Komatsu PC78US-8 Hydraulic Excavator Shop Manual SEN04543-17 PDF

Description

Komatsu PC78US-8 Hydraulic Excavator Shop Manual SEN04543-17 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC78US-8 Hydraulic Excavator Shop Manual SEN04543-17 – PDF DOWNLOAD 

Language : English
Pages : 1074
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC78US-8 Hydraulic Excavator Shop Manual SEN04543-17 – PDF DOWNLOAD 

SERIAL NUMBERS 15001 and up

Cover 1
00 Index and foreword 1
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 57
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 69
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 for boom 217
Anti-drop valve for arm 222
Multi-control valve 227
500 Work equipment 229
Work equipment 230
Dimensions of components 232
Work equipment cylinder 238
600 Cab and its attachments 241
Air conditioner 242
700 Electrical system 255
Electronic control system 256
Monitor system 288
KOMTRAX system 302
Sensor 304
20 Standard value table 311
100 Standard service value table 311
Standard value table for engine related parts 312
Standard value table for chassis 313
30 Testing and adjusting 323
101 Testing and adjusting, Part 1 323
Tools for testing, adjusting, and troubleshooting 325
Testing engine speed 330
Testing exhaust temperature 331
Checking exhaust gas color 332
Adjusting valve clearance 333
Testing compression pressure 335
Testing blow-by pressure 337
Testing engine oil pressure 338
Handling fuel system parts 339
Testing fuel pressure 340
Testing fuel return rate and fuel leakage 341
Bleeding air from fuel circuit 343
Checking fuel circuit for leakage 345
Testing and adjusting fan belt tension 346
Checking and adjusting air conditioner compressor belt tension 348
Testing swing circle bearing clearance 349
Checking and adjusting track shoe tension 350
Testing and adjusting oil pressure in work equipment and travel circuits 352
Testing and adjusting swing and blade circuit oil pressure (Blade specification) 354
Testing control circuit basic pressure 357
Testing and adjusting oil pressure in pump PC control circuit 358
Testing PC-EPC solenoid output pressure 361
Testing LS differential pressure and adjusting LS valve 362
Testing solenoid valve output pressure 364
Testing PPC valve output pressure 366
Adjusting play of work equipment and swing PPC valves 368
Checking parts which cause hydraulic drift of work equipment 369
Testing and adjusting travel deviation 371
Releasing residual pressure from hydraulic circuit 373
Testing oil leakage 376
Bleeding air from each part 379
Adjusting mirrors 381
Testing and adjusting hood catch 382
Adjusting rear view and right side view monitor cameras 384
102 Testing and adjusting, Part 2 387
Special functions of machine monitor 388
103 Testing and adjusting, Part 3 439
Handling voltage circuit of engine controller 440
Preparation work for troubleshooting of electrical system 441
Procedure for testing diodes 446
Pm Clinic service 447
40 Troubleshooting 453
100 Failure code table and fuse locations 453
Failure code table 454
Fuse locations 456
200 General information on troubleshooting 461
Points to remember when troubleshooting 462
Sequence of events in troubleshooting 463
Checks before troubleshooting 464
Classification and troubleshooting steps 465
Information in troubleshooting table 466
Phenomena looking like troubles and troubleshooting Nos 468
Connection table for connector pin numbers 471
T- branch box and T- branch adapter table 507
301 Troubleshooting by failure code, Part 1 511
Failure code [989L00] Engine controller lock caution 1 513
Failure code [989M00] Engine controller lock caution 2 514
Failure code [989N00] Engine controller lock caution 3 515
Failure code [AB00KE] Charge voltage low 516
Failure code [B@BAZG] Eng oil press low 518
Failure code [B@BCNS] Eng coolant overheat 519
Failure code [B@HANS] Hydr oil overheat 519
Failure code [CA111] ECM critical internal failure 520
Failure code [CA115] Eng Ne and Bkup speed sensor error 523
Failure code [CA122] Charge air press sensor high error 524
Failure code [CA123] Charge air press sensor low error 526
Failure code [CA131] Throttle sensor high error 528
Failure code [CA132] Throttle sensor low error 530
Failure code [CA144] Coolant temp sensor high error 532
Failure code [CA145] Coolant temp sensor low error 534
Failure code [CA153] Charge air temp sensor high error 536
Failure code [CA154] Charge air temp sensor low error 538
Failure code [CA187] Sensor sup 2 volt low error 539
Failure code [CA221] Ambient air press sensor high error 540
Failure code [CA222] Ambient air press sensor low error 542
Failure code [CA227] Sensor sup 2 volt high error 543
Failure code [CA234] Eng overspeed 544
Failure code [CA238] Ne speed sensor sup volt error 546
Failure code [CA271] IMV/PCV1 short error 548
Failure code [CA272] IMV/PCV1 open error 549
Failure code [CA322] Injector #1 (L #1) system open/short error 550
Failure code [CA324] Injector #3 (L #3) system open/short error 552
Failure code [CA331] Injector #2 (L #2) system open/short error 554
Failure code [CA332] Injector #4 (L #4) system open/short error 556
302 Troubleshooting by failure code, Part 2 559
Failure code [CA351] Inj drive circuit error 561
Failure code [CA352] Sensor sup 1 volt low error 564
Failure code [CA386] Sensor sup 1 volt high error 566
Failure code [CA435] Abnormality in engine oil pressure switch 568
Failure code [CA441] Battery voltage low error 569
Failure code [CA442] Battery voltage high error 570
Failure code [CA449] Rail press very high error 571
Failure code [CA451] Rail press sensor high error 572
Failure code [CA452] Rail press sensor low error 574
Failure code [CA488] Chg air temp high torque derate 575
Failure code [CA553] Rail press high error 576
Failure code [CA559] Rail press low error 577
Failure code [CA689] Eng Ne speed sensor error 580
Failure code [CA731] Eng Bkup speed sensor phase error 582
Failure code [CA757] All persistent data lost error 583
Failure code [CA778] Eng Bkup speed sensor error 584
Failure code [CA1633] KOMNET datalink timeout error 586
Failure code [CA2185] Throttle sens sup volt high error 588
Failure code [CA2186] Throttle sens sup volt low error 590
Failure code [CA2249] Rail press very low error 590
Failure code [CA2311] Abnormality in IMV solenoid 591
Failure code [D110KB] Battery relay drive short 592
Failure code [D19JKZ] Personal code relay abnormality 594
Failure code [D862KA] GPS antenna discon 596
Failure code [DA22KK] Pump solenoid power low error 598
Failure code [DA25KP] 5V sensor 1 power abnormality 600
Failure code [DA26KP] 5V sensor 2 power abnormality 602
Failure code [DA29KQ] Model selection abnormality 604
303 Troubleshooting by failure code, Part 3 607
Failure code [DA2RMC] CAN discon (Pump controller detected) 608
Failure code [DAF8KB] Short circuit in camera power supply 610
Failure code [DAFGMC] GPS module error 612
Failure code [DAFRMC] CAN discon (Monitor detected) 614
Failure code [DGH2KB] Hydr oil sensor short 616
Failure code [DHPAMA] Pump press sensor abnormality 618
Failure code [DHS5KX] Travel PPC press sensor abnormality 620
Failure code [DHSAMA] Swing right PPC press sensor abnormality 622
Failure code [DHSBMA] Swing left PPC press sensor abnormality 624
Failure code [DHX1MA] Overload sensor abnormality (Analog) 626
Failure code [DV20KB] Travel alarm S/C 627
Failure code [DW43KA] Travel speed sol discon 628
Failure code [DW43KB] Travel speed sol short 629
Failure code [DW45KA] Swing brake sol discon 630
Failure code [DW45KB] Swing brake sol short 632
Failure code [DWJ0KA] Merge-divider sol discon 634
Failure code [DWJ0KB] Merge-divider sol short 635
304 Troubleshooting by failure code, Part 4 637
Failure code [DXA8KA] PC-EPC sol discon 638
Failure code [DXA8KB] PC-EPC sol short 640
Failure code [DXE4KA] Service current EPC discon 642
Failure code [DXE4KB] Service current EPC short 643
Failure code [DY20KA] Wiper working abnormality 644
Failure code [DY20MA] Wiper parking abnormality 646
Failure code [DY2CKA] Washer drive discon 648
Failure code [DY2CKB] Washer drive short 650
Failure code [DY2DKB] Wiper drive (for) short 652
Failure code [DY2EKB] Wiper drive (rev) short 654
400 Troubleshooting of electrical system (E-mode) 657
Before carrying out troubleshooting of electrical system 659
Information in troubleshooting table 662
E-1 When starting switch is turned ON, machine monitor displays nothing 664
E-2 Engine does not start (Engine does not turn) 666
E-3 Preheater does not operate 670
E-4 Automatic warm-up system does not operate (in cold season) 672
E-5 All work equipment, swing, and travel mechanism do not move or cannot be locked 674
E-6 Precaution lights up while engine is running 676
E-7 Emergency stop item lights up while engine is running 679
E-8 Engine coolant temperature gauge does not indicate normally 680
E-9 Hydraulic oil temperature gauge does not indicate normally 682
E-10 Fuel level gauge does not indicate normally 685
E-11 Contents of display by machine monitor are different from applicable machine 687
E-12 Machine monitor does not display some items 687
E-13 Function switch does not work 687
E-14 Auto-decelerator does not operate normally 688
E-15 Working mode does not change 689
E-16 Travel speed does not change 690
E-17 Alarm buzzer cannot be stopped 691
E-18 Windshield wiper and window washer do not operate 692
E-19 Swing holding brake does not operate normally 696
E-20 Travel alarm does not sound or does not stop sounding 698
E-21 Air conditioner does not operate normally (including air conditioner abnormality record) 699
E-22 While starting switch is in OFF position, service meter is not displayed 712
E-23 Machine monitor cannot be set in service mode 713
E-24 Monitoring function does not display lever control signal normally 714
E-25 KOMTRAX system does not operate normally 730
500 Troubleshooting of hydraulic and mechanical system (H-mode) 733
Information contained in troubleshooting table 735
System chart for hydraulic and mechanical systems 736
H-1 Speed or power of all work equipment, swing, and travel are low 738
H-2 Engine speed sharply drops or engine stalls 739
H-3 No work equipment, travel and swing move 740
H-4 Abnormal noise is heard from around hydraulic pump 740
H-5 Fine control performance or response of work equipment and travel is low 741
H-6 Speed or power of boom is low 742
H-7 Speed or power of arm is low 743
H-8 Speed or power of bucket is low 744
H-9 Speed or power of blade is low 745
H-10 Work equipment does not move in its single operation 746
H-11 Hydraulic drift of work equipment is large 747
H-12 Time lag of work equipment is large 749
H-13 Work equipment loaded more is slower during compound operation 749
H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE 749
H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel 750
H-16 Machine deviates during travel 751
H-17 Travel speed is low 752
H-18 Machine cannot be steered easily or steering power is low 753
H-19 Travel speed does not change or it is kept low or high 754
H-20 Track does not move (only either side) 754
H-21 Machine does not swing 755
H-22 Swing acceleration, swing speed and swing power are low 756
H-23 Excessive overrun when stopping swing 758
H-24 When upper structure stops swinging, it makes large shock 759
H-25 When upper structure stops swinging, it makes large sound 759
H-26 Hydraulic drift of swing is large 760
H-27 Flow rate in attachment circuit cannot be adjusted 761
600 Troubleshooting of engine (S-mode) 763
Method of using troubleshooting chart 764
S-1 Starting performance is poor 768
S-2 Engine does not start 769
S-3 Engine does not pick up smoothly 772
S-4 Engine stops during operations 773
S-5 Engine does not rotate smoothly 774
S-6 Engine lacks output (or lacks power) 775
S-7 Exhaust smoke is black (incomplete combustion) 776
S-8 Oil consumption is excessive (or exhaust smoke is blue) 777
S-9 Oil becomes contaminated quickly 778
S-10 Fuel consumption is excessive 779
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 780
S-12 Oil pressure drops 781
S-13 Oil level rises (Entry of coolant or fuel) 782
S-14 Coolant temperature becomes too high (overheating) 783
S-15 Abnormal noise is made 784
S-16 Vibration is excessive 785
50 Disassembly and assembly 787
100 General information on disassembly and assembly 787
How to read this manual 788
Coating materials list 790
Special tool list 793
Sketches of special tools 797
200 Engine and cooling system 803
Removal and installation of fuel supply pump assembly 804
Removal and installation of fuel injector assembly 808
Removal and installation of engine front seal 812
Removal and installation of engine rear seal 813
Removal and installation of cylinder head assembly 815
Removal and installation of radiator assembly 826
Removal and installation of aftercooler assembly 829
Removal and installation of hydraulic oil cooler assembly 831
Removal and installation of engine and hydraulic pump assembly 834
Removal and installation of engine hood assembly 844
Removal and installation of fuel tank assembly 845
300 Power train 849
Removal and installation of travel motor and final drive assembly 851
Disassembly and assembly of travel motor and final drive assembly 853
Removal and installation of swing motor and swing machinery assembly 891
Disassembly and assembly of swing machinery 893
Removal and installation of swing circle assembly 900
400 Undercarriage and frame 903
Disassembly and assembly of track roller assembly 904
Disassembly and assembly of idler assembly 907
Disassembly and assembly of recoil spring assembly 910
Spreading and installation of track shoe assembly 912
Removal and installation of sprocket 914
Removal and installation of revolving frame assembly 915
Removal and installation of counterweight assembly 917
500 Hydraulic system 921
Removal and installation of center swivel joint assembly 922
Disassembly and assembly of center swivel joint assembly 924
Removal and installation of hydraulic tank assembly 926
Removal and installation of hydraulic pump assembly 929
Removal and installation of control valve assembly 933
Disassembly and assembly of control valve assembly 941
Disassembly and assembly of work equipment PPC valve assembly 944
Disassembly and assembly of travel PPC valve assembly 946
Removal and installation of anti- drop valve assembly for boom 948
Removal and installation of anti- drop valve assembly for arm 951
Disassembly and assembly of anti-drop valve assembly 954
Disassembly and assembly of hydraulic cylinder assembly 955
600 Work equipment 961
Removal and installation of work equipment assembly 962
Removal and installation of blade assembly 965
700 Cab and its attachments 969
Removal and installation of operator cab assembly 970
Removal and installation of operator’s cab glass (Stuck glass) 975
Removal and installation of front window assembly 985
Removal and installation of floor frame assembly 986
Removal and installation of work equipment control lever assembly 992
800 Electrical system 1005
Removal and installation of air conditioner compressor assembly 1006
Removal and Installation of air conditioner condenser assembly 1007
Removal and installation of air conditioner unit assembly 1008
Removal and installation of machine monitor assembly 1012
Removal and installation of pump controller assembly 1013
Removal and installation of engine controller assembly 1014
Removal and installation of KOMTRAX terminal assembly 1016
90 Diagrams and drawings 1019
100 Hydraulic diagrams and drawings 1019
Hydraulic circuit diagram 1021
Actuator attachment hydraulic circuit diagram 1027
200 Electrical diagrams and drawings 1031
Electrical circuit diagram 1033
Air conditioner unit electrical circuit diagram 1069
Connector list and stereogram 1071

DESCRIPTION:

Komatsu PC78US-8 Hydraulic Excavator Shop Manual SEN04543-17 – PDF DOWNLOAD 

SERIAL NUMBERS 15001 and up

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)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

S.V 29/12/24