] Engine controller lock caution 2........................................... 506 Failure code [989N00] Engine controller lock caution 3........................................... 507 Failure code [AB00KE] Charge voltage low......................................................... 508 Failure code [B@BAZG] Eng oil press. low......................................................... 510 Failure code [B@BCNS] Eng coolant overheat....................................................... 511 Failure code [B@HANS] Hydr oil overheat.......................................................... 511 Failure code [CA111] ECM critical internal failure............................................... 512 Failure code [CA115] Eng. Ne and Bkup speed sensor error......................................... 515 Failure code [CA122] Charge air press sensor high error.......................................... 516 Failure code [CA123] Charge air press sensor low error........................................... 518 Failure code [CA131] Throttle sensor high error.................................................. 520 Failure code [CA132] Throttle sensor low error................................................... 522 Failure code [CA144] Coolant temp. sensor high error............................................. 524 Failure code [CA145] Coolant temp. sensor low error.............................................. 526 Failure code [CA153] Charge air temp. sensor high error.......................................... 528 Failure code [CA154] Charge air temp. sensor low error........................................... 530 Failure code [CA187] Sensor sup. 2 volt. low error............................................... 531 Failure code [CA221] Ambient air press. sensor high error........................................ 532 Failure code [CA222] Ambient air press. sensor low error......................................... 534 Failure code [CA227] Sensor sup. 2 volt. high error.............................................. 535 Failure code [CA234] Eng. overspeed.............................................................. 536 Failure code [CA238] Ne speed sensor sup. volt. error............................................ 538 Failure code [CA271] IMV/PCV1 short error........................................................ 540 Failure code [CA272] IMV/PCV1 open error......................................................... 541 Failure code [CA322] Injector #1 (L #1) system open/short error.................................. 542 Failure code [CA324] Injector #3 (L #3) system open/short error.................................. 544 Failure code [CA331] Injector #2 (L #2) system open/short error.................................. 546 Failure code [CA332] Injector #4 (L #4) system open/short error.................................. 548 302 Troubleshooting by failure code, Part 2.......................................................... 551 Failure code [CA351] Inj. drive circuit error.................................................... 553 Failure code [CA352] Sensor sup. 1 volt. low error............................................... 556 Failure code [CA386] Sensor sup. 1 volt. high error.............................................. 558 Failure code [CA435] Abnormality in engine oil pressure switch................................... 560 Failure code [CA441] Battery voltage low error................................................... 561 Failure code [CA442] Battery voltage high error.................................................. 562 Failure code [CA449] Rail press. very high error................................................. 563 Failure code [CA451] Rail press. sensor high error............................................... 564 Failure code [CA452] Rail press. sensor low error................................................ 566 Failure code [CA488] Chg air temp high torque derate............................................. 567 Failure code [CA553] Rail press. high error...................................................... 568 Failure code [CA559] Rail press. low error....................................................... 569 Failure code [CA689] Eng. Ne speed sensor error.................................................. 572 Failure code [CA731] Eng. Bkup speed sensor phase error.......................................... 574 Failure code [CA757] All persistent data lost error.............................................. 575 Failure code [CA778] Eng. Bkup speed sensor error................................................ 576 Failure code [CA1633] KOMNET datalink timeout error.............................................. 578 Failure code [CA2185] Throttle sens. sup. volt. high error....................................... 580 Failure code [CA2186] Throttle sens. sup. volt. low error........................................ 582 Failure code [CA2249] Rail press. very low error................................................. 582 Failure code [CA2311] Abnormality in IMV solenoid................................................ 583 Failure code [D110KB] Battery relay drive short.................................................. 584 Failure code [D19JKZ] Personal code relay abnormality............................................ 586 Failure code [D862KA] GPS antenna discon......................................................... 588 Failure code [DA22KK] Pump solenoid power low error.............................................. 590 Failure code [DA25KP] 5V sensor 1 power abnormality.............................................. 592 Failure code [DA26KP] 5V sensor 2 power abnormality.............................................. 594 Failure code [DA29KQ] Model selection abnormality................................................ 596 303 Troubleshooting by failure code, Part 3.......................................................... 599 Failure code [DA2RMC] CAN discon (Pump controller detected)...................................... 600 Failure code [DAFGMC] GPS module error........................................................... 602 Failure code [DAFRMC] CAN discon (Monitor detected).............................................. 604 Failure code [DGH2KB] Hydr oil sensor short...................................................... 606 Failure code [DHPAMA] Pump press sensor abnormality.............................................. 608 Failure code [DHS5KX] Travel PPC press sensor abnormality........................................ 610 Failure code [DHSAMA] Swing right PPC press sensor abnormality................................... 612 Failure code [DHSBMA] Swing left PPC press sensor abnormality.................................... 614 Failure code [DHX1MA] Overload sensor abnormality (Analog)....................................... 616 Failure code [DV20KB] Travel alarm S/C........................................................... 617 Failure code [DW43KA] Travel speed sol discon.................................................... 618 Failure code [DW43KB] Travel speed sol short..................................................... 619 Failure code [DW45KA] Swing brake sol discon..................................................... 620 Failure code [DW45KB] Swing brake sol short...................................................... 622 Failure code [DWJ0KA] Merge-divider sol discon................................................... 624 Failure code [DWJ0KB] Merge-divider sol short.................................................... 625 304 Troubleshooting by failure code, Part 4.......................................................... 627 Failure code [DXA8KA] PC-EPC sol discon.......................................................... 628 Failure code [DXA8KB] PC-EPC sol short........................................................... 630 Failure code [DXE4KA] Service current EPC discon................................................. 632 Failure code [DXE4KB] Service current EPC short.................................................. 633 Failure code [DY20KA] Wiper working abnormality.................................................. 634 Failure code [DY20MA] Wiper parking abnormality.................................................. 636 Failure code [DY2CKA] Washer drive discon........................................................ 638 Failure code [DY2CKB] Washer drive short......................................................... 640 Failure code [DY2DKB] Wiper drive (for) short.................................................... 642 Failure code [DY2EKB] Wiper drive (rev) short.................................................... 644 400 Troubleshooting of electrical system (E-mode).................................................... 647 Before carrying out troubleshooting of electrical system......................................... 649 Information in troubleshooting table............................................................. 652 E-1 When starting switch is turned ON, machine monitor displays nothing.......................... 654 E-2 Engine does not start (Engine does not turn)................................................. 656 E-3 Preheater does not operate................................................................... 660 E-4 Automatic warm-up system does not operate (in cold season)................................... 662 E-5 All work equipment, swing, and travel mechanism do not move or cannot be locked.............. 664 E-6 Precaution lights up while engine is running................................................. 666 E-7 Emergency stop item lights up while engine is running........................................ 669 E-8 Engine coolant temperature gauge does not indicate normally.................................. 670 E-9 Hydraulic oil temperature gauge does not indicate normally................................... 672 E-10 Fuel level gauge does not indicate normally................................................. 675 E-11 Contents of display by machine monitor are different from applicable machine................ 677 E-12 Machine monitor does not display some items................................................. 677 E-13 Function switch does not work............................................................... 677 E-14 Auto-decelerator does not operate normally.................................................. 678 E-15 Working mode does not change................................................................ 679 E-16 Travel speed does not change................................................................ 680 E-17 Alarm buzzer cannot be stopped.............................................................. 681 E-18 Windshield wiper and window washer do not operate........................................... 682 E-19 Swing holding brake does not operate normally............................................... 686 E-20 Travel alarm does not sound or does not stop sounding....................................... 688 E-21 Air conditioner does not operate normally (including air conditioner abnormality record).... 689 E-22 While starting switch is in OFF position, service meter is not displayed.................... 702 E-23 Machine monitor cannot be set in service mode............................................... 703 E-24 Monitoring function does not display lever control signal normally.......................... 704 E-25 KOMTRAX system does not operate normally.................................................... 720 500 Troubleshooting of hydraulic and mechanical system (H-mode)...................................... 723 Information contained in troubleshooting table................................................... 725 System chart for hydraulic and mechanical systems................................................ 726 H-1 Speed or power of all work equipment, swing, and travel are low.............................. 728 H-2 Engine speed sharply drops or engine stalls.................................................. 729 H-3 No work equipment, travel and swing move..................................................... 730 H-4 Abnormal noise is heard from around hydraulic pump........................................... 730 H-5 Fine control performance or response of work equipment and travel is low..................... 731 H-6 Speed or power of boom is low................................................................ 732 H-7 Speed or power of arm is low................................................................. 733 H-8 Speed or power of bucket is low.............................................................. 734 H-9 Speed or power of blade is low............................................................... 735 H-10 Work equipment does not move in its single operation........................................ 736 H-11 Hydraulic drift of work equipment is large.................................................. 737 H-12 Time lag of work equipment is large......................................................... 739 H-13 Work equipment loaded more is slower during compound operation.............................. 739 H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE......................... 739 H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel...... 740 H-16 Machine deviates during travel.............................................................. 741 H-17 Travel speed is low......................................................................... 742 H-18 Machine cannot be steered easily or steering power is low................................... 743 H-19 Travel speed does not change or it is kept low or high...................................... 744 H-20 Track does not move (only either side)...................................................... 744 H-21 Machine does not swing...................................................................... 745 H-22 Swing acceleration, swing speed and swing power are low..................................... 746 H-23 Excessive overrun when stopping swing....................................................... 748 H-24 When upper structure stops swinging, it makes large shock................................... 749 H-25 When upper structure stops swinging, it makes large sound................................... 749 H-26 Hydraulic drift of swing is large........................................................... 750 H-27 Flow rate in attachment circuit cannot be adjusted.......................................... 751 600 Troubleshooting of engine (S-mode)............................................................... 753 Method of using troubleshooting chart............................................................ 754 S-1 Starting performance is poor................................................................. 758 S-2 Engine does not start........................................................................ 759 S-3 Engine does not pick up smoothly............................................................. 762 S-4 Engine stops during operations............................................................... 763 S-5 Engine does not rotate smoothly.............................................................. 764 S-6 Engine lacks output (or lacks power)......................................................... 765 S-7 Exhaust smoke is black (incomplete combustion)............................................... 766 S-8 Oil consumption is excessive (or exhaust smoke is blue)...................................... 767 S-9 Oil becomes contaminated quickly............................................................. 768 S-10 Fuel consumption is excessive............................................................... 769 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....................... 770 S-12 Oil pressure drops.......................................................................... 771 S-13 Oil level rises (Entry of coolant or fuel).................................................. 772 S-14 Coolant temperature becomes too high (overheating).......................................... 773 S-15 Abnormal noise is made...................................................................... 774 S-16 Vibration is excessive...................................................................... 775 50 Disassembly and assembly.............................................................................. 0 100 General information on disassembly and assembly.................................................. 777 How to read this manual.......................................................................... 778 Coating materials list........................................................................... 780 Special tool list................................................................................ 783 Sketches of special tools........................................................................ 787 200 Engine and cooling system........................................................................ 793 Removal and installation of fuel supply pump assembly............................................ 794 Removal and installation of fuel injector assembly............................................... 798 Removal and installation of engine front seal.................................................... 802 Removal and installation of engine rear seal..................................................... 803 Removal and installation of cylinder head assembly............................................... 805 Removal and installation of radiator assembly.................................................... 816 Removal and installation of aftercooler assembly................................................. 819 Removal and installation of hydraulic oil cooler assembly........................................ 821 Removal and installation of engine and hydraulic pump assembly................................... 824 Removal and installation of fuel tank assembly................................................... 834 Removal and installation of fuel tank assembly................................................... 835 300 Power train...................................................................................... 839 Removal and installation of travel motor and final drive assembly................................ 841 Disassembly and assembly oftravel motor and final driveassembly.................................. 843 Removal and installation of swing motor and swing machinery assembly............................. 881 Disassembly and assembly of swing machinery...................................................... 883 Removal and installation of swing circle assembly................................................ 890 400 Undercarriage and frame.......................................................................... 893 Disassembly and assembly of track roller assembly................................................ 894 Disassembly and assembly of idler assembly....................................................... 897 Disassembly and assembly of recoil spring assembly............................................... 900 Spreading and installation of track shoe assembly................................................ 902 Removal and installation of sprocket............................................................. 904 Removal and installation of revolving frame assembly............................................. 905 Removal and installation of counterweight assembly............................................... 907 500 Hydraulic system................................................................................. 911 Removal and installation of center swivel joint assembly......................................... 912 Disassembly and assembly of center swivel joint assembly......................................... 914 Removal and installation of hydraulic tank assembly.............................................. 916 Removal and installation of hydraulic pump assembly.............................................. 919 Removal and installation of control valve assembly............................................... 923 Disassembly and assembly of control valve assembly............................................... 931 Disassembly and assembly of work equipment PPC valve assembly.................................... 934 Disassembly and assembly of travel PPC valve assembly............................................ 936 Disassembly and assembly of hydraulic cylinder assembly.......................................... 938 600 Work equipment................................................................................... 945 Removal and installation of work equipment assembly.............................................. 946 Removal and installation of blade assembly....................................................... 949 700 Cab and its attachments.......................................................................... 953 Removal and installation of operator cab assembly................................................ 954 Removal and installation of operator's cab glass (Stuck glass)................................... 959 Removal and installation of front window assembly................................................ 969 Removal and installation of floor frame assembly................................................. 970 800 Electrical system................................................................................ 977 Removal and installation of air conditioner unit assembly........................................ 978 Removal and Installation of air conditioner condenser assembly................................... 979 Removal and installation of air conditioner unit assembly........................................ 980 Removal and installation of machine monitor assembly............................................. 984 Removal and installation of pump controller assembly............................................. 985 Removal and installation of engine controller assembly........................................... 986 Removal and installation of KOMTRAX terminal assembly............................................ 988 90 Diagrams and drawings................................................................................. 0 100 Hydraulic diagrams and drawings.................................................................. 991 Hydraulic circuit diagram........................................................................ 993 Actuator attachment hydraulic circuit diagram.................................................... 996 200 Electrical diagrams and drawings................................................................. 999 Electrical circuit diagram.......................................................................1001 Air conditioner unit electrical circuit diagram..................................................1013 Connector list and stereogram....................................................................1014
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