Service manual Komatsu PC78US-6, PC78UU-6 | SEBM025109

Komatsu PC78US-6, PC78UU-6 SEBM025109 (Preview)

MAIN MENU
COVER
CONTENTS
SAFETY
FOREWORD
01 GENERAL
SPECIFICATION DIMENSIONS DRAWING
WORKING RANGE DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANTS AND COOLANT
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
PTO
COOLING SYSTEM
POWER TRAIN SYSTEM
SWING CIRCLE
SWING MACHINERY
TRACK FRAME AND IDLER CUSHION
IDLER
TRACK ROLLER
CARRIER ROLLER
SPROCKET
TRACK SHOE
ARRANGEMENT OF HYDRAULIC COMPONENTS
HYDRAULIC TANK AND OIL FILTER
CENTER SWIVEL JOINT
TRAVEL MOTOR
WORK EQUIPMENT CYLINDER
SOLENOID VALVE
MULTI-CONTROL VALVE
ACCUMULATOR FOR BRAKE
HYDRAULIC PUMP PC78US-6 (with blade) Serial No.: 4001 – 5500; PC78UU-6 (with blade) Serial No.: 22832 – 23500
PC78US-6 (with blade) Serial No.: 5501 and up; PC78UU-6 (with blade) Serial No.: 23501 and up
PC78US-6 (without blade) Serial No.: 5501 and up
CONTROL VALVE
CLSS
SWING MOTOR
WORK EQUIPMENT AND SWING PPC VALVE
TRAVEL PPC VALVE
OFFSET PPC VALVE, ATTACHMENT PPC VALVE, AND BLADE PPC VALVE
WORK EQUIPMENT
DIMENSIONS OF EACH PART OF WORK EQUIPMENT
AIR CONDITIONER PIPING SYSTEM
ELECTRIC CONTROL SYSTEM
SYSTEM COMPONENTS
MONITOR SYSTEM
SENSORS
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
LIST OF DEVICES FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING EXHAUST GAS COLOR
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURING ENGINE OIL PRESSURE
ADJUSTING FUEL STOP SOLENOID
ADJUSTING FUEL CONTROL LINKAGE
ADJUSTING ENGINE SPEED SENSOR
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
MEASURING LS DIFFERENTIAL PRESSURE ANDADJUSTING LS VALVE
ADJUSTING PC VALVE
TESTING TVC-EPC SOLENOID OUTPUT PRESSURE
MEASURING CONTROL CIRCUIT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
TESTING SOLENOID VALVE OUTPUT PRESSURE
ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE
TESTING TRAVEL DEVIATION
TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTORS
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT
TESTING CLEARENCE OF SWING CIRCLE BEARING
TESTING AND ADJUSTING TRACK SHOE TENSION
BLEEDING AIR FROM HYDRAULIC CIRCUIT
PROCEDURE FOR ADJUSTING INSTALLATION OF LONG ARM
REPLACEMENT PROCEDURE OF POTENTIOMETERS
PROCEDURE FOR TESTING DIODE
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS PC78US-6 SERIAL NO. 4001-5500
CONNECTOR ARRANGEMENT DIAGRAM PC78US-6 SERIAL NO. 4001-5500
CONNECTOR TYPES AND MOUNTING LOCATIONS PC78US-6 SERIAL NO. 5501 and up
CONNECTOR ARRANGEMENT DIAGRAM PCUS78-6 SERIAL NO. 5501 and up
CONNECTOR TYPES AND MOUNTING LOCATIONS PC78UU-6 SERIAL NO. 22832-23500
CONNECTOR ARRANGEMENT DIAGRAM PC78UU-6 SERIAL NO. 22832-23500
CONNECTOR TYPES AND MOUNTING LOCATIONS PC78UU-6 SERIAL NO. 23501 and up
CONNECTOR ARRANGEMENT DIAGRAM PC78UU-6 SERIAL NO. 23501 and up
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL MECHANISM
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
TVC VALVE CURRENT ADJUSTMENT TABLE
ADJUSTING SERVICE METER
HOW TO READ FLOW OF TROUBLESHOOTING
CONTENTS AND PROCEDURE OF TROUBLESHOOTING
TROUBLESHOOTING FOR COMMUNICATION SYSTEM (N MODE)
N-1 DEFECTIVE COMMUNICATION
TROUBLESHOOTING FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (PUMP CONTROL SYSTEM)
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE
JUDGEMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE
E-1 CONTROLLER POWER SUPPLY IS DEFECTIVE (LED OF CONTROLLER IS TURNED OFF)
E-2 [E321] (SHORT CIRCUIT IN MOTOR DRIVE RELAY) IS DISPLAYED
E-3 [E323] (SHORT CIRCUIT IN ACCELERATOR RELAY) IS DISPLAYED
E-4 [E325] (SHORT CIRCUIT IN DECELERATOR RELAY) IS DISPLAYED
E-5 [E328] (STALL OF MOTOR) IS DISPLAYED
E-6 [E227] (TROUBLE IN ENGINE SPEED SENSOR) IS DISPLAYED
E-7 ONE-TOUCH SLOW-DOWN MECHANSISM DOES NOT WORK
E-8 ENGINE DOES NOT START
A) [E304] SHORT CIRCUIT IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED
B) [E314] DISCONNECTION IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED
C) ENGINE STOP SOLENOID SYSTEM
D) STARTING SYSTEM
E-9 ENGINE DOES NOT STOP
TROUBLESHOOTING FOR CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (PUMP CONTROL SYSTEM)
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC EQUIPMENT
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM
C-1 [E232] TROUBLE IN TVC-EPC SOLENOID SYSTEM
C-2 [E233] TROUBLE IN TVC-EPC SOLENOID SYSTEM
C-3 [E203] TROUBLE IN SWING HOLDING BRAKE SOLENIOD SYSTEM
C-4 [E213] TROUBLE IN SWING HOLDING BRAKE SOLENIOD SYSTEM
C-5 [E206] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENIOD SYSTEM
C-6 [E216] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENIOD SYSTEM
C-7 [E403] TROUBLE IN BOOM ANGLE SENSOR CORRECTION
C-8 [E406] TROUBLE IN ARM ANGLE SENSOR CORRECTION
C-9 [E411] TROUBLE IN OFFSET BOOM ANGLE SENSOR CORRECTION
C-10 [E441] TROUBLE IN INTERFERENCE PREVENTION (FRONT) CORRECTION
C-11 [E442] TROUBLE IN INTERFERENCE PREVENTION (SIDE) CORRECTION (ONLY PC78UU-6)
C-12 [E443] TROUBLE IN DEPTH INDICATION CORRECTION (ONLY PC78UU-6)
C-13 [E258] SHORT CIRCUIT IN 5V SYSTEM OF SENSOR POWER SUPPLY (ONLY PC78UU-6)
C-14 [E401], C-15 [E402] TROUBLE IN BOOM ANGLE SENSOR SYSTEM (ONLY PC78UU-6)
C-16 [E404], C-17 [E405] TROUBLE IN ARM ANGLE SENSOR SYSTEM (ONLY PC78UU-6)
C-18 [E407], C-19 [E408] TROUBLE IN OFFSET ANGLE SENSOR SYSTEM (ONLY PC78UU-6)
C-20 [E421] DISCONNECTION IN BOOM RAISE EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6)
C-21 [E422] DISCONNECTION IN BOOM RAISE EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6)
C-22 [E423] SHORT CIRCUIT OR GROUNDING FAULT IN ARM-IN EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6)
C-23 [E424] DISCONNECTION IN ARM IN EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6)
C-24 [E425] SHORT CIRCUIT OR GROUNDING FAULT IN OFFSET LEFT EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6)
C-25 [E426] DISCONNECTION IN OFFSET LEFT EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6)
C-26 [E431] SHORT CIRCUIT OR GROUNDING FAULT IN PPC BASIC PRESSURE LOCK SOLENOID SYSTEM IS DISPLAYED (ONLY PC78UU-6)
C-27 BOOM DOES NOT STOP AUTOMATICALLY AT NORMAL POSITION BUT INTERFERES WHEN IT IS RAISED (ONLY PC78UU-6)
C-28 ARM DOES NOT STOP AUTOMATICALLY AT NORMAL POSITION BUT INTERFERES WHEN IT IS MOVED IN (ONLY PC78UU-6)
C-29 OFFSET DOES NOT STOP AUTOMATICALLY AT NORMAL POSITION BUT INTERFERES WHEN IT IS MOVED TO LEFT (ONLY PC78UU-6)
C-30 WORK EQUIPMENT STOPS FAR OR NEAR (ONLY PC78UU-6)
C-31 BUZZER SOUNDS FOR 7 SECONDS WHILE EMERGENCY WORK EQUIPMENT OPERATION SWITCH IS NOT TURNED ON (ONLY PC78UU-6)
C-32 BOOM RAISE END CUSHION DOES NOT WORK AT ALL OR NORMALLY (ONLY PC78UU-6)
C-33 ARM-IN END CUSHION DOES NOT WORK AT ALL OR NORMALLY (ONLY PC78UU-6)
C-34 OFFSET SEND CUSHION DOES NOT WORK AT ALL OR NORMALLY (ONLY PC78UU-6)
C-35 WORK EQUIPMENT STOPS AFTER OR BEFORE SET HEIGHT (ONLY PC78UU-6)
C-36 WHEN DEPTH DISPLAY IS RESET, 0.0 M IS NOT INDICATED AT GL (ONLY PC78UU-6)
C-37 WORK EQUIPMENT STILL MOVES AFTER WORK EQUIPMENT LOCK LEVER IS SET TO LOCK
C-38 MACHINE DOES NOT SWING
C-39 TRAVEL SPEED DOES NOT RISE
C-40 TROUBLE IN CONTROLLER POWER SUPPLY (LED OF CONTROLLER IS TURNED OFF)
TROUBLESHOOTING FOR CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)
F-1 BIT PATTERN 1023-4 SWING PRESSURE SWITCH DOES NOT LIGHT UP
F-2 BIT PATTERN 1023-3 TRAVEL PRESSURE SWITCH DOES NOT LIGHT UP
F-3 BIT PATTERN 1023-6 BOOM RAISE PRESSURE SWITCH DOES NOT LIGHT UP
F-4 BIT PATTERN 1023-5 ARM IN PRESSURE SWITCH DOES NOT LIGHT UP
F-5 BIT PATTERN 1026-1 DECELERATION SWITCH OF LEFT KNOB DOES NOT LIGHT UP
F-6 BIT PATTERN 1021-4 2ND TRAVEL SPEED SELECTION SWITCH (PEDAL) DOES NOT LIGHT UP (US WITH BLADE)
F-7 BIT PATTERN 1021-3 COMPRESSOR SIGNAL DOES NOT LIGHT UP
F-8 BIT PATTERN 1026-(3) EMERGENCY WORK EQUIPMENT OPERATION SWITCH DOES NOT LIGHT UP (ONLY PC78UU-6)
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
TABLE OF HYRAULIC FAILURE MODES AND CAUSES
H-1 SPEED OR POWER OF 2 OR MORE SYSTEMS OF WORK EQUIPMENT (BOOM, ARM, BUCKET, OFFSET), TRAVEL, SWING, AND BLADE IS LOW
A) SPEED OR POWER OF ALL WORK EQUIPMENT (INCLUDING BLADE), TRAVEL AND SWING IS LOW
B) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE), AND TRAVEL IS LOW
C) SPEED OR POWER OF SWING AND BLADE IS LOW
D) SPEED OR POWER OF TRAVEL AND BLADE IS LOW
E) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE) IS LOW
F) SPEED OR POWER OF TRAVEL AND SWING IS LOW
G) SPEED OR POWER OF ALL WORK EQUIPMENT AND SWING IS LOW
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS
H-3 2 OR MORE SYSTEMS (INCLUDING BLADE), TRAVEL, AND SWING SYSTEMS DO NOT MOVE
A) ALL WORK EQUIPMENT (INCLUDING BLADE), TRAVEL, AND SWING SYSTEMS DO NOT MOVE
B) ALL WORK (EXCLUDING BLADE) AND TRAVEL SYSTEMS DO MOVE
C) SWING AND BLADE SYSTEMS DO NOT MOVE
D) TRAVEL AND BLADE SYSTEMS DO NOT MOVE
E) ALL WORK EQUIPMENT (EXCLUDING BLADE) DOES NOT MOVE
H-4 ABNORMAL SOUND COMES OUT (FROM AROUND PUMP)
H-5 FINE CONTROLLABILITY OR RESPONSE IS LOW
H-6 HYDRAULIC DRIFT IS LARGE (ALL WORK EQUIPMENT AND BLADE)
H-7 BOOM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)
A) BOOM RAISE SPEED OR POWER IS LOW
B) BOOM LOWER SPEED OR POWER IS LOW
H-8 ARM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)
A) ARM IN SPEED OR POWER IS LOW
B) ARM OUT SPEED OR POWER IS LOW
H-9 BUCKET SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)
A) BUCKET CURL SPEED OR POWER IS LOW
B) BUCKET DUMP SPEED OR POWER IS LOW
H-10 OFFSET SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL) (ONLY PC78UU-6)
A) OFFSET LEFT SPEED OR POWER IS LOW
B) OFFSET RIGHT SPEED OR POWER IS LOW
H-11 BOOM DOES NOT MOVE
A) BOOM DOES NOT RISE
B) BOOM DOES NOT LOWER
H-12 ARM DOES NOT MOVE
A) ARM DOES NOT MOVE IN
B) ARM DOES NOT MOVE OUT
H-13 BUCKET DOES NOT MOVE
A) BUCKET DOES NOT CURL
B) BUCKET DOES NOT DUMP
H-14 OFFSET BOOM DOES NOT MOVE (ONLY PC78UU-6)
A) OFFSET BOOM LEFT DOES NOT MOVE
B) OFFSET BOOM RIGHT DOES NOT MOVE
H-15 HYDRAULIC DRIFT OF BOOM IS LARGE
H-16 HYDRAULIC DRIFT OF ARM IS LARGE
H-17 HYDRAULIC DRIFT OF BUCKET IS LARGE
H-18 HYDRAULIC DRIFT OF OFFSET IS LARGE (ONLY PC78UU-6)
A) HYDRAULIC DRIFT OF OFFSET TO LEFT IS LARGE
B) HYDRAULIC DRIFT OF OFFSET TO RIGHT IS LARGE
H-19 TIME LAG IS LARGE (WHEN ENGINE SPEED IS LOW)
H-20 PART LOADED MORE MOVES SLOWER IN COMPOUND OPERATION OF WORK EQUIPMENT
H-21 BOOM RAISE SPEED IS LOW IN COMPOUND OPERATION OF SWING AND BOOM RAISE
H-22 TRAVEL SPEED LOWERS EXTREMELY IN COMPOUND OPERATION OF TRAVEL AND BOOM RAISE
H-23 SPEED IS LOW IN COMPOUND OPERATION OF WORK EQUIPMENT RELIEF AND SWING, WORK EQUIPMENT RELIEF AND OTHER WORK EQUIPMENT
H-24 WORK EQUIPMENT DOES NOT MOVE OR ITS SPEED IS LOW IN COMPOUND OPERAITON OF TRAVEL AND WORK EQUIPMENT
H-25 TRAVEL DEVIATION IS LARGE
A) TRAVEL DEVIATION DEVIATION IS LARGE DURING ORDINARY TRAVEL
B) TRAVEL DEVIATION IS LARGE WHEN MACHINE STARTS (BUT DURING NORMAL ORDINARY TRAVEL)
H-26 TRAVEL DEVIATION IS LARGE IN COMPOUND OPERATION OF TRAVEL AND SWING, TRAVEL AND WORK EQUIPMENT
H-27 TRAVEL SPEED OR POWER IS LOW (WORK EQUIPMENT, SWING AND BLADE OPERATIONS ARE NORMAL)
H-28 MACHINE CANNOT BE STEERED SHARPLY OR STEERING FORCE IS INSUFFICIENT
H-29 TRAVEL SPEED DOES NOT CHANGE AT ALL OR DOES NOT CHANGE QUICKLY
H-30 MACHINE DOES NOT TRAVEL
H-30 SUPPLEMENT
H-31 OVERRUN OF TRAVEL IS LARGE
H-32 TRAVEL HYDRAULIC DRIFT IS LARGE
H-33 FINE CONTROLLABILITY OR RESPONSE IS LOW
H-34 SWING SPEED OR POWER IS LOW (WORK EQUIPMENT, SWING, AND BLADE OPERATIONS ARE NORMAL)
H-35 MACHINE DOES NOT SWING (WORK EQUIPMENT, TRAVEL, AND BLADE OPERATIONS ARE NORMAL)
A) SWING SPEED OR POWER IS LOW IN BOTH DIRECTIONS
B) SWING SPEED OR POWER IS LOW IN EITHER DIRECTION
H-36 SWING ACCLERATION IS LOW
A) SWING ACCELERATION IS LOW IN BOTH DIRECTIONS
B) SWING ACCELERATION IS LOW IN EITHER DIRECTION
H-37 OVERRUN OF SWING IS LARGE
A) OVERRUN OF SWING IS LARGE IN BOTH DIRECTIONS
B) OVERRUN OF SWING IS LARGE IN EITHER DIRECTION
H-38 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING
H-39 LARGE ABNORMAL SOUND IS MADE WHEN MACHINE STOPS SWINGING
H-40 SWING HYDRAULIC DRIFT IS LARGE
H-41 FINE CONTROLLABILTY MORE RESPONSE OF SWING IS LOW
H-42 BLADE SPEED OR POWER IS LOW (WORK EQUIPMENT, TRAVEL, AND BLADE OPERATIONS ARE NORMAL)
H-43 BLADE DOES NOT MOVE (WORK EQUIPMENT, TRAVEL, AND SWING OPERATIONS ARE NORMAL)
A) BLADE DOES NOT RISE
B) BLADE DOES NOT LOWER
H-44 HYDRAULIC DRIFT OF BLADE IS LARGE
H-45 FINE CONTROLLABILITY OR REPSONSE OF BLADE IS LOW
H-46 MONITOR PANEL DISPLAYS ERROR CODE AND BOOM RAISE, ARM IN, AND OFFSET LEFT OPERATIONS STOP JUST BEFORE INTERFERENCE (ONLY
H-47 MACHINE DOES NOT STOP BOOM RAISE, ARM IN, AND OFFSET LEFT OPERATIONS AUTOMATICALLY BUT INTERFERES (ONLY PC78UU-6)
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M MODE)
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE
ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM
M-1 [E101] (ERROR HISTORY DATA ARE ABNORMAL) IS DISPLAYED
M-2 [E108] (ENGINE COOLANT TEMPERATURE IS 105°C ) IS DISPLAYED
M-3 [E114] (WIPER FORWARD OUTPUT IS SHORTED) IS DISPLAYED
M-4 [E115] (WIPER REVERSE OUTPUT OF 24 V) IS DISPLAYED
M-5 [E116] (CONTACT WITH WASHER OUTPUT OF 24 V) IS DISPLAYED
M-6 [E117] (WIPER DOES NOT START WIPING IN 10 SECONDS) IS DISPLAYED
M-7 [E118] (WIPER IS NOT RETRACTED IN 10 SECONDS) IS DISPLAYED
M-8 WHEN STARTING SWITCH IS TURNED ON POSITION, MONITOR PANEL SEGMENTS DO NOT LIGHT UP FOR 3 SECONDS
A) MONITOR PANEL SEGMENTS DO NOT LIGHT UP AT ALL
B) SOME MONITOR PANEL SEGMENTS DO NOT LIGHHT UP AT ALL
M-9 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL SEGMENTS LIGHT UP BUT DO NOT GO OFF
M-10 WHILE PREHEATING IS NOT EXECUTED, “PREHEATER MONITOR” LIGHTS UP
M-11 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH
A) ALTERNATOR SYSTEM
B) ENGINE OIL SYSTEM
M-12 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED), CAUTION ITEMS AND EMERGENCY STOP ITEMS (EXCLUDING BA
A) ALTERNATOR SYSTEM
B) ENGINE OIL SYSTEM
M-13 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH (WHEN THE
A) “ENGINE OIL” FLASHES
B) “CHARGE LEVEL” FLASHES
C) “COOLANT TEMPERATURE” FLASHES
D) “FUEL LEVEL” FLASHES
M-14 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND
M-15 MONITOR PLANE LAMP FOR NIGHTTIME IS NOT TURNED ON (LC DISPLAY IS NORMAL)
M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE
M-17 COOLANT TEMPERATURE GAUGE IS NOT DISPLAYED (GAUGE DOES NOT RISE TO 1ST LINE DURING OPERATION)
M-18 FUEL LEVEL GAUGE ALWAYS DISPALYS FULL
M-19 FUEL LEVEL GAUGE IS NOT DISPLAYED
M-20 WHILE ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE
M-21 TROUBLE IN FUEL LEVEL SENSOR
M-22 TROUBLE IN COOLANT TEMPERATURE SENSOR
M-23 WIPER DOES NOT OPERATE OR OPERATES WHILE WIPER SWITCH IS TURNED OFF
A) WIPER DOES NOT OPERATE
B) WIPER OPERATES WHILE WIPER SWITCH IS TURNED OFF
M-24 WASHER MOTOR DOES NOT OPERATE OR OPERATES WHILE WASHER SWITCH IS TURNED OFF
A) WASHER MOTOR DOES NOT OPERATE
B) WASHER OPERATES WHILE WIPER SWITCH IS TURNED OFF
M-25 DEPTH SET 0 MODE AND HEIGHT MODE CANNOT BE SELECTED AND SET (ONLY PC78UU-6)
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
REMOVAL, INSTALLATION OF COUNTERWEIGHT ASSEMBLY
REMOVAL, INSTALLATION OF INJECTION PUMP ASSEMBLY
REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY
REMOVAL, INSTALLATION OF MAIN PUMP ASSEMBLY
REMOVAL, INSTALLATION OF CONTROL PUMP ASSEMBLY
REMOVAL, INSTALLATION OF ENGINE AND MAIN PUMP ASSEMBLY
REMOVAL, INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY
REMOVAL, INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL, INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY
DISASSEMBLY, ASSEMBLY OF SWING MACHINERY ASSEMBLY
REMOVAL, INSTALLATION OF SWING MOTOR ASSEMBLY
REMOVAL, INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY
DISASSEMBLY, ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
REMOVAL, INSTALLATION OF CONTROL VALVE ASSEMBLY
ASSEMBLY OF CONTROL VALVE ASSEMBLY
ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY
ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY
REMOVAL, INSTALLATION OF HYDRAULIC TANK ASSEMBLY
REMOVAL, INSTALLATION OF FUEL TANK ASSEMBLY
REMOVAL, INSTALLATION OF CONTROLLER ASSEMBLY
REMOVAL, INSTALLATION OF MONITOR PANEL ASSEMBLY
REMOVAL, INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
REMOVAL, INSTALLATION OF OPERATOR’S CAB ASSEMBLY
REMOVAL, INSTALLATION OF FLOOR FRAME ASSEMBLY
REMOVAL, INSTALLATION OF REVOLVING FRAME ASSEMBLY
REMOVAL, INSTALLATION OF SWING CIRCLE ASSEMBLY
REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY
REMOVAL, INSTALLATION OF FIRST BOOM ASSEMBLY
REMOVAL, INSTALLATION OF SECOND BOOM ASSEMBLY
REMOVAL, INSTALLATION OF OFFSET BRACKET ASSEMBLY
EXPANSION, INSTALLATION OF STEEL SHOE, RUBBER PAD SHOE, ROAD LINER ASSEMBLY
REMOVAL, INSTALLATION OF RUBBER SHOE ASSEMBLY
REMOVAL, INSTALLATION OF FINAL DRIVE ASSEMBLY
ASSEMBLY OF IDLER ASSEMBLY
DISASSEMBLY, ASSEMBLY OF RECOIL SPRING ASSEMBLY
DISASSEMBLY, ASSEMBLY OF TRACK ROLLER ASSEMBLY
DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
50 OTHER SPECIFICATIONS
PC78US-6 (FOR NORWAY)
CONTENTS
GENERAL
SPECIFICATION DIMENSIONS DRAWING (FOR NORWAY)
WORKING RANGE DRAWING (FOR NORWAY)
SPECIFICATIONS (FOR NORWAY)
WEIGHT TABLE (FOR NORWAY)
STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD
ARRANGEMENT OF HYDRAULIC COMPONENTS (FOR NORWAY)
DIMENSIONS OF EACH PART OF WORK EQUIPMENT
BOOM HYDRAULIC ANTI-BURST VALVE
ELECTRIC CONTROL SYSTEM (FOR NORWAY)
GENERAL SYSTEM DIAGRAM (FOR NORWAY)
OVERLOAD ALARM FUNCTION (FOR NORWAY)
OVERLOAD ALARM PRESSURE SWITCH (FOR NORWAY)
METER DISPLAY UNIT (FOR NORWAY)
TROUBLESHOOTING
CONNECTION TYPES AND MOUNTING LOCATIONS
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL MECHANISM
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
TROUBLESHOOTING FOR CONTROLLER PUMP CONTROL SYSTEM (C MODE)
PRECAUTIONS FOR TROUBLESHOOTING CONTROLLER (PUMP CONTROL SYSTEM)
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC EQUIPMENT
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM
C-1 [E232] TROUBLE IN TVC-EPC SOLENOID SYSTEM
C-2 [E233] TROUBLE IN TVC-EPC SOLENOID SYSTEM
C-3 [E203] TROUBLE IN SWING HOLDING BRAKE SOLENOID SYSTEM
C-4 [E213] TROUBLE IN SWING HOLDING BRAKE SOLNOID SYSTEM
C-5 [E206] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENOID SYSTEM
C-6 [E216] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENOID SYSTEM
C-7 [E251] TROUBLE IN BOOM PRESSURE SENSOR (OVERLOAD SENSOR) SYSTEM
C-8 [E258] SHORT CIRCUIT IN 5 V SYSTEM OF SENSOR POWER SUPPLY
C-9 WORK EQUIPMENT STILL MOVES AFTER WORK EQUIPMENT LOCK LEVER IS SET TO LOCK
C-10 MACHINE DOES NOT SWING
C-11 TRAVEL SPEED DOES NOT RISE
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M MODE)
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLESM ON MACHINE
ELECTRIC CIRCUIT DIAGRAM
M-1 [E101] (ERROR HISTORY DATA ARE ABNORMAL) IS DISPLAYED
M-2 [E108] (ENGINE COOLANT TEMPERATURE IS 105°C) IS DISPLAYED
M-3 [E114] (WIPER FORWARD OUTPOUT IS HSORTED) IS DISPLAYED
M-4 [E115] (WIPER REVERSE OUTPUT IS SHORTED) IS DISPLAYED
M-5 [E-116] (CONTACT WITH WASHER OUTPUT OF 24 V) IS DISPLAYED
M-6 [E117] (WIPER DOES NOT START WIPING IN 10 SECONDS) IS DISPLAYED
M-7 [E118] (WIPER IS NOT RETRACTED IN 10 SECONDS) IS DISPLAYED
M-8 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL SEGMENTS DO NOT LIGHT UP FOR 3 SECONDS
A) MONITOR PANEL SEGEMENTS DO NOT LIGHT UP AT ALL
B) SOME MONITOR PANEL SEGMENTS DO NOT LIGHT UP
M-9 WHEN STARTING SWITHC IS SET TO ON POSITION, ALL MONITOR PANEL SEGMENTS LIGHT UP BUT DO NOT GO OFF
M-10 WHILE PREHEATING IS EXECUTED, “PREHEATER MONITOR” LIGHT UP
M-11 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH
A) ALTERNATOR SYSTEM
B) ENGINE OIL PRESSURE SYSTEM
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
A) ALTERNATOR SYSTEM
B) ENGINE OIL PRESSURE SENSOR SYSTEM
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)
A) “ENGINE OIL” FLASHES
B) “CHARGE LEVEL” FLASHES
C) “FUEL LEVEL” FLASHES
D) “FUEL LEVEL” FLASHES
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
M-15 MONITOR PANEL LAMP FOR NIGHTTIME IS NOT TURNED ON (LC DISPLAYED IS NORMAL)
M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE
M-17 COOLANT TEMPERATURE GAUGE IS NOT DISPLAYED (GAUGE DOES NOT RISE TO 1ST LINE DURING OPERATION)
M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL
M-19 FUEL LEVEL GAUGE IS NOT DISPLAYED
M-20 WHILE ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE
M-21 TROUBLE IN FUEL LEVEL SENSOR
M-22 TROUBLE IN COOLANT TEMPERATURE SENSOR
M-23 WIPER DOES NOT OPERATOR OR OPERATES WHILE WIPER SWITCH IS TURNED OFF
A) WIPER DOES NOT OPERATE
B) WIPER OPERATES WHILE WIPER SWICH IS TURNED OFF
M-24 WASHER MOTOR DOES NOT OPERATE OR OPERATES WHILE WASHER SWITCH IS TURNED OFF
A) WASHER MOTOR DOES NOT OPERATE
B) WASHER OPERATES WHILE WIPER SWITCH IS TURNED OFF
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM
PC78US-6 BLADE-LESS SPECIFICATION
PC78US-6 ADDITIONAL ATTACHMENT CIRCUIT
PC78US-6 BLADE SPECIFICATION
PC78US-6 NORWAY SPECIFICATION
PC78UU-6
ELECTRICAL CIRCUIT DIAGRAM
PC78US-6 SERIAL NO.: 4001-5500 (1/2)
PC78US-6 SERIAL NO.: 4001-5500 (2/2)
PC78US-6 SERIAL NO.: 5501 and up (1/2)
PC78US-6 SERIAL NO.: 5501 and up (2/2)
PC78US-6 SERIAL NO.: 4809-5500 NORWAY SPECIFICATION (1/2)
PC78US-6 SERIAL NO.: 4809-5500 NORWAY SPECIFICATION (2/2)
PC78US-6 SERIAL NO.: 5501 and up NORWAY SPECIFICATION (1/2)
PC78US-6 SERIAL NO.: 5501 and up NORWAY SPECIFICATION (2/2)
PC79UU-6 SERIAL NO.: 22832-23500 (1/2)
PC79UU-6 SERIAL NO.: 22832-23500 (2/2)
PC79UU-6 SERIAL NO.: 23501 and up (1/2)
PC79UU-6 SERIAL NO.: 23501 and up (2/2)