Komatsu PC78US-10 Install guide
HYDRAULIC
EXCAVATOR
SEN06518-03
PC78US-10
SERIAL NUMBERS
30001
and up
INDEX
00 INDEX AND FOREWORD ........................................................................................................................ 00-1
ABBREVIATION LIST ........................................................................................................................... 00-15
FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-21
HOW TO READ THE SHOP MANUAL........................................................................................... 00-21
SAFETY NOTICE FOR OPERATION............................................................................................. 00-23
PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-31
ACTIONS IF FIRE OCCURS ......................................................................................................... 00-33
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-34
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-35
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-38
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-44
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-46
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-47
PRACTICAL USE OF KOMTRAX .................................................................................................. 00-48
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-49
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-53
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-57
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-58
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-60
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-61
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
................................................................................................................................................... 00-63
HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-64
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-68
STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-71
CONVERSION TABLE................................................................................................................... 00-78
01 SPECIFICATIONS .................................................................................................................................... 01-1
CONTENTS ............................................................................................................................................ 01-2
ABBREVIATION LIST ............................................................................................................................. 01-3
SPECIFICATIONS .................................................................................................................................. 01-9
SPECIFICATION DRAWING............................................................................................................ 01-9
WORKING RANGE DRAWINGS ....................................................................................................01-11
SPECIFICATIONS ......................................................................................................................... 01-12
WEIGHT TABLE ............................................................................................................................ 01-16
TABLE OF FUEL, COOLANT, AND LUBRICANTS ........................................................................ 01-18
10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1
CONTENTS ............................................................................................................................................ 10-2
ABBREVIATION LIST ............................................................................................................................. 10-5
BOOT-UP SYSTEM ...............................................................................................................................10-11
LAYOUT DRAWING OF BOOT-UP SYSTEM..................................................................................10-11
SYSTEM OPERATING LAMP SYSTEM ........................................................................................ 10-12
BATTERY DISCONNECT SWITCH ............................................................................................... 10-13
ENGINE SYSTEM ................................................................................................................................ 10-15
LAYOUT DRAWING OF ENGINE SYSTEM................................................................................... 10-15
ENGINE CONTROL SYSTEM ....................................................................................................... 10-17
AUTO-DECELERATION SYSTEM................................................................................................. 10-20
ENGINE AUTOMATIC WARM-UP SYSTEM .................................................................................. 10-22
OVERHEAT PREVENTION SYSTEM ............................................................................................ 10-24
TURBOCHARGER PROTECTION SYSTEM................................................................................. 10-25
AUTOMATIC IDLE STOP SYSTEM ............................................................................................... 10-26
COMPONENT PARTS OF ENGINE SYSTEM ............................................................................... 10-29
COOLING SYSTEM.............................................................................................................................. 10-44
LAYOUT DRAWING OF COOLING SYSTEM ................................................................................ 10-44
CONTROL SYSTEM............................................................................................................................. 10-47
LAYOUT DRAWING OF CONTROL SYSTEM ............................................................................... 10-47
MACHINE MONITOR SYSTEM ..................................................................................................... 10-49
INDEX 00 INDEX AND FOREWORD
00-2 PC78US-10
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KOMTRAX SYSTEM...................................................................................................................... 10-50
COMPONENT PARTS OF CONTROL SYSTEM............................................................................ 10-51
HYDRAULIC SYSTEM.......................................................................................................................... 10-78
LAYOUT DRAWING OF HYDRAULIC SYSTEM ............................................................................ 10-78
CLSS ............................................................................................................................................. 10-81
ENGINE AND PUMP COMBINED CONTROL SYSTEM................................................................ 10-84
COMPONENT PARTS OF HYDRAULIC SYSTEM ........................................................................ 10-88
WORK EQUIPMENT SYSTEM ............................................................................................................10-155
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ..............................................................10-155
STRUCTURE OF VALVE CONTROL............................................................................................10-158
PPC LOCK SYSTEM ....................................................................................................................10-160
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM ..............................................10-161
OVERLOAD CAUTION SYSTEM..................................................................................................10-163
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.................................................................10-165
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM...........................................................10-166
SWING SYSTEM .................................................................................................................................10-195
LAYOUT DRAWING OF SWING SYSTEM ...................................................................................10-195
SWING CONTROL SYSTEM DIAGRAM ......................................................................................10-198
COMPONENT PARTS OF SWING SYSTEM................................................................................10-200
TRAVEL SYSTEM................................................................................................................................10-212
LAYOUT DRAWING OF TRAVEL SYSTEM ..................................................................................10-212
TRAVEL CONTROL SYSTEM DIAGRAM.....................................................................................10-214
COMPONENT PARTS OF TRAVEL SYSTEM ..............................................................................10-216
UNDERCARRIAGE AND FRAME........................................................................................................10-230
LAYOUT DRAWING OF UNDERCARRIAGE ................................................................................10-230
IDLER CUSHION..........................................................................................................................10-232
WORK EQUIPMENT............................................................................................................................10-233
STRUCTURE OF WORK EQUIPMENT ........................................................................................10-233
FUNCTION OF WORK EQUIPMENT ...........................................................................................10-234
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM............................................................10-235
BUCKET CLEARANCE ADJUSTMENT SHIM ..............................................................................10-236
CAB AND ITS ATTACHMENTS ...........................................................................................................10-237
ROPS CAB ...................................................................................................................................10-237
CAB MOUNT ................................................................................................................................10-238
TAKE WIRING HARNESS OUT OF CAB......................................................................................10-240
20 STANDARD VALUE TABLE ...................................................................................................................... 20-1
CONTENTS ............................................................................................................................................ 20-2
ABBREVIATION LIST ............................................................................................................................. 20-3
STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-9
STANDARD VALUE TABLE FOR ENGINE: PC78US-10 ................................................................. 20-9
STANDARD VALUE TABLE FOR MACHINE......................................................................................... 20-12
STANDARD VALUE TABLE FOR MACHINE: PC78US-10............................................................. 20-12
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......................... 20-26
STANDARD VALUE TABLE FOR ELECTRICAL ................................................................................... 20-30
STANDARD VALUE TABLE FOR ELECTRICAL ............................................................................ 20-30
30 TESTING AND ADJUSTING..................................................................................................................... 30-1
CONTENTS ............................................................................................................................................ 30-2
ABBREVIATION LIST ............................................................................................................................. 30-5
RELATED INFORMATION ON TESTING AND ADJUSTING .................................................................30-11
TOOLS FOR TESTING AND ADJUSTING......................................................................................30-11
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ............................................................... 30-16
ENGINE AND COOLING SYSTEM....................................................................................................... 30-17
TEST ENGINE SPEED .................................................................................................................. 30-17
TEST EXHAUST GAS COLOR...................................................................................................... 30-21
TEST AND ADJUST VALVE CLEARANCE .................................................................................... 30-23
TEST COMPRESSION PRESSURE.............................................................................................. 30-25
TEST BLOWBY PRESSURE ......................................................................................................... 30-28
TEST ENGINE OIL PRESSURE .................................................................................................... 30-30
00 INDEX AND FOREWORD INDEX
PC78US-10 00-3
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TEST FUEL PRESSURE ............................................................................................................... 30-32
TEST FUEL RETURN RATE AND LEAKAGE................................................................................ 30-34
BLEED AIR FROM FUEL SYSTEM ............................................................................................... 30-38
TEST FUEL CIRCUIT FOR LEAKAGE .......................................................................................... 30-40
HANDLE CYLINDER CUT-OUT MODE OPERATION.................................................................... 30-42
HANDLE NO-INJECTION CRANKING OPERATION ..................................................................... 30-43
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ................................. 30-44
TEST ALTERNATOR BELT............................................................................................................ 30-45
TEST AUTOMATIC TENSIONER .................................................................................................. 30-46
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER.................................. 30-49
POWER TRAIN..................................................................................................................................... 30-55
TEST SWING CIRCLE BEARING CLEARANCE ........................................................................... 30-55
UNDERCARRIAGE AND FRAME......................................................................................................... 30-56
TEST AND ADJUST TRACK TENSION......................................................................................... 30-56
HYDRAULIC SYSTEM.......................................................................................................................... 30-58
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................. 30-58
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, AND TRAVEL CIRCUITS............ 30-62
TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE .......................................... 30-70
TEST OIL PRESSURE OF CONTROL CIRCUIT ........................................................................... 30-74
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT .................................... 30-76
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT..................................... 30-81
TEST OUTLET PRESSURE OF SOLENOID VALVE ..................................................................... 30-85
TEST PPC VALVE OUTLET PRESSURE ...................................................................................... 30-88
ADJUST WORK EQUIPMENT AND SWING PPC VALVES ........................................................... 30-90
TEST AND ADJUST TRAVEL DEVIATION .................................................................................... 30-91
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT................................. 30-94
TEST OIL LEAKAGE ..................................................................................................................... 30-96
BLEED AIR FROM HYDRAULIC CIRCUIT ...................................................................................30-100
CAB AND ITS ATTACHMENTS ...........................................................................................................30-105
METHOD FOR ADJUSTING MIRRORS .......................................................................................30-105
TEST AND ADJUST ENGINE HOOD CATCHER..........................................................................30-107
ELECTRICAL SYSTEM .......................................................................................................................30-110
SET AND OPERATE MACHINE MONITOR..................................................................................30-110
METHOD FOR STARTING UP KOMTRAX TERMINAL ................................................................30-156
ADJUST REARVIEW CAMERA ANGLE .......................................................................................30-161
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER .........................................................30-163
HANDLE BATTERY DISCONNECT SWITCH ...............................................................................30-164
TEST DIODES ..............................................................................................................................30-165
Pm CLINIC...........................................................................................................................................30-166
Pm CLINIC SERVICE ...................................................................................................................30-166
40 TROUBLESHOOTING .............................................................................................................................. 40-1
CONTENTS ............................................................................................................................................ 40-2
ABBREVIATION LIST ............................................................................................................................. 40-8
RELATED INFORMATION ON TROUBLESHOOTING ......................................................................... 40-14
GENERAL TROUBLESHOOTING POINTS ................................................................................... 40-14
SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 40-15
CHECKS BEFORE TROUBLESHOOTING.................................................................................... 40-17
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ..................................................... 40-19
TESTING IN ACCORDANCE WITH TESTING PROCEDURE....................................................... 40-21
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION................................................. 40-45
PROCEDURE FOR TESTING AND TROUBLESHOOTING .......................................................... 40-52
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS ............................................. 40-55
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................... 40-59
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SEN-
SOR SYSTEM............................................................................................................................ 40-61
CONNECTORS LIST AND LAYOUT.............................................................................................. 40-63
CONNECTOR CONTACT IDENTIFICATION ................................................................................. 40-74
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ..................................................................40-114
INDEX 00 INDEX AND FOREWORD
00-4 PC78US-10
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FUSE LOCATION TABLE .............................................................................................................40-120
FAILURE CODES TABLE .............................................................................................................40-122
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....................................................40-130
FAILURE CODE [879AKA]............................................................................................................40-130
FAILURE CODE [879AKB]............................................................................................................40-132
FAILURE CODE [879BKA]............................................................................................................40-133
FAILURE CODE [879BKB]............................................................................................................40-135
FAILURE CODE [879CKA]............................................................................................................40-137
FAILURE CODE [879CKB]............................................................................................................40-138
FAILURE CODE [879DKZ]............................................................................................................40-139
FAILURE CODE [879EMC] ...........................................................................................................40-141
FAILURE CODE [879FMC] ...........................................................................................................40-142
FAILURE CODE [879GKX] ...........................................................................................................40-143
FAILURE CODE [989L00] .............................................................................................................40-145
FAILURE CODE [989M00] ............................................................................................................40-146
FAILURE CODE [989N00] ............................................................................................................40-147
FAILURE CODE [A900FR]............................................................................................................40-148
FAILURE CODE [A900N6] ............................................................................................................40-149
FAILURE CODE [A900NY]............................................................................................................40-150
FAILURE CODE [AB00KE] ...........................................................................................................40-151
FAILURE CODE [B@BAZG] .........................................................................................................40-153
FAILURE CODE [B@BCNS] .........................................................................................................40-154
FAILURE CODE [CA115] ..............................................................................................................40-155
FAILURE CODE [CA122] ..............................................................................................................40-156
FAILURE CODE [CA123] ..............................................................................................................40-158
FAILURE CODE [CA131] ..............................................................................................................40-160
FAILURE CODE [CA132] ..............................................................................................................40-162
FAILURE CODE [CA144] ..............................................................................................................40-164
FAILURE CODE [CA145] ..............................................................................................................40-166
FAILURE CODE [CA153] ..............................................................................................................40-168
FAILURE CODE [CA154] ..............................................................................................................40-170
FAILURE CODE [CA187] ..............................................................................................................40-172
FAILURE CODE [CA221] ..............................................................................................................40-174
FAILURE CODE [CA222] ..............................................................................................................40-176
FAILURE CODE [CA227] ..............................................................................................................40-178
FAILURE CODE [CA234] ..............................................................................................................40-179
FAILURE CODE [CA238] ..............................................................................................................40-180
FAILURE CODE [CA239] ..............................................................................................................40-182
FAILURE CODE [CA271] ..............................................................................................................40-184
FAILURE CODE [CA272] ..............................................................................................................40-186
FAILURE CODE [CA322] ..............................................................................................................40-187
FAILURE CODE [CA324] ..............................................................................................................40-189
FAILURE CODE [CA331] ..............................................................................................................40-191
FAILURE CODE [CA332] ..............................................................................................................40-193
FAILURE CODE [CA343] ..............................................................................................................40-195
FAILURE CODE [CA351] ..............................................................................................................40-196
FAILURE CODE [CA352] ..............................................................................................................40-197
FAILURE CODE [CA356] ..............................................................................................................40-199
FAILURE CODE [CA357] ..............................................................................................................40-201
FAILURE CODE [CA386] ..............................................................................................................40-203
FAILURE CODE [CA435] ..............................................................................................................40-204
FAILURE CODE [CA441] ..............................................................................................................40-206
FAILURE CODE [CA442] ..............................................................................................................40-208
FAILURE CODE [CA449] ..............................................................................................................40-209
FAILURE CODE [CA451] ..............................................................................................................40-210
FAILURE CODE [CA452] ..............................................................................................................40-212
FAILURE CODE [CA466] ..............................................................................................................40-214
FAILURE CODE [CA515] ..............................................................................................................40-216
00 INDEX AND FOREWORD INDEX
PC78US-10 00-5
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FAILURE CODE [CA516] ..............................................................................................................40-218
FAILURE CODE [CA553] ..............................................................................................................40-220
FAILURE CODE [CA555] ..............................................................................................................40-221
FAILURE CODE [CA556] ..............................................................................................................40-222
FAILURE CODE [CA559] ..............................................................................................................40-223
FAILURE CODE [CA689] ..............................................................................................................40-227
FAILURE CODE [CA691] ..............................................................................................................40-229
FAILURE CODE [CA692] ..............................................................................................................40-231
FAILURE CODE [CA697] ..............................................................................................................40-233
FAILURE CODE [CA698] ..............................................................................................................40-234
FAILURE CODE [CA731] ..............................................................................................................40-235
FAILURE CODE [CA778] ..............................................................................................................40-237
FAILURE CODE [CA1117] ............................................................................................................40-239
FAILURE CODE [CA1695] ............................................................................................................40-240
FAILURE CODE [CA1696] ............................................................................................................40-241
FAILURE CODE [CA1843] ............................................................................................................40-242
FAILURE CODE [CA1844] ............................................................................................................40-244
FAILURE CODE [CA1896] ............................................................................................................40-246
FAILURE CODE [CA1942] ............................................................................................................40-247
FAILURE CODE [CA1961] ............................................................................................................40-248
FAILURE CODE [CA2185] ............................................................................................................40-249
FAILURE CODE [CA2186] ............................................................................................................40-250
FAILURE CODE [CA2249] ............................................................................................................40-252
FAILURE CODE [CA2272] ............................................................................................................40-253
FAILURE CODE [CA2311] ............................................................................................................40-256
FAILURE CODE [CA2349] ............................................................................................................40-257
FAILURE CODE [CA2353] ............................................................................................................40-259
FAILURE CODE [CA2357] ............................................................................................................40-261
FAILURE CODE [CA2765] ............................................................................................................40-262
FAILURE CODE [CA3419] ............................................................................................................40-263
FAILURE CODE [CA3421] ............................................................................................................40-265
FAILURE CODE [CA3724] ............................................................................................................40-267
FAILURE CODE [CA3918] ............................................................................................................40-269
FAILURE CODE [CA3919] ............................................................................................................40-270
FAILURE CODE [CA3921] ............................................................................................................40-271
FAILURE CODE [CA3922] ............................................................................................................40-272
FAILURE CODE [CA3923] ............................................................................................................40-274
FAILURE CODE [D110KB]............................................................................................................40-276
FAILURE CODE [D19JKZ] ............................................................................................................40-278
FAILURE CODE [D811MC] ...........................................................................................................40-281
FAILURE CODE [D862KA]............................................................................................................40-282
FAILURE CODE [D8ALKA] ...........................................................................................................40-283
FAILURE CODE [D8ALKB] ...........................................................................................................40-285
FAILURE CODE [D8AQKR] ..........................................................................................................40-287
FAILURE CODE [DA20MC] ..........................................................................................................40-289
FAILURE CODE [DA22KK] ...........................................................................................................40-290
FAILURE CODE [DA25KP] ...........................................................................................................40-293
FAILURE CODE [DA26KP] ...........................................................................................................40-296
FAILURE CODE [DA29KQ]...........................................................................................................40-298
FAILURE CODE [DA2LKA] ...........................................................................................................40-300
FAILURE CODE [DA2LKB] ...........................................................................................................40-302
FAILURE CODE [DA2QKR] ..........................................................................................................40-304
FAILURE CODE [DA2RKR] ..........................................................................................................40-306
FAILURE CODE [DAF0MB] ..........................................................................................................40-307
FAILURE CODE [DAF0MC] ..........................................................................................................40-308
FAILURE CODE [DAF8KB] ...........................................................................................................40-309
FAILURE CODE [DAF9KQ]...........................................................................................................40-311
FAILURE CODE [DAFGMC] .........................................................................................................40-312
INDEX 00 INDEX AND FOREWORD
00-6 PC78US-10
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FAILURE CODE [DAFLKA] ...........................................................................................................40-313
FAILURE CODE [DAFLKB] ...........................................................................................................40-315
FAILURE CODE [DAFQKR] ..........................................................................................................40-316
FAILURE CODE [DAZ9KQ]...........................................................................................................40-317
FAILURE CODE [DAZQKR] ..........................................................................................................40-318
FAILURE CODE [DB2QKR] ..........................................................................................................40-323
FAILURE CODE [DB2RKR] ..........................................................................................................40-328
FAILURE CODE [DDNRKA]..........................................................................................................40-333
FAILURE CODE [DDNRKY]..........................................................................................................40-335
FAILURE CODE [DDNS00]...........................................................................................................40-337
FAILURE CODE [DGH2KB] ..........................................................................................................40-339
FAILURE CODE [DHPAMA] ..........................................................................................................40-341
FAILURE CODE [DHS3MA] ..........................................................................................................40-343
FAILURE CODE [DHS4MA] ..........................................................................................................40-346
FAILURE CODE [DHS5MA] ..........................................................................................................40-349
FAILURE CODE [DHS8MA] ..........................................................................................................40-351
FAILURE CODE [DHS9MA] ..........................................................................................................40-354
FAILURE CODE [DHSAMA]..........................................................................................................40-357
FAILURE CODE [DHSBMA]..........................................................................................................40-360
FAILURE CODE [DHSCMA] .........................................................................................................40-363
FAILURE CODE [DHSDMA] .........................................................................................................40-366
FAILURE CODE [DKULKA]...........................................................................................................40-369
FAILURE CODE [DKULKB]...........................................................................................................40-371
FAILURE CODE [DKULKY]...........................................................................................................40-373
FAILURE CODE [DV20KB] ...........................................................................................................40-375
FAILURE CODE [DW43KA] ..........................................................................................................40-377
FAILURE CODE [DW43KB] ..........................................................................................................40-379
FAILURE CODE [DW43KY] ..........................................................................................................40-381
FAILURE CODE [DW45KA] ..........................................................................................................40-382
FAILURE CODE [DW45KB] ..........................................................................................................40-385
FAILURE CODE [DW45KY] ..........................................................................................................40-388
FAILURE CODE [DW4CKY]..........................................................................................................40-390
FAILURE CODE [DWJ0KA] ..........................................................................................................40-392
FAILURE CODE [DWJ0KB] ..........................................................................................................40-394
FAILURE CODE [DWJ0KY] ..........................................................................................................40-396
FAILURE CODE [DXA8KA]...........................................................................................................40-397
FAILURE CODE [DXA8KB]...........................................................................................................40-399
FAILURE CODE [DXE4KA]...........................................................................................................40-401
FAILURE CODE [DXE4KB]...........................................................................................................40-403
FAILURE CODE [DXE4KY]...........................................................................................................40-405
FAILURE CODE [DY20KA] ...........................................................................................................40-407
FAILURE CODE [DY20MA]...........................................................................................................40-409
FAILURE CODE [DY2CKB]...........................................................................................................40-411
FAILURE CODE [DY2DKB]...........................................................................................................40-414
FAILURE CODE [DY2EKB]...........................................................................................................40-416
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ...........................................................40-418
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ................................................40-418
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK..........................................................40-424
E-3 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP.......40-427
E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING..................................................................................................................................40-429
E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-432
E-6 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-433
E-7 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .................40-434
E-8 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING........................40-435
00 INDEX AND FOREWORD INDEX
PC78US-10 00-7
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E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-436
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..40-437
E-11 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-438
E-12 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM ...................40-439
E-13 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL.................................40-441
E-14 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
OR MAXIMUM...........................................................................................................................40-442
E-15 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOL-
ANT TEMPERATURE................................................................................................................40-443
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM .................................................................................................................................40-444
E-17 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEM-
PERATURE ...............................................................................................................................40-446
E-18 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED ........................40-447
E-19 FUNCTION SWITCH DOES NOT OPERATE .......................................................................40-448
E-20 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)....................40-449
E-21 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR
DOES NOT LIGHT UP OR DOES NOT GO OFF ......................................................................40-450
E-22 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER ......................40-451
E-23 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS
NOT DISPLAYED ......................................................................................................................40-453
E-24 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS
NOT CHANGED........................................................................................................................40-454
E-25 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT
CHANGE...................................................................................................................................40-455
E-26 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE...................................................................................................................................40-456
E-27 ALARM BUZZER CANNOT BE CANCELED ........................................................................40-457
E-28 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION.........
..................................................................................................................................................40-458
E-29 SERVICE MODE CANNOT BE SELECTED.........................................................................40-459
E-30 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE ......40-460
E-31 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK..........40-463
E-32 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT
SWING ......................................................................................................................................40-465
E-33 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING
BRAKE DOES NOT OPERATE .................................................................................................40-467
E-34 WORK EQUIPMENT DOES NOT OPERATE WHILE LOCK LEVER AUTOMATIC RELEASE
SWITCH IS IN RELEASE POSITION ........................................................................................40-469
E-35 ALARM DOES NOT SOUND DURING TRAVEL ..................................................................40-471
E-36 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED............................40-473
E-37 HORN DOES NOT SOUND..................................................................................................40-474
E-38 HORN DOES NOT STOP SOUNDING.................................................................................40-476
E-39 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF.
..................................................................................................................................................40-477
E-40 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE.....40-478
E-41 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPER-
ATE ...........................................................................................................................................40-480
E-42 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ...
..................................................................................................................................................40-481
E-43 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .
..................................................................................................................................................40-482
E-44 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION..........
..................................................................................................................................................40-483
E-45 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ..40-484
INDEX 00 INDEX AND FOREWORD
00-8 PC78US-10
Find manuals at https://best-manuals.com
E-46 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
..................................................................................................................................................40-485
E-47 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.
..................................................................................................................................................40-486
E-48 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...40-487
E-49 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .40-488
E-50 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ..........
..................................................................................................................................................40-489
E-51 BLADE RAISE ON IS NOT DISPLAYED CORRECTLY WITH MONITORING ......................40-492
E-52 BLADE LOWER ON IS NOT DISPLAYED CORRECTLY WITH MONITORING....................40-494
E-53 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY ...................................................40-496
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .......................40-497
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE).................................40-497
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS ............................................40-498
FAILURE MODE AND CAUSE TABLE..........................................................................................40-500
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK........................................40-509
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER ....................40-510
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR..............................................40-512
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP ....................................40-513
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS ....................................................40-514
H-6 SPEED OR POWER OF BOOM IS LOW ...............................................................................40-516
H-7 ARM SPEED OR POWER IS LOW ........................................................................................40-520
H-8 BUCKET SPEED OR POWER IS LOW..................................................................................40-523
H-9 BLADE SPEED OR POWER IS LOW ....................................................................................40-526
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION .....................................40-528
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE ..........................................................................40-529
H-12 HYDRAULIC DRIFT OF ARM IS LARGE .............................................................................40-530
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE.......................................................................40-531
H-14 HYDRAULIC DRIFT OF BLADE IS LARGE .........................................................................40-532
H-15 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIP-
MENT MOVES ..........................................................................................................................40-534
H-16 TIME LAG OF WORK EQUIPMENT IS LARGE ...................................................................40-535
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .......................................40-536
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD
MOVES SLOWER .....................................................................................................................40-537
H-19 IN COMBINED OPERATION OF TRAVEL WITH WORK EQUIPMENT OR SWING, TRAVEL
SPEED DROPS LARGELY .......................................................................................................40-538
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW ....
..................................................................................................................................................40-539
H-21 MACHINE DOES NOT TRAVEL STRAIGHT ........................................................................40-540
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW...............................40-542
H-23 TRAVEL SPEED IS LOW .....................................................................................................40-545
H-24 ONE OF TRACKS DOES NOT RUN ....................................................................................40-547
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST ....40-549
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT ...................40-550
H-27 SWINGS ONLY IN ONE DIRECTION...................................................................................40-552
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND
LEFT) ........................................................................................................................................40-553
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY
ONE DIRECTION ......................................................................................................................40-555
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH
RIGHT AND LEFT)....................................................................................................................40-556
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE
DIRECTION EITHER RIGHT OR LEFT)....................................................................................40-557
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING ...............................40-558
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING..40-559
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED).40-560
00 INDEX AND FOREWORD INDEX
PC78US-10 00-9
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)........
..................................................................................................................................................40-561
TROUBLESHOOTING OF ENGINE (S-MODE) ...................................................................................40-562
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE).................................40-562
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.......
..................................................................................................................................................40-563
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT ...................................................40-564
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) ..........................................................................................................40-565
S-4 ENGINE STARTABILITY IS POOR.........................................................................................40-566
S-5 ENGINE DOES NOT PICK UP SMOOTHLY ..........................................................................40-568
S-6 ENGINE STOPS DURING OPERATION ................................................................................40-570
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ..........................................................................40-572
S-8 ENGINE LACKS POWER.......................................................................................................40-573
S-9 EXHAUST SMOKE IS BLACK................................................................................................40-575
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ....................................................................40-577
S-11 OIL BECOMES CONTAMINATED QUICKLY ........................................................................40-578
S-12 FUEL CONSUMPTION IS EXCESSIVE ...............................................................................40-579
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .......
..................................................................................................................................................40-580
S-14 OIL PRESSURE DROPS .....................................................................................................40-581
S-15 FUEL MIXES INTO ENGINE OIL..........................................................................................40-583
S-16 WATER MIXES INTO ENGINE OIL (MILKY) ........................................................................40-584
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)......................................40-585
S-18 UNUSUAL NOISE IS HEARD...............................................................................................40-586
S-19 VIBRATION IS EXCESSIVE .................................................................................................40-587
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT...................................................................40-588
50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1
CONTENTS ............................................................................................................................................ 50-2
ABBREVIATION LIST ............................................................................................................................. 50-6
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ........................................................ 50-12
HOW TO READ THIS MANUAL..................................................................................................... 50-12
COATING MATERIALS LIST.......................................................................................................... 50-14
SPECIAL TOOLS LIST .................................................................................................................. 50-19
SKETCHES OF SPECIAL TOOLS................................................................................................. 50-28
ENGINE AND COOLING SYSTEM....................................................................................................... 50-32
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-32
REMOVE AND INSTALL INJECTOR ASSEMBLY ......................................................................... 50-41
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .............................................................. 50-53
REMOVE AND INSTALL EGR VALVE ASSEMBLY........................................................................ 50-77
REMOVE AND INSTALL EGR COOLER ASSEMBLY.................................................................... 50-80
REMOVE AND INSTALL STARTER ASSEMBLY........................................................................... 50-84
REMOVE AND INSTALL ALTERNATOR BELT .............................................................................. 50-87
REMOVE AND INSTALL AUTOMATIC TENSIONER..................................................................... 50-90
REMOVE AND INSTALL RADIATOR ASSEMBLY ......................................................................... 50-91
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY ...............................................50-100
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY................................................................50-108
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY ...............................................50-113
REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-137
REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-140
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .................................................................50-143
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .................................................................50-146
REMOVE AND INSTALL KDOC MUFFLER ..................................................................................50-149
REMOVE AND INSTALL FUEL TANK ASSEMBLY.......................................................................50-157
REMOVE AND INSTALL KCCV VENTILATOR ASSEMBLY .........................................................50-163
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...................................................................50-167
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY ................................50-170
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ...................................50-175
INDEX 00 INDEX AND FOREWORD
00-10 PC78US-10
POWER TRAIN....................................................................................................................................50-177
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ...............................50-177
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.................50-180
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................50-227
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .........................................50-230
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY ................................................................50-239
UNDERCARRIAGE AND FRAME........................................................................................................50-241
SEPARATION AND CONNECTION OF TRACK ASSEMBLY........................................................50-241
REMOVE AND INSTALL SPROCKET ..........................................................................................50-243
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...........................................50-245
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .................................................................50-247
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY ..........................................50-251
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ................................................50-254
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ........................................................50-259
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...........................................................50-264
HYDRAULIC SYSTEM.........................................................................................................................50-270
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY ..................................................50-270
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY ...................................50-273
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY............................................................50-276
REMOVE AND INSTALL MAIN PUMP ASSEMBLY ......................................................................50-284
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .............................................................50-294
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY ......................50-304
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY ..........................................50-306
WORK EQUIPMENT............................................................................................................................50-309
REMOVE AND INSTALL BLADE ASSEMBLY ..............................................................................50-309
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .........................................................50-312
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM.......................................50-318
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM..........................................50-322
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY ............................................50-326
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY........................50-327
CAB AND ITS ATTACHMENTS ...........................................................................................................50-333
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY ...........................................................50-333
REMOVE AND INSTALL OPERATOR'S CAB DOOR ...................................................................50-345
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) ....................................50-348
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY .............................................................50-361
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.................................................................50-364
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .................................................50-376
REMOVE AND INSTALL OPERATOR'S SEAT .............................................................................50-390
REMOVE AND INSTALL SEAT BELT ...........................................................................................50-392
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .................................................................50-394
ELECTRICAL SYSTEM .......................................................................................................................50-408
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...................................................50-408
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.......................................................50-411
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ........................................................50-413
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR ..............................50-419
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.........................................50-421
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY......................................................50-423
60 MAINTENANCE STANDARD.................................................................................................................... 60-1
CONTENTS ............................................................................................................................................ 60-2
ABBREVIATION LIST ............................................................................................................................. 60-3
ENGINE AND COOLING SYSTEM......................................................................................................... 60-9
MAINTENANCE STANDARD OF ENGINE MOUNT ........................................................................ 60-9
MAINTENANCE STANDARD FOR PTO ........................................................................................ 60-10
MAINTENANCE STANDARD OF COOLING SYSTEM ...................................................................60-11
POWER TRAIN..................................................................................................................................... 60-13
MAINTENANCE STANDARD OF SWING CIRCLE ........................................................................ 60-13
MAINTENANCE STANDARD OF SWING MACHINERY................................................................ 60-15
MAINTENANCE STANDARD OF SPROCKET .............................................................................. 60-17
00 INDEX AND FOREWORD INDEX
PC78US-10 00-11
UNDERCARRIAGE AND FRAME......................................................................................................... 60-18
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION.................................... 60-18
MAINTENANCE STANDARD OF IDLER ....................................................................................... 60-20
MAINTENANCE STANDARD OF TRACK ROLLER....................................................................... 60-22
MAINTENANCE STANDARD OF CARRIER ROLLER................................................................... 60-23
MAINTENANCE STANDARD OF TRACK SHOE........................................................................... 60-24
MAINTENANCE STANDARD OF TRIPLE SHOE........................................................................... 60-27
MAINTENANCE STANDARD OF ROAD LINER ............................................................................ 60-28
MAINTENANCE STANDARD FOR RUBBER SHOE...................................................................... 60-29
HYDRAULIC SYSTEM.......................................................................................................................... 60-30
MAINTENANCE STANDARD OF HYDRAULIC TANK ................................................................... 60-30
MAINTENANCE STANDARD OF MAIN PUMP.............................................................................. 60-31
MAINTENANCE STANDARD OF PC-EPC VALVE......................................................................... 60-34
MAINTENANCE STANDARD OF SWING MOTOR........................................................................ 60-35
MAINTENANCE STANDARD OF TRAVEL MOTOR ...................................................................... 60-38
MAINTENANCE STANDARD OF CONTROL VALVE..................................................................... 60-39
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM .............................................. 60-49
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM ................................................. 60-51
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE ....................... 60-53
MAINTENANCE STANDARD OF BLADE PPC VALVE .................................................................. 60-56
MAINTENANCE STANDARD OF TRAVEL PPC VALVE ................................................................ 60-58
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...... 60-61
MAINTENANCE STANDARD OF SOLENOID VALVE.................................................................... 60-64
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE
CIRCUIT) ................................................................................................................................... 60-65
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT.......................................................... 60-66
WORK EQUIPMENT............................................................................................................................. 60-67
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE................................................. 60-67
MAINTENANCE STANDARD OF BOOM CYLINDER .................................................................... 60-76
MAINTENANCE STANDARD OF ARM CYLINDER ....................................................................... 60-77
MAINTENANCE STANDARD OF BUCKET CYLINDER................................................................. 60-78
MAINTENANCE STANDARD OF BLADE CYLINDER ................................................................... 60-79
80 APPENDIX................................................................................................................................................ 80-1
CONTENTS ............................................................................................................................................ 80-2
ABBREVIATION LIST ............................................................................................................................. 80-4
AIR CONDITIONER SYSTEM .............................................................................................................. 80-10
PRECAUTIONS FOR REFRIGERANT .......................................................................................... 80-10
AIR CONDITIONER COMPONENT ................................................................................................80-11
SPECIFICATIONS OF AIR CONDITIONER ................................................................................... 80-13
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE ............................................. 80-14
OUTLINE OF REFRIGERATION CYCLE....................................................................................... 80-15
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .................................................................... 80-17
AIR CONDITIONER UNIT.............................................................................................................. 80-17
COMPONENT PARTS OF AIR CONDITIONER UNIT.................................................................... 80-20
AIR CONDITIONER CONTROLLER.............................................................................................. 80-25
COMPRESSOR ............................................................................................................................. 80-26
CONDENSER ................................................................................................................................ 80-27
RECEIVER DRIER......................................................................................................................... 80-28
SENSORS FOR AIR CONDITIONER SYSTEM............................................................................. 80-29
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER......
.......................................................................................................................................................... 80-31
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER ......... 80-33
AIR CONDITIONER SYSTEM DIAGRAM ............................................................................................. 80-35
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .................................... 80-36
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS ..
.......................................................................................................................................................... 80-38
TESTING AIR LEAKAGE (DUCT)......................................................................................................... 80-44
METHOD FOR TESTING AIR LEAKAGE (DUCT) ......................................................................... 80-44
INDEX 00 INDEX AND FOREWORD
00-12 PC78US-10
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION................................................ 80-45
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE
OF THE MACHINE MONITOR .......................................................................................................... 80-46
TEST VENT (MODE) CHANGEOVER .................................................................................................. 80-47
METHOD FOR TESTING VENT (MODE) CHANGEOVER ............................................................ 80-47
TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................. 80-48
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .................................................. 80-48
TEST SUNLIGHT SENSOR.................................................................................................................. 80-49
METHOD FOR TESTING SUNLIGHT SENSOR............................................................................ 80-49
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.................................................................. 80-50
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT............................ 80-50
TEST RELAYS...................................................................................................................................... 80-52
METHOD FOR TESTING RELAYS................................................................................................ 80-52
AIR CONDITIONER TROUBLESHOOTING CHART 1 ......................................................................... 80-53
AIR CONDITIONER TROUBLESHOOTING CHART 2 ......................................................................... 80-54
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 80-57
FAILURE CODE [879AKA].................................................................................................................... 80-59
FAILURE CODE [879AKB].................................................................................................................... 80-60
FAILURE CODE [879BKA].................................................................................................................... 80-61
FAILURE CODE [879BKB].................................................................................................................... 80-63
FAILURE CODE [879CKA].................................................................................................................... 80-65
FAILURE CODE [879CKB].................................................................................................................... 80-66
FAILURE CODE [879DKZ].................................................................................................................... 80-67
FAILURE CODE [879EMC] ................................................................................................................... 80-69
FAILURE CODE [879FMC] ................................................................................................................... 80-70
FAILURE CODE [879GKX] ................................................................................................................... 80-71
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE).
.......................................................................................................................................................... 80-73
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)...
.......................................................................................................................................................... 80-75
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) ..................................................................................................................................... 80-78
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER............................................... 80-80
TROUBLESHOOTING USING GAUGE PRESSURE............................................................................ 80-82
CONNECTION OF SERVICE TOOL ..................................................................................................... 80-85
METHOD FOR CONNECTING SERVICE TOOL ........................................................................... 80-85
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITION-
ER PIPINGS...................................................................................................................................... 80-87
HANDLE COMPRESSOR OIL .............................................................................................................. 80-89
90 CIRCUIT DIAGRAMS ............................................................................................................................... 90-1
CONTENTS ............................................................................................................................................ 90-2
ABBREVIATION LIST ............................................................................................................................. 90-3
HYDRAULIC CIRCUIT DIAGRAM .......................................................................................................... 90-9
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .................................................................. 90-9
HYDRAULIC CIRCUIT DIAGRAM (1/2) ......................................................................................... 90-13
HYDRAULIC CIRCUIT DIAGRAM (2/2) ......................................................................................... 90-15
HYDRAULIC CIRCUIT DIAGRAM (FOR EUROPEAN UNION) ..................................................... 90-17
ELECTRICAL CIRCUIT DIAGRAM ....................................................................................................... 90-19
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM............................................................... 90-19
ELECTRICAL CIRCUIT DIAGRAM (1/6)........................................................................................ 90-23
ELECTRICAL CIRCUIT DIAGRAM (2/6)........................................................................................ 90-25
ELECTRICAL CIRCUIT DIAGRAM (3/6)........................................................................................ 90-27
ELECTRICAL CIRCUIT DIAGRAM (4/6)........................................................................................ 90-29
ELECTRICAL CIRCUIT DIAGRAM (5/6)........................................................................................ 90-31
ELECTRICAL CIRCUIT DIAGRAM (6/6)........................................................................................ 90-33
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (1/6)............................................ 90-35
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (2/6)............................................ 90-37
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (3/6)............................................ 90-39
00 INDEX AND FOREWORD INDEX
PC78US-10 00-13
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (4/6)............................................ 90-41
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (5/6)............................................ 90-43
ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPEAN UNION) (6/6)............................................ 90-45
INDEX..................................................................................................................................................................1
INDEX 00 INDEX AND FOREWORD
00-14 PC78US-10
ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Abbrevia-
tion Actual word spelled out
Purpose of use (major ap-
plicable machine (*1), or
component/system)
Explanation
ABS Anti-skid Brake System
Travel and brake When the tires skid (wheels stop rotating), the
brakes are released, and when the wheels start
to rotate, the brakes are applied again.
(HD, HM)
AISS Automatic Idling Setting
System Engine This function automatically sets the idle speed.
AJSS Advanced Joystick
Steering System
Steering A lever is used to perform the steering operations
instead of a steering wheel. Moreover, it shifts
gear and changes direction (FORWARD or RE-
VERSE).
(WA)
ARAC Automatic Retarder Ac-
celerator Control
Travel and brake When the accelerator pedal is released while the
machine is traveling downhill, this function auto-
matically applies the retarder with a constant
braking force.
(HD, HM)
ARSC Automatic Retarder
Speed Control
Travel and brake When the accelerator pedal is released while the
machine is traveling downhill, this function auto-
matically applies the retarder to ensure that the
machine speed does not accelerate above the
speed set by the operator.
(HD, HM)
ASR Automatic Spin Regula-
tor
Travel and brake When the tires spin on soft ground surfaces, this
function automatically uses the optimum braking
force to drive both wheels.
(HD, HM)
ATT Attachment Work equipment A device that can be fixed onto the standard ma-
chine in order to enable it to do different jobs.
BCV Brake cooling oil control
valve
Brake When the retarder is not being used, this valve
bypasses part of the brake cooling oil to reduce
the load on the hydraulic pump.
(HD)
CAN Controller Area Network Communication and elec-
tronic control
One of communication standards that is used in
the network on the machine.
CDR Crankcase Depression
Regulator Engine
A regulator valve which is installed to KCCV ven-
tilator. It is written as CDR valve and it is not
used independently.
CLSS Closed-center Load
Sensing System Hydraulic system
This system can simultaneously actuate multiple
actuators regardless of the load (provides better
combined operation than OLSS).
CRI Common Rail Injection Engine
Engine controller electronically controls supply
pump, common rail, and injector. This function
maintains optimum fuel injection amount and fuel
injection timing.
00 INDEX AND FOREWORD ABBREVIATION LIST
PC78US-10 00-15
Abbrevia-
tion Actual word spelled out
Purpose of use (major ap-
plicable machine (*1), or
component/system)
Explanation
ECM Electronic Control Mod-
ule Electronic control system
Electronic control device uses the signals from
the sensors on the machine. These signals indi-
cate the optimum actuation to the actuators.
(Same as ECU)
ECMV Electronic Control Mod-
ulation Valve
Transmission Proportional electromagnetic valve that gradually
increases oil pressure to engage clutch and re-
duces transmission shock.
(D, HD, WA, etc)
ECSS Electronically Controlled
Suspension System
Travel This system ensures smooth high-speed travel
by absorbing vibration of machine during travel
with hydraulic spring effect of accumulator.
(WA)
ECU Electronic Control Unit Electronic control system
Electronic control device uses the signals from
the sensors on the machine. These signals indi-
cate the optimum actuation to the actuators.
(Same as ECM)
EGR Exhaust Gas Recircula-
tion Engine
This function recirculates part of exhaust gas to
combustion chamber in order to reduce combus-
tion temperature, controls emission of NOx.
EMMS Equipment Manage-
ment Monitoring System Machine monitor
This system allows data (filter, oil replacement in-
terval, malfunctions on machine, failure code,
and failure history) from each sensor on the ma-
chine to be checked on the monitor.
EPC Electromagnetic Propor-
tional Control Hydraulic system This mechanism allows actuators to be operated
in proportion to the current supplied.
FOPS Falling Object Protective
Structure Cab and canopy
This structure protects the operator's head from
falling objects.
This performance is standardized as ISO 3449.
F-N-R Forward-Neutral-Re-
verse Operation Forward - Neutral - Reverse
GPS Global Positioning Sys-
tem
Communication Global Positioning System: This system uses sat-
ellites to determine the current location on the
earth.
(KOMTRAX, KOMTRAX
Plus)
GNSS Global Navigation Satel-
lite System
Communication Global Navigation Satellite System: This system
uses satellites such as GPS, GALILEO, etc. to
determine the current location on the earth.
(KOMTRAX, KOMTRAX
Plus)
HSS Hydrostatic Steering
System
Steering This function uses a combination of hydraulic
motor and bevel shaft to control difference in
travel speed of right and left tracks. Accordingly
machine can turn without using steering clutch.
(D)
HST Hydro Static Transmis-
sion
Transmission This function uses a combination of hydraulic
pump and hydraulic motor for stepless shifting of
the speed range without using gears.
(D, WA)
ICT Information and Com-
munication Technology
Communication and elec-
tronic control
A general term for the engineering and its social-
ly applied technology of information processing
and communication.
IMA Inlet Metering Actuator Engine
This valve is installed at inlet port of pump, and it
adjusts fuel intake amount in order to control fuel
discharged volume of supply pump. (Same as
IMV)
ABBREVIATION LIST 00 INDEX AND FOREWORD
00-16 PC78US-10
Abbrevia-
tion Actual word spelled out
Purpose of use (major ap-
plicable machine (*1), or
component/system)
Explanation
IMU Inertial Measurement
Unit Engine
This is a device to detect the angle (or angular
velocity) and acceleration of the 3 axes that con-
trol motions.
IMV Inlet Metering Valve Engine
This valve is installed at inlet port of pump, and it
adjusts fuel intake amount in order to control fuel
discharged volume of supply pump. (Same as
IMA)
KCCV Komatsu Closed Crank-
case Ventilation Engine
This mechanism separates oil in blowby gas and
returns it to the intake side to combust it there. It
primarily consists of filters.
KCSF Komatsu Catalyzed
Soot Filter Engine This filter captures soot in exhaust gas.
It is built in to KDPF.
KDOC Komatsu Diesel Oxida-
tion Catalyst Engine
The catalyst is used for purifying exhaust gas.
It is built in to KDPF or assembled with the muf-
fler.
KDPF Komatsu Diesel Particu-
late Filter Engine
This component is used to purify the exhaust
gas. KDOC (catalyst) and KCSF (filter to capture
soot) are built-in it.
It is installed in place of the conventional muffler.
KTCS Komatsu Traction Con-
trol System
Travel and brake This function recovers the drive force of the
wheels by braking automatically with the opti-
mum force and at the same time activates the in-
ter-axle differential lock when the wheels idle
while the machine travels on the soft ground
road.
(HM)
LCD Liquid Crystal Display Machine monitor Image display equipment such as a monitor
which assembles in the liquid crystal element.
LED Light Emitting Diode Electronic parts It refers to semiconductor element that emits light
when the voltage is applied in forward direction.
LIN Local Interconnect Net-
work
Communication and elec-
tronic control
One of communication standards that is used in
the network on the machine.
LS Load Sensing Hydraulic system
Function that detects differential pressure of
pump and controls discharged volume corre-
sponding to load.
LVDS Low Voltage Differential
Signaling
Communication and elec-
tronic control
One of communication standards that is used in
the network on the machine.
MAF Mass Air Flow Engine
This indicates engine intake air flow. It is not
used independently but it is used as combined
with sensor. Mass air flow sensor can be called
as MAF sensor.
MMS Multimedia Messaging
Service Communication
Service that allows transmission and reception of
short messages consisting of characters or voice
or images between cell phones.
NC Normally Closed Electrical system, Hydraul-
ic system
Characteristics of electrical or hydraulic circuits.
Circuit is normally closed if it is not actuated, and
it opens when it is actuated.
00 INDEX AND FOREWORD ABBREVIATION LIST
PC78US-10 00-17
Abbrevia-
tion Actual word spelled out
Purpose of use (major ap-
plicable machine (*1), or
component/system)
Explanation
NO Normally Open Electrical system, Hydraul-
ic system
Characteristics of electrical or hydraulic circuits.
Circuit is normally open if it is not actuated, and it
closes when it is actuated.
OLSS Open-center Load
Sensing System Hydraulic system Hydraulic system that can operate multiple actua-
tors at the same time, regardless of the load.
PC Pressure Compensation Hydraulic system A function used to correct oil pressure.
PCCS Palm command control
system
Steering System in which a controller instantly analyses
data from each lever, pedal, and dial, and per-
forms optimum electronic control of the engine
and transmission.
(D)
PCV Pre-stroke Control Valve Engine
This valve is installed at inlet port of pump and it
adjusts fuel intake amount in order to control fuel
discharged volume of supply pump.
PPC Proportional Pressure
Control Hydraulic system
This system is used for controlling proportional
pressure. It moves actuators in proportion to the
oil pressure.
PPM Piston Pump and Motor Hydraulic system Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism.
PTP Power Tilt and power
Pitch dozer
Work equipment This function performs hydraulic control of the tilt
and pitch of the bulldozer blade.
(D)
ROPS Roll-Over Protective
Structure Cab and canopy
Sturcture protects the operator who wear the
seatbelt so that he will not be crushed by a ma-
chine when it is tipped. (Operator Protective
structure when tipping)
Structure which is standardized as ISO 3471 or
ISO 12117-2.
SCR Selective Catalytic Re-
duction Urea SCR system
It is exhaust gas purifier using urea water con-
verts nitrogen oxides (NOx) to harmless nitrogen
and water by oxidation-reduction reaction. It may
also be mentioned as exhaust gas purification
catalyst or part of the name of related devices.
SI
Le Systeme Internation-
al d' Unites (Internation-
al unit system)
Unit
Abbreviation for "Le Systeme International d' Uni-
tes". It is the universal unit system and "a single
unit for a single quantity" is the basic principle ap-
plied.
SOL Solenoid Electrical system
It refers to an actuator consisting of a solenoid
and an iron core that is moved by the magnetic
force when the solenoid is energized.
TOPS Tip-Over Protectuive
Structure Cab and canopy
Sturcture protects the operator who wear the
seatbelt so that he will not be crushed by a ma-
chine when it is overtuned.(Hydraulic excavator
tip-over protective structure)
Structure which is standardized as ISO 12117.
TWV 2-Way Valve Hydraulic system Solenoid valve that switches over direction of
flow.
ABBREVIATION LIST 00 INDEX AND FOREWORD
00-18 PC78US-10
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