Day: June 8, 2025

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC88MR, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavators PC88MR workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

CEBM007301 – Hydraulic Excavator PC88MR-8 Shop Manual.pdf
SEN04329-11 – Hydraulic Excavator PC88MR-8 Shop Manual.pdf
SEN06467-02 – Hydraulic Excavator PC88MR-10 Shop Manual.pdf
TEN00287-06 – Hydraulic Excavator PC88MR-8 Operation & Maintenance Manual.pdf
TEN00468-01 – Hydraulic Excavator PC88MR-8 Operation & Maintenance Manual.pdf
WEAM009700 – Hydraulic Excavator PC80MR-3 Operation & Maintenance Manual.pdf
CEAM021202 – Hydraulic Excavator PC88MR-8 Operation & Maintenance Manual.pdf

Total Pages: 4,973 pages
File Format: PDF
Language: English

EEAM004900 – Hydraulic Excavator PC95-1 Operation & Maintenance Manual….2
CONTENTS….11
FOREWORD….4
SAFETY INFORMATION….5
INTRODUCTION….7
PERMITTED USES….7
MAIN FEATURES….7
RUNNING IN THE MACHINE….7
LOCATION OF MACHINE COMPONENT IDENTIFICATION PLATES….9
SERIAL NUMBERS AND ADDRESS OF DEALER….10
SAFETY AND ACCIDENT PREVENTION….17
1. SAFETY MEASURES ….18
1.1 GENERAL PRECAUTIONS ….18
1.2 SAFETY DEVICES ….18
1.3 PERSONAL PROTECTIVE CLOTHING AND EQUIPMENT ….18
1.4 UNAUTHORISED MODIFICATIONS ….19
1.5 LEAVING THE DRIVING SEAT ….19
1.6 ENTERING AND LEAVING THE MACHINE ….20
1.7 PREVENTION OF FUEL AND OIL FIRES ….20
1.8 PREVENTION OF BURNS AND SCALDING ….21
1.9 PREVENTION OF ASBESTOS DUST CONTAMINATION ….22
1.10 PREVENTION OF INJURY BY WORK EQUIPMENT ….22
1.11 FIRE EXTINGUISHERS AND FIRST AID KIT ….23
1.12 PRECAUTIONS REGARDING THE CAB FRAME ….23
1.13 PRECAUTIONS REGARDING EQUIPMENT ….23
PRECAUTIONS….24
2. PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE ….25
2.1 ON-SITE SAFETY ….25
2.2 FIRE PREVENTION ….25
2.3 PRECAUTIONS REGARDING THE CAB ….26
2.4 VENTILATION OF ENCLOSED AREAS ….26
2.5 CLEANING WINDOWS, MIRRORS AND HEADLIGHTS – CHECKING WIPER BLADES, LAMPS ….26
3. PRECAUTIONS TO BE TAKEN WHILE WORKING ….27
3.1 STARTING THE ENGINE ….27
3.2 CHECKS PRIOR TO REVERSING ….27
3.3 MOVING THE MACHINE ….28
3.4 WORKING ON SLOPES ….29
3.5 PREVENTION OF ELECTROCUTION ….30
3.6 VISIBILITY ….31
3.7 WORKING ON FROZEN OR SNOW-COVERED GROUND ….31
3.8 PREVENTION OF DAMAGE BY THE EQUIPMENT ….31
3.9 WORKING ON LOOSE OR PLOUGHED SOIL ….31
3.10 PARKING THE MACHINE ….32
4. TRANSPORTING THE MACHINE ON ANOTHER VEHICLE ….33
4.1 LOADING AND UNLOADING ….33
4.2 THE ROUTE ….33
5. THE BATTERY ….34
5.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES ….34
5.2 STARTING THE ENGINE WITH JUMP LEADS ….34
6. PRECAUTIONS FOR EMERGENCY RECOVERY ….35
7. PRECAUTIONS TO BE TAKEN DURING MAINTENANCE ….36
7.1 WARNING NOTICES ….36
7.2 TOOLS ….36
7.3 PERSONAL PRECAUTIONS ….36
7.4 EQUIPMENT ….37
7.5 KEEPING THE MACHINE CLEAN ….37
7.6 RUNNING THE ENGINE DURING MAINTENANCE ….37
7.7 RULES FOR REFUELLING AND ADDING OIL ….38
7.8 LEVEL OF COOLANT IN THE RADIATOR ….38
7.9 USING LAMPS ….39
7.10 BATTERY AND ALTERNATOR PRECAUTIONS ….39
7.11 PRECAUTIONS REGARDING HIGH PRESSURE HOSES ….40
7.12 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH PRESSURE SYSTEMS ….40
7.13 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES ….40
7.14 THE RADIATOR COOLING FAN AND FAN BELT ….41
8. SAFETY AND NOISE ABATEMENT NOTICES ….42
8.1 LOCATION OF SAFETY NOTICES ….42
8.2 LOCATION OF NOISE ABATEMENT NOTICES ….43
TECHNICAL SPECIFICATIONS ….44
OVERALL DIMENSIONS WITH MONOBLOCK BOOM….45
OVERALL DIMENSIONS WITH ARTICULATED BOOM….45
TECHNICAL SPECIFICATIONS….46
THE MACHINE AND ITS OPERATIONS….47
9. SAFETY DEVICES ….48
9.1 EQUIPMENT SAFETY DEVICES ….48
10. GENERAL VIEWS ….49
10.1 GENERAL VIEW (MONOBLOCK BOOM) ….49
10.2 GENERAL VIEW (ARTICULATED BOOM) ….50
10.3 GENERAL VIEW OF INSIDE OF CAB ….51
11. INSTRUMENTS AND CONTROLS ….52
11.1 INSTRUMENTS, WARNING LIGHTS, AND PUSH-BUTTONS ….52
11.1.1 INSTRUMENTS….53
11.1.2 WARNING LIGHTS AND INDICATORS….53
11.1.3 PUSH-BUTTONS AND SWITCHES….54
11.2 LOCATION OF MACHINE CONTROLS ….57
11.2.1 MACHINE CONTROLS….58
1 – ARTICULATED BOOM CONTROL PEDAL….58
2 – 3 TRANSLATION AND STEERING LEVER….58
4 – BOOM ROTATION PEDAL….59
5 – 6 EQUIPMENT CONTROL LEVERS….60
7 – BLADE CONTROL LEVER….62
8 – ACCELERATOR LEVER….62
9 – SWING LOCK LEVER….62
10 – EQUIPMENT CONTROL LOCK….63
11 – SPEED CONTROL PEDAL….64
12 – WORKING BRAKE….64
12. FUSES AND RELAYS ….65
12.1 FUSES ….65
12.2 RELAYS….67
13. THE CAB AND DRIVING POSITION ….68
13.1 THE CAB ….68
13.2 VENTILATION AND HEATING ….71
13.3 THE DRIVING SEAT ….72
13.4 THE SAFETY BELT ….73
14. OPERATING THE MACHINE ….74
14.1 CHECKS PRIOR TO STARTING THE ENGINE ….74
14.1.1 VISUAL CHECKS….74
14.1.2 DAILY CHECKS….74
14.1.3 OPERATING CHECKS….75
14.2 STARTING THE ENGINE ….76
14.2.1 STARTING A WARM ENGINE AND STARTING IN WARM WEATHER….76
14.2.2 STARTING A COLD ENGINE AND STARTING IN COLD WEATHER….77
14.3 WARMING UP THE ENGINE….77
14.4 WARMING UP THE HYDRAULIC FLUID ….78
14.5 MOVING THE MACHlNE ….78
14.5.1 STEERING AND DIRECTION CHANGING….79
14.5.2 NEGOTIATING SLOPES….81
14.5.3 MAXIMUM DEPTH OF WATER….82
15. PARKING THE MACHINE ….83
15.1 PARKING ON LEVEL GROUND ….83
15.2 PARKING ON A SLOPE ….84
16. STOPPING THE ENGINE ….85
17. TRANSPORTING THE MACHINE ON ANOTHER VEHICLE ….86
17.1 LOADING AND UNLOADING ….86
17.2 THE ROUTE ….87
18. COLD WEATHER PRECAUTIONS ….88
18.1 FUEL AND LUBRICANTS ….88
18.2 COOLANT ….88
18.3 THE BATTERY ….89
18.4 OTHER PRECAUTIONS ….89
18.5 PRECAUTIONS AT THE END OF A WORKING DAY ….89
19. WARM WEATHER PRECAUTIONS ….90
20. USING THE WORK EQUIPMENT ….91
20.1 ORGANISATION OF THE WORK AREA ….91
20.2 POSITIONING THE BUCKET ACCORDING TO THE JOB ….91
20.3 POSITIONING THE MACHINE FOR DIGGING ….92
20.4 DIGGING METHOD ….93
20.5 CHANGING THE WORK EQUIPMENT ….95
20.5.1 CHANGING THE BUCKET….95
21. FAULT FINDING ….96
21.1 RUNNING OUT OF FUEL ….96
21.2 IF THE BATTERY IS FLAT….96
21.2.1 USING JUMP LEADS TO START THE ENGINE….97
21.3 OTHER FAULTS….99
21.3.1 ELECTRICAL SYSTEM….99
21.3.2 ENGINE….100
21.3.3 HYDRAULIC SYSTEM….101
MAINTENANCE….102
22. MAINTENANCE GUIDE ….103
23. MAINTENANCE NOTES ….105
23.1 ENGINE MAINTENANCE NOTES ….105
23.1.1 ENGINE OIL….105
23.1.2 COOLING WATER….106
23.1.3 FUEL….106
23.2 HYDRAULIC SYSTEM MAINTENANCE NOTES ….107
23.3 ELECTRICAL SYSTEM MAINTENANCE NOTES ….107
23.4 NOTES ON LUBRICATION ….108
23.5 PARTS SUBJECT TO RAPID WEAR AND REQUIRING REGULAR REPLACEMENT ….108
24. FUEL, COOLANT, AND LUBRICANTS ….109
25. NUT AND BOLT TIGHTENING TORQUES ….111
25.1 STANDARD TIGHTENING TORQUES ….111
25.2 SPECIAL TIGHTENING TORQUES ….111
26. SCHEDULED MAINTENANCE ….112
26.1 PRE-STARTING CHECKS ….116
26.1.a VARIOUS CHECKS….116
26.1.b CHECKING THE COOLANT LEVEL….116
26.1.c CHECKING THE FUEL LEVEL….117
26.1.d CHECKING THE ENGINE OIL LEVEL….117
26.1.e CHECKING THE LEVEL OF THE HYDRAULIC FLUID….118
26.1.f CHECKING THE ELECTRICAL SYSTEM….119
26.1.g DRAINING THE FUEL LINE WATER TRAP….119
26.2 AFTER THE FIRST 50 HOURS ….120
26.3 EVERY 50 HOURS ….120
26.3.a GREASING THE SWIVEL JOINT….120
26.3.b CLEANING THE ENGINE AIR FILTER DUST TRAP….120
26.4 EVERY 100 HOURS ….121
26.4.a GREASING THE ARTICULATIONS….121
26.4.b CLEANING THE MAIN AIR FILTER ELEMENT….125
26.5 AFTER THE FIRST 250 HOURS ….126
26.6 EVERY 250 HOURS ….126
26.6.a ADJUSTING FAN BELT TENSION….126
26.6.b CHECKING THE ELECTROLYTE LEVEL IN THE BATTERY….127
26.6.c CHECKING THE OIL LEVEL IN THE FINAL DRIVES….128
26.6.d CHECKING THE OIL LEVEL IN THE SWING MOTOR….129
26.6.e CHANGING THE HYDRAULIC SYSTEM FILTER ELEMENT….129
26.6.f CHANGING THE SERVOCONTROL FILTER ELEMENT….131
26.6.g CHANGING THE ENGINE OIL….131
26.6.h CHANGING THE ENGINE OIL FILTER….132
26.7 EVERY 500 HOURS ….133
26.7.a CHANGING THE MAIN AIR FILTER ELEMENT….133
26.7.b DRAINING THE FUEL TANK….133
26.7.c CLEANING THE OUTSIDE OF THE RADIATOR….134
26.7.d CHANGING THE FUEL FILTER AND CLEANING THE FUEL PUMP’S GAUZE FILTER….134
26.7.e CHECKING THE GREASE LEVEL IN THE FIFTH WHEEL PINION GEAR….136
26.7.f GREASING THE FIFTH WHEEL….136
26.8 EVERY 1000 HOURS ….137
26.8.a CHANGING THE AIR FILTER BACKUP ELEMENT….137
26.9 EVERY 2000 HOURS ….138
26.9.a CHANGING THE HYDRAULIC FLUID….138
26.9.b CHANGING THE FINAL DRIVES OIL….139
26.9.c CHANGING THE SWING MOTOR OIL….140
26.9.d CHANGING THE GREASE IN THE FIFTH WHEEL PINION GEAR….141
26.9.e CHANGING THE COOLANT….142
26.9.f CHECKING ENGINE VALVE CLEARANCE….142
26.9.g CHECKING THE ALTERNATOR AND STARTER MOTOR….142
26.10 OCCASIONAL MAINTENANCE….143
26.10.a WASHING OUT THE COOLING SYSTEM….143
26.10.b ADJUSTING TRACK TENSION….144
26.10.c CHECKING THE SECURITY OF THE TRACK SHOES….146
27. EXTENDED PERIODS OF DISUSE ….147
27.1 PREPARING TO LAY UP THE MACHINE ….147
27.2 PREPARING THE MACHINE FOR USE….147
FGAMPC9510 – Hydraulic Excavator PC95-1 Operation & Maintenance Manual….149
CONTENTS ….162
FOREWORD….150
SAFETY INFORMATION ….152
INTRODUCTION ….154
PERMITTED USES ….154
MAIN FEATURES ….154
RUNNING IN THE MACHINE ….154
SUMMARY OF PICTOGRAMS ….156
LOCATION OF MACHINE COMPONENT IDENTIFICATION PLATES ….159
SERIAL NUMBERS AND ADDRESS OF DEALER ….160
POSITION AND CONTENTS OF <<CE>> PLATE ….161
SAFETY AND ACCIDENT PREVENTION….169
1. SAFETY MEASURES ….170
1.1 GENERAL PRECAUTIONS ….170
1.2 SAFETY DEVICES ….170
1.3 PERSONAL PROTECTIVE CLOTHING AND EQUIPMENT ….170
1.4 UNAUTHORISED MODIFICATIONS ….171
1.5 LEAVING THE DRIVING SEAT ….171
1.6 ENTERING AND LEAVING THE MACHINE ….172
1.7 PREVENTION OF FUEL AND OIL FIRES ….172
1.8 PREVENTION OF BURNS AND SCALDING ….173
1.9 PREVENTION OF ASBESTOS DUST CONTAMINATION ….174
1.10 PREVENTION OF INJURY BY WORK EQUIPMENT ….174
1.11 FIRE EXTINGUISHERS AND FIRST AID KIT ….175
1.12 PRECAUTIONS REGARDING THE CAB FRAME ….175
1.13 PRECAUTIONS REGARDING EQUIPMENT ….175
PRECAUTIONS….176
2. PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE ….177
2.1 ON-SITE SAFETY ….177
2.2 FIRE PREVENTION ….177
2.3 PRECAUTIONS REGARDING THE CAB ….178
2.4 VENTILATION OF ENCLOSED AREAS ….178
2.5 CLEANING WINDOWS, MIRRORS AND HEADLIGHTS – CHECKING WIPER BLADES, LAMPS ….178
3. PRECAUTIONS TO BE TAKEN WHILE WORKING ….179
3.1 STARTING THE ENGINE ….179
3.2 CHECKS PRIOR TO REVERSING ….179
3.3 MOVING THE MACHINE ….180
3.4 WORKING ON SLOPES ….181
3.5 PREVENTION OF ELECTROCUTION ….182
3.6 VISIBILITY ….183
3.7 WORKING ON FROZEN OR SNOW-COVERED GROUND ….183
3.8 PREVENTION OF DAMAGE BY THE EQUIPMENT ….183
3.9 WORKING ON LOOSE OR PLOUGHED SOIL ….183
3.10 PARKING THE MACHINE ….184
4. TRANSPORTING THE MACHINE ON ANOTHER VEHICLE ….185
4.1 LOADING AND UNLOADING ….185
4.2 THE ROUTE ….185
5. THE BATTERY ….186
5.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES ….186
5.2 STARTING THE ENGINE WITH JUMP LEADS ….186
6. PRECAUTIONS FOR EMERGENCY RECOVERY ….187
7. PRECAUTIONS TO BE TAKEN DURING MAINTENANCE ….188
7.1 WARNING NOTICES ….188
7.2 TOOLS ….188
7.3 PERSONAL PRECAUTIONS ….189
7.4 EQUIPMENT ….189
7.5 KEEPING THE MACHINE CLEAN ….189
7.6 RUNNING THE ENGINE DURING MAINTENANCE ….190
7.7 RULES FOR REFUELLING AND ADDING OIL ….190
7.8 LEVEL OF COOLANT IN THE RADIATOR ….191
7.9 USING LAMPS ….191
7.10 BATTERY AND ALTERNATOR PRECAUTIONS ….191
7.11 PRECAUTIONS REGARDING HIGH PRESSURE HOSES ….192
7.12 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH PRESSURE SYSTEMS ….192
7.13 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES ….193
7.14 THE RADIATOR COOLING FAN AND FAN BELT ….193
8. SAFETY AND NOISE ABATEMENT NOTICES ….194
8.1 LOCATION OF SAFETY NOTICES ….194
8.2 LOCATION OF NOISE ABATEMENT NOTICES ….195
9. VIBRATIONS TO WHICH THE USER IS SUBJECTED….195
TECHNICAL SPECIFICATIONS….196
10. TECHNICAL SPECIFICATIONS ….197
10.1 OVERALL DIMENSIONS ….197
10.2 TECHNICAL SPECIFICATIONS ….198
10.3 LIFTING CAPACITY ….198
10.3.1 LIFTING CAPACITY WITH MONOBLOCK BOOM….199
10.3.2 LIFTING CAPACITY WITH ARTICULATED BOOM ….200
THE MACHINE AND ITS OPERATIONS….201
11. SAFETY DEVICES ….202
11.1 EQUIPMENT SAFETY DEVICES ….202
12. GENERAL VIEWS ….203
12.1 GENERAL VIEW (MONOBLOCK BOOM) ….203
12.2 GENERAL VIEW (ARTICULATED BOOM) ….204
12.3 GENERAL VIEW OF INSIDE OF CAB ….205
13. INSTRUMENTS AND CONTROLS ….206
13.1 INSTRUMENTS, WARNING LIGHTS, AND PUSH-BUTTONS ….206
13.1.1 INSTRUMENTS ….208
13.1.2 WARNING LIGHTS AND INDICATORS ….208
13.1.3 PUSH-BUTTONS AND SWITCHES ….209
13.1.4 ELECTRICAL ACCESSORIES ….211
13.2 LOCATION OF MACHINE CONTROLS ….213
13.2.1 MACHINE CONTROLS ….214
1 – ARTICULATED BOOM CONTROL PEDAL ….214
2 – 3 TRANSLATION AND STEERING LEVER ….214
4 – BOOM ROTATION PEDAL ….215
5 – 6 EQUIPMENT CONTROL LEVERS ….216
7 – BLADE CONTROL LEVER ….218
8 – ACCELERATOR LEVER ….218
9 – SWING LOCK LEVER ….219
10 – EQUIPMENT CONTROL LOCK ….220
11 – SPEED CONTROL PEDAL ….220
12 – WORKING BRAKE ….221
14. FUSES AND RELAYS ….222
14.1 FUSES ….222
14.2 RELAYS ….224
15. THE CAB AND DRIVING POSITION ….225
15.1 THE CAB ….225
15.2 VENTILATION AND HEATING ….228
15.3 THE DRIVING SEAT ….229
15.4 THE SAFETY BELT ….230
15.5 EMERGENCY EXIT ….231
15.6 FIRE EXTINGUISHERS ….231
15.7 FIRST AID KIT ….232
15.8 TECHNICAL DOCUMENTATION ….232
16. OPERATING THE MACHINE ….233
16.1 CHECKS PRIOR TO STARTING THE ENGINE ….233
16.1.1 VISUAL CHECKS ….233
16.1.2 DAILY CHECKS ….233
16.1.3 OPERATING CHECKS ….234
16.2 STARTING THE ENGINE ….235
16.2.1 STARTING A WARM ENGINE AND STARTING IN WARM WEATHER ….235
16.2.2 STARTING A COLD ENGINE AND STARTING IN COLD WEATHER ….236
16.3 WARMING UP THE ENGINE ….236
16.4 WARMING UP THE HYDRAULIC FLUID ….237
16.5 MOVING THE MACHINE ….237
16.5.1 STEERING AND DIRECTION CHANGING ….238
16.5.2 NEGOTIATING SLOPES ….240
16.5.3 MAXIMUM DEPTH OF WATER ….241
17. PARKING THE MACHINE ….242
17.1 PARKING ON LEVEL GROUND ….242
17.2 PARKING ON A SLOPE ….243
18. STOPPING THE ENGINE ….244
19. TRANSPORTING THE MACHINE ON ANOTHER VEHICLE….244
19.1 LOADING AND UNLOADING ….244
19.2 THE ROUTE ….246
20. COLD WEATHER PRECAUTIONS ….247
20.1 FUEL AND LUBRICANTS ….247
20.2 COOLANT ….247
20.3 THE BATTERY ….248
20.4 OTHER PRECAUTIONS ….248
20.5 PRECAUTIONS AT THE END OF A WORKING DAY ….248
21. WARM WEATHER PRECAUTIONS ….249
22. USING THE WORK EQUIPMENT ….250
22.1 ORGANISATION OF THE WORK AREA ….250
22.2 POSITIONING THE BUCKET ACCORDING TO THE JOB ….250
22.3 POSITIONING THE MACHINE FOR DIGGING ….251
22.4 DIGGING METHOD ….252
22.5 CHANGING THE WORK EQUIPMENT ….254
22.5.1 CHANGING THE BUCKET ….254
23. FAULT FINDING ….255
23.1 RUNNING OUT OF FUEL ….255
23.2 IF THE BATTERY IS FLAT ….255
23.2.1 USING JUMP LEADS TO START THE ENGINE ….256
23.3 OTHER FAULTS….258
23.3.1 ELECTRICAL SYSTEM….258
23.3.2 ENGINE ….259
23.3.3 HYDRAULIC SYSTEM ….260
MAINTENANCE….261
24. MAINTENANCE GUIDE ….262
25. MAINTENANCE NOTES ….264
25.1 ENGINE MAINTENANCE NOTES ….264
25.1.1 ENGINE OIL ….264
25.1.2 COOLING WATER ….265
25.1.3 FUEL ….265
25.2 HYDRAULIC SYSTEM MAINTENANCE NOTES ….266
25.3 ELECTRICAL SYSTEM MAINTENANCE NOTES ….266
25.4 NOTES ON LUBRICATION ….267
25.5 PARTS SUBJECT TO RAPID WEAR AND REQUIRING REGULAR REPLACEMENT ….267
26. FUEL, COOLANT, AND LUBRICANTS ….268
27. NUT AND BOLT TIGHTENING TORQUES ….270
27.1 STANDARD TIGHTENING TORQUES ….270
27.2 SPECIAL TIGHTENING TORQUES ….270
28. LUBRICATION ….271
28.1 LUBRICATION CHART ….271
29. SCHEDULED MAINTENANCE….272
29.1 PRE-STARTING CHECKS ….275
29.1.a VARIOUS CHECKS ….275
29.1.b CHECKING THE COOLANT LEVEL ….275
29.1.c CHECKING THE FUEL LEVEL ….276
29.1.d CHECKING THE ENGINE OIL LEVEL ….276
29.1.e CHECKING THE LEVEL OF THE HYDRAULIC FLUID….277
29.1.f CHECKING THE ELECTRICAL SYSTEM ….278
29.1.g DRAINING THE FUEL LINE WATER TRAP ….278
29.2 AFTER THE FIRST 50 HOURS ….279
29.3 EVERY 50 HOURS….279
29.3.a GREASING THE SWIVEL JOINT….279
29.3.b CLEANING THE ENGINE AIR FILTER DUST TRAP….279
29.4 EVERY 100 HOURS….280
29.4.a GREASING THE ARTICULATIONS….280
29.4.b CLEANING….283
29.4.c GREASING THE FIFTH WHEEL….284
29.4.d LUBRICATION OF THE OVERLOAD DEVICE CAM….284
29.5 AFTER THE FIRST 250 HOURS….284
29.6 EVERY 250 HOURS….285
29.6.a ADJUSTING FAN BELT TENSION….285
29.6.b CHECKING THE ELECTROLYTE LEVEL IN THE BATTERY….285
29.6.c CHECKING THE OIL LEVEL IN THE F….286
29.6.d CHECKING THE OIL LEVEL IN THE SWING….287
29.6.e CHANGING THE HYDRAULIC SYSTEM FILTER ELEMENT….287
29.6.f CHANGING THE SERVOCONTROL FILTER ELEMENT….288
29.6.g CHANGING THE ENGINE OIL….289
29.6.h CHANGING THE ENGINE OIL FILTER….290
29.7 EVERY 500 HOURS….291
29.7.a CHANGING THE MAIN AIR FILTER ELEMENT….291
29.7.b DRAINING THE FUEL TANK….291
29.7.c CLEANING THE OUTSIDE OF THE RADIATOR….292
29.7.d CHANGING THE FUEL FILTER AND CLEANING THE FUEL PUMP’S GAUZE FILTER….292
29.7.e CHECKING THE GREASE LEVEL IN THE FIFTH WHEEL PINION GEAR….294
29.8 EVERY 1000 HOURS….295
29.8.a CHANGING THE AIR FILTER BACKUP ELEMENT….295
29.9 EVERY 2000 HOURS….296
29.9.a CHANGING THE HYDRAULIC FLUID….296
29.9.b CHANGING THE FINAL DRIVES OIL….298
29.9.c CHANGING THE SWING MOTOR OIL….298
29.9.d CHANGING THE GREASE IN THE FIFTH WHEEL PINION GEAR….300
29.9.e CHANGING THE COOLANT….301
29.9.f CHECKING ENGINE VALVE CLEARANCE….302
29.9.g CHECKING THE ALTERNATOR AND STARTER MOTOR….302
29.10 OCCASIONAL MAINTENANCE….303
29.10.a WASHING OUT THE COOLING SYSTEM….303
29.10.b ADJUSTING TRACK TENSION….304
29.10.c CHECKING THE SECURITY OF THE TRACK SHOES….306
30. EXTENDED PERIODS OF DISUSE ….307
30.1 PREPARING TO LAY UP THE MACHINE ….307
30.2 PREPARING THE MACHINE FOR USE ….308
AUTHORISED OPTIONAL EQUIPMENT….309
31. AUTHORISED OPTIONAL EQUIPMENT ….310
31.1 OPTIONAL EQUIPMENT CHARACTERISTICS….310
32. DEMOLITION HAMMER ….311
32.1 DESCRIPTION AND OPERATION ….311
32.2 FITTING AND REMOVING THE DEMOLITION HAMMER ….311
32.2.1 FITTING THE DEMOLITION HAMMER ….311
32.2.2 REMOVING THE DEMOLITION HAMMER ….314
33. CLAMSHELL BUCKET….315
33.1 DESCRIPTION AND OPERATION….315
33.2 FITTING THE CLAMSHELL BUCKET ….316
WEAMPC9501 – Hydraulic Excavator PC95-1 Operation & Maintenance Manual….320
FOREWORD….322
SAFETY INFORMATION….324
INTRODUCTION….326
PERMITTED USES….326
MAIN FEATURES….326
RUNNING IN THE MACHINE….326
SUMMARY OF PICTOGRAMS….328
LOCATION OF MACHINE COMPONENT IDENTIFICATION PLATES….331
SERIAL NUMBERS AND ADDRESS OF DEALER….332
POSITION AND CONTENTS OF <<CE>> PLATE….333
CONTENTS….334
SAFETY AND ACCIDENT PREVENTION….342
1. SAFETY MEASURES….343
1.1 GENERAL PRECAUTIONS….343
1.2 SAFETY DEVICES….343
1.3 PERSONAL PROTECTIVE CLOTHING AND EQUIPMENT….343
1.4 UNAUTHORISED MODIFICATIONS….344
1.5 LEAVING THE DRIVING SEAT….344
1.6 ENTERING AND LEAVING THE MACHINE….345
1.7 PREVENTION OF FUEL AND OIL FIRES….345
1.8 PREVENTION OF BURNS AND SCALDING….346
1.9 PREVENTION OF ASBESTOS DUST CONTAMINATION….347
1.10 PREVENTION OF INJURY BY WORK EQUIPMENT….347
1.11 FIRE EXTINGUISHERS AND FIRST AID KIT….348
1.12 PRECAUTIONS REGARDING THE CAB FRAME….348
1.13 PRECAUTIONS REGARDING EQUIPMENT….348
PRECAUTIONS….350
2. PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE….351
2.1 ON-SITE SAFETY….351
2.2 FIRE PREVENTION….351
2.3 PRECAUTIONS REGARDING THE CAB….352
2.4 VENTILATION OF ENCLOSED AREAS….352
2.5 CLEANING WINDOWS, MIRRORS AND HEADLIGHTS – CHECKING WIPER BLADES, LAMPS….352
3. PRECAUTIONS TO BE TAKEN WHILE WORKING….353
3.1 STARTING THE ENGINE….353
3.2 CHECKS PRIOR TO REVERSING….353
3.3 MOVING THE MACHINE….354
3.4 WORKING ON SLOPES….355
3.5 PREVENTION OF ELECTROCUTION….356
3.6 VISIBILITY….357
3.7 WORKING ON FROZEN OR SNOW-COVERED GROUND….357
3.8 PREVENTION OF DAMAGE BY THE EQUIPMENT….357
3.9 WORKING ON LOOSE OR PLOUGHED SOIL….357
3.10 PARKING THE MACHINE….358
4. TRANSPORTING THE MACHINE ON ANOTHER VEHICLE….359
4.1 LOADING AND UNLOADING….359
4.2 THE ROUTE….359
5. THE BATTERY….360
5.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES….360
5.2 STARTING THE ENGINE WITH JUMP LEADS….360
6. PRECAUTIONS FOR EMERGENCY RECOVERY….361
7. PRECAUTIONS TO BE TAKEN DURING MAINTENANCE….362
7.1 WARNING NOTICES….362
7.2 TOOLS….362
7.3 PERSONAL PRECAUTIONS….363
7.4 EQUIPMENT….363
7.5 KEEPING THE MACHINE CLEAN….363
7.6 RUNNING THE ENGINE DURING MAINTENANCE….364
7.7 RULES FOR REFUELLING AND ADDING OIL….364
7.8 LEVEL OF COOLANT IN THE RADIATOR….365
7.9 USING LAMPS….365
7.10 BATTERY AND ALTERNATOR PRECAUTIONS….365
7.11 PRECAUTIONS REGARDING HIGH PRESSURE HOSES….366
7.12 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH PRESSURE SYSTEMS….366
7.13 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES….367
7.14 THE RADIATOR COOLING FAN AND FAN BELT….367
8. SAFETY AND NOISE ABATEMENT NOTICES….368
8.1 LOCATION OF SAFETY NOTICES….368
8.2 LOCATION OF NOISE ABATEMENT NOTICES….369
9. VIBRATIONS TO WHICH THE USER IS SUBJECTED….369
TECHNICAL SPECIFICATIONS….370
10.TECHNICAL SPECIFICATIONS….371
10.1 OVERALL DIMENSIONS….371
10.2 TECHNICAL SPECIFICATIONS….372
10.3 LIFTING CAPACITY….372
10.3.1 LIFTING CAPACITY TABLE….373
10.3.2 LIFTING CAPACITY WITH MONOBLOCK BOOM….375
10.3.3 LIFTING CAPACITY WITH ARTICULATED BOOM….376
THE MACHINE AND ITS OPERATIONS….378
11. SAFETY DEVICES….379
11.1 EQUIPMENT SAFETY DEVICES….379
12. GENERAL VIEWS….380
12.1 GENERAL VIEW (MONOBLOCK BOOM)….380
12.2 GENERAL VIEW (ARTICULATED BOOM)….381
12.3 GENERAL VIEW OF INSIDE OF CAB….382
13. INSTRUMENTS AND CONTROLS….383
13.1 INSTRUMENTS, WARNING LIGHTS, AND PUSH-BUTTONS….383
13.1.1 INSTRUMENTS….385
13.1.2 WARNING LIGHTS AND INDICATORS….385
13.1.3 PUSH-BUTTONS AND SWITCHES….386
13.1.4 ELECTRICAL ACCESSORIES….389
13.2 LOCATION OF MACHINE CONTROLS….390
13.2.1 MACHINE CONTROLS….391
1 – ARTICULATED BOOM CONTROL PEDAL….391
2 – 3 TRANSLATION AND STEERING LEVER….391
4 – BOOM ROTATION PEDAL….392
5 – 6 EQUIPMENT CONTROL LEVERS….393
7 – BLADE CONTROL LEVER….395
8 – ACCELERATOR LEVER….395
9 – SWING LOCK LEVER….396
10 – EQUIPMENT CONTROL LOCK….397
11 – WORKING BRAKE….398
14. FUSES AND RELAYS….399
14.1 FUSES….399
14.2 RELAYS….401
15. THE CAB AND DRIVING POSITION….402
15.1 THE CAB….402
15.2 VENTILATION AND HEATING….405
15.3 THE DRIVING SEAT….406
15.4 THE SAFETY BELT….407
15.5 EMERGENCY EXIT….408
15.6 FIRE EXTINGUISHERS….408
15.7 FIRST AID KIT….409
15.8 TECHNICAL DOCUMENTATION….409
16. OPERATING THE MACHINE….410
16.1 CHECKS PRIOR TO STARTING THE ENGINE….410
16.1.1 VISUAL CHECKS….410
16.1.2 DAILY CHECKS….410
16.1.3 OPERATING CHECKS….411
16.2 STARTING THE ENGINE….412
16.2.1 STARTING A WARM ENGINE AND STARTING IN WARM WEATHER….412
16.2.2 STARTING A COLD ENGINE AND STARTING IN COLD WEATHER….413
16.3 WARMING UP THE ENGINE….413
16.4 WARMING UP THE HYDRAULIC FLUID….414
16.5 MOVING THE MACHINE….414
16.5.1 STEERING AND DIRECTION CHANGING….415
16.5.2 NEGOTIATING SLOPES….417
16.5.3 MAXIMUM DEPTH OF WATER….418
17. PARKING THE MACHINE….419
17.1 PARKING ON LEVEL GROUND….419
17.2 PARKING ON A SLOPE….420
18. STOPPING THE ENGINE….421
19. TRANSPORTING THE MACHINE ON ANOTHER VEHICLE….421
19.1 LOADING AND UNLOADING….421
19.2 THE ROUTE….423
20. COLD WEATHER PRECAUTIONS….424
20.1 FUEL AND LUBRICANTS….424
20.2 COOLANT….424
20.3 THE BATTERY….425
20.4 OTHER PRECAUTIONS….425
20.5 PRECAUTIONS AT THE END OF A WORKING DAY….425
21. WARM WEATHER PRECAUTIONS….426
22. USING THE WORK EQUIPMENT….427
22.1 ORGANISATION OF THE WORK AREA….427
22.2 POSITIONING THE BUCKET ACCORDING TO THE JOB….427
22.3 POSITIONING THE MACHINE FOR DIGGING….428
22.4 DIGGING METHOD….429
22.5 CHANGING THE WORK EQUIPMENT….431
22.5.1 CHANGING THE BUCKET….431
23. FAULT FINDING….432
23.1 RUNNING OUT OF FUEL….432
23.2 IF THE BATTERY IS FLAT….432
23.2.1 USING JUMP LEADS TO START THE ENGINE….433
23.3 OTHER FAULTS….435
23.3.1 ELECTRICAL SYSTEM….435
23.3.2 ENGINE….436
23.3.3 HYDRAULIC SYSTEM….437
MAINTENANCE….438
24. MAINTENANCE GUIDE….439
25. MAINTENANCE NOTES….441
25.1 ENGINE MAINTENANCE NOTES….441
25.1.1 ENGINE OIL….441
25.1.2 COOLING WATER….442
25.1.3 FUEL….442
25.2 HYDRAULIC SYSTEM MAINTENANCE NOTES….443
25.3 ELECTRICAL SYSTEM MAINTENANCE NOTES….443
25.4 NOTES ON LUBRICATION….444
25.5 PARTS SUBJECT TO RAPID WEAR AND REQUIRING REGULAR REPLACEMENT….444
26. FUEL, COOLANT, AND LUBRICANTS….445
27. NUT AND BOLT TIGHTENING TORQUES….447
27.1 STANDARD TIGHTENING TORQUES….447
27.2 SPECIAL TIGHTENING TORQUES….447
28. LUBRICATION….448
28.1 LUBRICATION CHART….448
29. SCHEDULED MAINTENANCE….449
29.1 PRE-STARTING CHECKS….452
29.1.a VARIOUS CHECKS….452
29.1.b CHECKING THE COOLANT LEVEL….452
29.1.c CHECKING THE FUEL LEVEL….453
29.1.d CHECKING THE ENGINE OIL LEVEL….453
29.1.e CHECKING THE LEVEL OF THE HYDRAULIC FLUID….454
29.1.f CHECKING THE ELECTRICAL SYSTEM….455
29.1.g DRAINING THE FUEL LINE WATER TRAP….455
29.2 AFTER THE FIRST 50 HOURS….456
29.3 EVERY 50 HOURS….456
29.3.a GREASING THE SWIVEL JOINT….456
29.3.b CLEANING THE ENGINE AIR FILTER DUST TRAP….456
29.4 EVERY 100 HOURS….457
29.4.a GREASING THE ARTICULATIONS….457
29.4.b CLEANING THE MAIN AIR FILTER ELEMENT….460
29.4.c GREASING THE FIFTH WHEEL….461
29.4.d LUBRICATION OF THE OVERLOAD DEVICE CAM….461
29.5 AFTER THE FIRST 250 HOURS….461
29.6 EVERY 250 HOURS….462
29.6.a ADJUSTING FAN BELT TENSION….462
29.6.b CHECKING THE ELECTROLYTE LEVEL IN THE BATTERY….462
29.6.c CHECKING THE OIL LEVEL IN THE FINAL DRIVES….463
29.6.d CHECKING THE OIL LEVEL IN THE SWING MOTOR….464
29.6.e CHANGING THE HYDRAULIC SYSTEM FILTER ELEMENT….464
29.6.f CHANGING THE SERVOCONTROL FILTER ELEMENT….465
29.6.g CHANGING THE ENGINE OIL….466
29.6.h CHANGING THE ENGINE OIL FILTER….467
29.7 EVERY 500 HOURS….468
29.7.a CHANGING THE MAIN AIR FILTER ELEMENT….468
29.7.b DRAINING THE FUEL TANK….468
29.7.c CLEANING THE OUTSIDE OF THE RADIATOR….469
29.7.d CHANGING THE FUEL FILTER AND CLEANING THE FUEL PUMP’S GAUZE FILTER….469
29.7.e CHECKING THE GREASE LEVEL IN THE FIFTH WHEEL PINION GEAR….471
29.8 EVERY 1000 HOURS….472
29.8.a CHANGING THE AIR FILTER BACKUP ELEMENT….472
29.9 EVERY 2000 HOURS….473
29.9.a CHANGING THE HYDRAULIC FLUID….473
29.9.b CHANGING THE FINAL DRIVES OIL….475
29.9.c CHANGING THE SWING MOTOR OIL….475
29.9.d CHANGING THE GREASE IN THE FIFTH WHEEL PINION GEAR….477
29.9.e CHANGING THE COOLANT….478
29.9.f CHECKING ENGINE VALVE CLEARANCE….479
29.9.g CHECKING THE ALTERNATOR AND STARTER MOTOR….479
29.10 OCCASIONAL MAINTENANCE….480
29.10.a WASHING OUT THE COOLING SYSTEM….480
29.10.b ADJUSTING TRACK TENSION….481
29.10.c CHECKING THE SECURITY OF THE TRACK SHOES….483
30. EXTENDED PERIODS OF DISUSE….484
30.1 PREPARING TO LAY UP THE MACHINE….484
30.2 PREPARING THE MACHINE FOR USE….485
AUTHORISED OPTIONAL EQUIPMENT….486
31. AUTHORISED OPTIONAL EQUIPMENT….487
31.1 OPTIONAL EQUIPMENT CHARACTERISTICS….487
32. DEMOLITION HAMMER….488
32.1 DESCRIPTION AND OPERATION….488
32.2 FITTING AND REMOVING THE DEMOLITION HAMMER….488
32.2.1 FITTING THE DEMOLITION HAMMER….488
32.2.2 REMOVING THE DEMOLITION HAMMER….491
33. CLAMSHELL BUCKET….492
33.1 DESCRIPTION AND OPERATION….492
33.2 FITTING THE CLAMSHELL BUCKET….493
WEBMPC9500 – Hydraulic Excavator PC95-1 Shop Manual….496
COVER PAGE….496
CONTENTS….498
10 STRUCTURE AND FUNCTION….511
P.T.O…512
POWER TRAIN….513
FINAL DRIVE – SPROCKET….514
TRACK FRAME….515
IDLER AND RECOIL SPRING….516
CARRIER ROLLER….517
TRACK ROLLER….517
TRACK SHOE….518
SWING CIRCLE….519
SWING MACHINERY….520
CHECK VALVE AND OIL COOLER SAFETY BY-PASS….521
HYDRAULIC CIRCUIT DIAGRAM….522
MAIN HYDRAULIC PUMP….523
PUMP DRIVE….524
SUMMATION HORSEPOWER CONTROL….525
3 CIRCUIT CONTROL VALVE….528
MODE-SYSTEM….530
AUXILIARY PUMP….531
CONTROL VALVE (Ports)….532
CONTROL VALVE (Valve)….534
SWING MOTOR….535
SWING MOTOR RELIEF VALVE….536
CENTER SWIVEL JOINT….537
TRAVEL MOTOR….538
TRAVEL ACCELERATION VALVE….539
SERVOCONTROL FEED UNIT….540
SWING MOTOR BRAKING CIRCUIT SELECTOR VALVE….542
ACCUMULATOR….543
R.H. PPC VALVE….544
L.H. PPC VALVE….545
TRAVEL PPC VALVE….546
2nd BOOM PPC VALVE….547
BOOM SWING PPC VALVE….548
BLADE PPC VALVE….549
BLADE SAFETY VALVE….550
SOLENOID VALVES….551
ELECTRICAL CIRCUIT DIAGRAM (Engine Line)….553
ELECTRICAL CIRCUIT DIAGRAM (Solenoid Valve)….555
ELECTRICAL CIRCUIT DIAGRAM (Light Line)….557
20 TESTING AND ADJUSTMENTS….559
NORMAL OR STANDARD TECHNICAL DATA….560
EQUIPMENT FOR TESTING, ADJUSTING, AND IDENTIFYING FAULTS….577
MEASURING THE ENGINE SPEED….579
VALVE CLEARANCE ADJUSTMENT….580
MEASUREMENT OF COMPRESSION PRESSURE….581
CHECKING AND TIGHTENING THE FAN-BELT….582
ADJUSTING THE STROKE OF THE ACCELERATOR LEVER….583
ADJUSTING PPC VALVES CLEARANCE….584
ADJUSTING THE SAFETY MICROSWITCH….586
CENTRING THE STROKE OF THE BLADE CONTROL LEVER….586
MEASURING THE SWING CIRCLE AXIAL CLEARANCE….587
TESTING AND ADJUSTING TRACK-SHOE TENSION….588
BLEEDING AIR – RELEASING RESIDUAL PRESSURE….589
Bleeding air from pumps P1 and P2….589
Bleeding air from the PPC valves circuit….589
Bleeding air from the cylinders….590
Releasing residual pressure from the circuits….590
CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS….591
CHECKING THE INTERVENTION POINT OF THE SUMMATION HORSEPOWER CONTROL….597
CHECKING THE INITIAL HORSEPOWER CONTROL POINT FOR THE 3-CIRCUIT CONTROL VALVE….598
CHECKING AND ADJUSTING PRESSURES IN THE SERVOCONTROL SUPPLY UNITS….599
ADJUSTING THE MAIN SAFETY VALVE OF PUMP P4….600
MEASURING PUMP DELIVERY….601
MEASURING TRAVEL DEVIATION….602
ADJUSTING THE MAXIMUM SPEED OF THE TRAVEL MOTORS….603
CHECKING THE CORRECT FUNCTIONING OF THE TRAVEL ACCELERATION VALVE….605
TESTING FOR INTERNAL OIL LEAKAGE IN THE TRAVEL MOTORS….606
ADJUSTING BOOM AND ARM SAFETY VALVES….607
ADJUSTING 2nd BOOM SAFETY VALVES….608
MEASURING THE INITIAL INTERVENTION POINT OF THE OVERLOAD SENSOR….609
ADJUSTING THE VALVE THAT CONTROLS THE CLOSING SPEED OF THE 2nd BOOM….610
MEASUREMENT OF INTERNAL OIL LEAKAGES IN THE SWING MOTOR….611
CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT….612
ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS….614
1. Boom test….614
2. Arm test….614
3. Testing the functionality of the boom and arm safety valve….615
4. 2nd boom test….616
5. Testing the functionality of the 2nd boom safety valves….617
6. Bucket test….617
7. Boom swing test….618
8. Blade test….618
9. Swing motor test….619
10. Testing the travel motors….620
TROUBLESHOOTING….623
PROCEDURES TO FOLLOW WHILE TROUBLESHOOTING….624
RULES TO BE OBSERVED WHEN WORKING ON HYDRAULIC CIRCUITS OR EQUIPMENT….625
TABLE OF FAILURE MODES AND CAUSES TESTS TO BE CARRIED OUT BEFORE TROUBLESHOOTING….627
EXCESSIVE TRAVEL DEVIATION….628
THE MACHINE DEVIATES EXCESSIVELY AT THE COMMENCEMENT OF TRAVEL….632
WORK EQUIPMENT, REVOLVING FRAME SWING AND TRAVEL ARE SLOW OR WITHOUT POWER….633
WORK EQUIPMENT, REVOLVING FRAME SWING AND TRAVEL MECHANISMS FUNCTION INTERMITTENTLY….634
THE REVOLVING FRAME SWING SPEED IS SLOW IN BOTH DIRECTIONS….635
THE REVOLVING FRAME SWING SPEED IS SLOW IN ONE DIRECTION, AND DOES NOT BRAKE PROPERLY ON THAT SIDE….636
DIFFICULTIES WITH RAISING OR LOWERING THE BOOM….637
EXCESSIVE RESPONSE TIME FOR THE BOOM, ARM AND BUCKET….638
BOOM SLOW TO RISE – ARM SLOW TO CLOSE….640
THE SERVOCONTROL SUPPLY GROUP DOES NOT FUNCTION OR THE PRESSURE IS UNSTABLE ….641
THE CONTROL LEVERS MOVE, BUT EQUIPMENT MOVEMENTS ARE INCOMPLETE OR HAVE NO EFFECT….642
SPEEDS DO NOT CHANGE IF THE WORKING MODE SELECTOR IS POSITIONED ON E….644
ABNORMAL NOISES IN THE PUMPS….644
ENGINE LOSES POWER OR STALLS DURING WORK….645
30 DISASSEMBLY AND ASSEMBLY….646
HOW TO READ THE MANUAL….648
PRECAUTIONS TO BE TAKEN WHEN WORKING….649
SPECIAL TOOLS….650
STARTER MOTOR….652
REMOVAL AND INSTALLATION….652
ALTERNATOR….653
REMOVAL AND INSTALLATION….653
NOZZLE HOLDER….654
REMOVAL AND INSTALLATION….654
AIR FILTER GROUP….655
REMOVAL AND INSTALLATION….655
MUFFLER….656
REMOVAL….656
INSTALLATION….657
ENGINE HOOD….658
REMOVAL AND INSTALLATION….658
FIXED HOOD….659
REMOVAL….659
INSTALLATION….660
SEAT….661
REMOVAL AND INSTALLATION….661
CABIN….662
REMOVAL AND INSTALLATION….662
COUNTERWEIGHT….663
REMOVAL AND INSTALLATION….663
RADIATOR….664
REMOVAL AND INSTALLATION….664
HYDRAULIC OIL COOLER….665
REMOVAL AND INSTALLATION….665
HEATING FAN….666
REMOVAL….666
INSTALLATION….667
FUEL TANK….668
REMOVAL AND INSTALLATION….668
HYDRAULIC OIL TANK….669
REMOVAL AND INSTALLATION….669
ENGINE-PUMP GROUP….670
REMOVAL….670
INSTALLATION….672
PUMP GROUP….673
REMOVAL AND INSTALLATION….673
HYDRAULIC PUMP….674
DISASSEMBLY….674
ASSEMBLY….681
GEAR-PUMP….687
REMOVAL AND INSTALLATION….687
DISASSEMBLY….688
ASSEMBLY….691
ENGINE-PUMP COUPLING JOINT….696
REMOVAL AND INSTALLATION….696
SWIVEL JOINT….697
REMOVAL AND INSTALLATION….697
SWING MOTOR….698
REMOVAL AND INSTALLATION….698
SWING MACHINERY….699
REMOVAL AND INSTALLATION….699
DISASSEMBLY….700
ASSEMBLY….708
REVOLVING FRAME….719
REMOVAL….719
INSTALLATION….720
SWING CIRCLE….721
REMOVAL AND INSTALLATION….721
TRAVEL MOTOR….722
REMOVAL AND INSTALLATION….722
TRACK SHOES….723
REMOVAL AND INSTALLATION….723
SPROCKET….724
REMOVAL AND INSTALLATION….724
FINAL DRIVE….725
REMOVAL AND INSTALLATION….725
DISASSEMBLY….726
ASSEMBLY….732
IDLER AND RECOIL SPRING….742
REMOVAL AND INSTALLATION….742
IDLER….743
DISASSEMBLY AND ASSEMBLY….743
RECOIL SPRING AND CYLINDER….744
DISASSEMBLY AND ASSEMBLY….744
TRACK ROLLER….745
REMOVAL AND INSTALLATION….745
CARRIER ROLLER….746
REMOVAL AND INSTALLATION….746
R.H. PPC VALVE (BOOM – BUCKET)….747
REMOVAL AND INSTALLATION….747
L.H. PPC VALVE (ARM-SWING)….748
REMOVAL AND INSTALLATION….748
BLADE PPC VALVE….749
REMOVAL AND INSTALLATION….749
PPC VALVE (For travel, boom swing, 2-piece boom)….750
REMOVAL AND INSTALLATION….750
SERVOCONTROL FEED UNIT….751
REMOVAL AND INSTALLATION….751
CONTROL VALVE….752
REMOVAL AND INSTALLATION….752
BOOM CYLINDER….753
REMOVAL AND INSTALLATION….753
BOOM CYLINDER (For 2-piece boom)….754
REMOVAL….754
INSTALLATION….755
2-PIECE BOOM CYLINDER….756
REMOVAL….756
INSTALLATION….757
ARM CYLINDER….758
REMOVAL AND INSTALLATION….758
BUCKET CYLINDER….759
REMOVAL AND INSTALLATION….759
BOOM SWING CYLINDER….760
REMOVAL AND INSTALLATION….760
BLADE CYLINDER….761
REMOVAL AND INSTALLATION….761
WORK EQUIPMENT CYLINDERS….762
DISASSEMBLY….762
ASSEMBLY….763
OVERLOAD SENSOR….767
REMOVAL AND INSTALLATION….767
WORK EQUIPMENT (For the boom)….768
REMOVAL AND INSTALLATION….768
WORK EQUIPMENT (2-piece boom version)….769
REMOVAL….769
INSTALLATION….770
BUCKET….771
REMOVAL AND INSTALLATION….771
ARM….772
REMOVAL….772
INSTALLATION….774
2-PIECE BOOM….775
REMOVAL….775
INSTALLATION….776
BOOM….777
REMOVAL AND INSTALLATION….777
BOOM (2-piece boom version)….778
REMOVAL….778
INSTALLATION….779
SWING BRACKET….780
REMOVAL AND INSTALLATION….780
BLADE….781
REMOVAL AND INSTALLATION….781
40 MAINTENANCE STANDARD….782
P.T.O…783
TRAVEL MACHINERY….784
SPROCKET….785
TRACK FRAME AND RECOIL SPRING….786
IDLER….787
CARRIER ROLLER….788
TRACK ROLLER….789
TRACK SHOE….790
SWING CIRCLE….791
SWING MACHINERY….792
CHECK VALVE AND OIL COOLER SAFETY BY-PASS….793
PUMP DRIVE….794
SUMMATION HORSEPOWER CONTROL – MODE SYSTEM….795
AUXILIARY PUMP….796
CONTROL VALVE….797
SWING MOTOR RELIEF VALVE….798
TRAVEL MOTOR….799
SERVOCONTROL FEED UNIT….800
L.H. AND R.H. PPC VALVE….801
2nd BOOM, R.H. TRAVEL, L.H. TRAVEL AND BOOM SWING PPC VALVE….802
BLADE PPC VALVE….803
BLADE SAFETY VALVE….804
CYLINDERS….805
WORK EQUIPMENT (1 – piece boom)….807
WORK EQUIPMENT (2 – piece boom)….809

Komatsu Hydraulic Excavators PC88MR Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC80MR, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC80MR workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

WEBM008601 – Hydraulic Excavator PC80MR-3 Shop Manual.pdf

Total Pages: 302 pages
File Format: PDF
Language: English

CEAM021202 – Hydraulic Excavator PC88MR-8 Operation & Maintenance Manual…2
COVER…2
INTRODUCTION…4
FOREWORD…5
SAFETY INFORMATION…6
Signal Words…6
Other Signal Words…6
Safety Labels…7
Safety Label Using Words…7
Safety Label Using Pictogram…7
INTRODUCTION…8
Directional Reference of Machine…8
Visibility from Operator’s Seat…8
BREAKING IN THE MACHINE…9
PRODUCT INFORMATION…10
Product Identification Number (PIN) – Machine Serial No. Plate…10
EPA* Regulations, Engine Serial Number Plate and its Location…10
Service Meter Location…11
Your Machine Serial Numbers and Distributor…11
TABLE OF CONTENTS…12
SAFETY…24
SAFETY AND WARNING DECALS…25
Location of Safety Decals…26
GENERAL SAFETY RULES AND PRECAUTIONS…33
General Safety Rules…33
General Safety at Job Site…34
Working on Loose Ground…34
Safety Features…35
Personal Protective Equipment…35
Fire and Explosion Prevention…36
Fire Caused by Fuel or Oil…36
Fire Caused by Accumulation of Flammable Material…36
Fire Coming From Electric Wiring…37
Fire Coming From Hydraulic Line…37
Windshield Washer Fluid…37
Action if Fire Occurs…37
Fire Extinguisher and First Aid Kit…37
Fire Prevention and Suppression…38
Fire Prevention Steps…38
Fixed Fire Detection System…38
Fixed Fire Suppression System…38
Fire Prevention Procedures…38
Dust Hazard Precautions…39
Keep Operator’s Cab Clean…39
Unauthorized Modifications…39
Leaving Operator’s Compartment…40
Mounting and Dismounting…41
Crush or Pinch Point Dangers…41
Inside Operator’s Compartment…42
Precautions When Using ROPS…42
Protection Against Falling or Flying Objects…43
Precautions for Attachments…44
Quick Coupler Attachment…44
Large Attachments…44
PRECAUTIONS BEFORE STARTING OPERATIONS…45
Pre-Operational Checks…45
Seat Belt Inspection…46
Starting Your Work Operations…47
Work Site Hazards…47
Avoiding Dangerous Situations…48
Working Clearances…52
Operations on Slopes…53
Operating on Snow or Icy Surfaces…53
Asbestos Hazard Alert…53
RULES FOR ROAD TRAVEL…54
Precautions When Traveling…54
Traveling with Carriage Reversed…54
Travel on Slopes…55
Parking the Machine…57
PRECAUTIONS DURING MAINTENANCE OPERATIONS…58
Warning Tags…58
Equipment Storage…58
Working Under the Machine…59
Using Drop Lamps…59
Keeping the Machine Clean…59
Performing General Maintenance Procedures…60
Running the Engine During Maintenance…61
Proper Tools…61
Engine System High-Voltage…61
Welding, Grinding or Cutting…62
Adjusting Track Tension…62
DO NOT Disassemble Recoil Springs…62
When Using Hammer…62
Refueling the Machine…63
Cooling System Precautions…63
Battery Precautions…64
Starting the Machine…65
High-Pressure Hoses…65
Handling High-Pressure Hoses…65
Precaution for High Fuel Pressure…66
High Temperatures Areas…66
Disposal of Waste Materials…66
Accumulator…67
Critical Parts…67
TRANSPORTING THE MACHINE…68
Loading and Unloading a Trailer…68
Loading the Machine…69
Securing the Machine…71
TOWING…72
Safety Rules for Towing…72
OPERATION…74
MACHINE VIEW ILLUSTRATIONS…75
Overall Machine View…75
Controls and Gauges…76
Machine Monitor…77
DETAILED CONTROLS AND GAUGES…78
Monitoring System…78
Basic Operation of Machine Monitor…79
Starting Engine When Situation is Normal…79
Stopping Engine When Situation is Normal…80
If There Is Abnormality When Starting Engine…81
If Any Abnormality Occurs During Operation…81
Emergency Monitors…83
Engine Coolant Temperature Monitor…83
Hydraulic Oil Temperature Monitor…83
Engine Oil Pressure Monitor…84
Caution Monitors…85
Engine Coolant Temperature Monitor…85
Hydraulic Oil Temperature Monitor…86
Fuel Level Monitor…86
Charge Level Monitor…86
Basic Check Monitors…87
Maintenance Interval Monitor…87
Meter Display Portion…88
Pilot Display…88
Engine Pre-heating Monitor…88
Swing Lock Monitor…89
Wiper Monitor…89
Auto-deceleration Monitor…89
Working Mode Monitor…89
Travel Speed Monitor…90
Air Conditioner Monitor…90
Message Monitor…90
Idle Stop Guidance…90
Gauges and Meter…91
Engine Coolant Temperature Gauge…91
Hydraulic Oil Temperature Gauge…92
Fuel Gauge…92
Service Meter, Clock…93
ECO Gauge…94
Monitor Switches Portion…95
Working Mode Selector Switch…95
Auto-deceleration Switch…98
Travel Speed Selector Switch…99
Wiper Switch…100
Window Washer Switch…101
Buzzer Cancel Switch…101
Function Switches…102
Air Conditioner Switch…102
Handling Function Switches…103
Service Meter/Clock Display Selector Switch…104
Maintenance Selector Switch…105
Operations on Maintenance List Screen…106
Operations on Maintenance Interval Reset Screen…107
User Mode Selector Switch…108
Breaker/Attachment Setting…110
Message Display…123
Adjusting Screen…125
Clock Adjustment…128
Language Selection…134
Adjusting Economy Mode…136
Switches…138
Ignition Switch…138
Fuel Control Dial…139
Cigarette Lighter…139
1st-Line Attachment Proportional Switch…140
Breaker Operation Switch…140
Horn Switch…140
Room Lamp Switch…140
Emergency Pump Drive Switch…141
Swing Parking Brake Release Switch…141
Revolving Warning Lamp Switch (If Equipped)…141
Lamp Switch…142
Quick Coupler Switches…142
Control Levers and Pedals…143
Lock Lever…144
Travel Levers…145
Work Equipment Control Lever…146
Blade Control Lever…147
Swing Lock Cover…147
Boom Swing Control Pedal…147
SUN ROOF…148
WINDSHIELD…149
Opening…149
Closing…153
Removing Lower Windshield…155
SLIDING DOOR…156
EMERGENCY ESCAPE HAMMER…157
COVER WITH LOCK…158
Opening and Closing Covers with Lock…158
Opening the Cover…158
Locking the Cover…158
ENGINE HOOD…159
MUD COVER…161
BATTERY INSPECTION COVER…162
AIR CONDITIONER CONTROLS…163
Air Conditioner Control Panel…163
OFF Switch…163
Fan Switch…164
Temperature Control Switch…164
Vent Selector Switch…165
Auto Switch…166
FRESH/RECIRC Selector Switch…166
Display Monitor…166
Air Conditioner Switch…167
Sunlight Sensor…167
Method of Operation…168
Automatic Operation…168
Stopping Automatic Operation…169
Manual Operation…169
Stopping Manual Operation…171
Operation with Cold Air to Face and Warm Air to Feet…171
Defroster Operation…173
Use Air Conditioner with Care…175
Ventilation…175
Temperature Control…175
Inspection and maintenance of Air Conditioner Equipped Machine…175
RADIO…177
Control Panel…177
Power Switch, Volume Control Knob, Balance Control Knob…177
Sel Button…177
FM/AM Selection Button (AM/FM)…177
Display Selection Button (TIME)…177
AS/PS button…178
Preset Station Buttons (1, 2, 3, 4, 5, 6)…178
Display…178
Time Reset Button…178
Tuning Button (TUNING)…178
Controls of Radio…179
Method of Setting with Preset Button…179
Method of Tuning…179
Method of Operating Mode…179
Setting Correct Time…180
Antenna…180
Use Radio with Care…180
FUSE…181
Fuse Capacities and Circuit Names…181
Fusible Link…182
AUXILIARY ELECTRIC POWER…183
CONTROLLERS…184
OPERATION MANUAL STORAGE…185
CUP HOLDER…185
TOOL BOX…185
GREASE PUMP HOLDER…185
ASHTRAY…186
FIRE EXTINGUISHER (IF EQUIPPED)…186
MACHINE OPERATIONS AND CONTROLS…187
Before Starting Engine…187
Walk-Around Checks…187
Checks Before Starting…188
Check Coolant Level, Add Coolant…188
Check Oil Level in Engine Oil Pan, Add Oil…189
Check Fuel Level, Add Fuel…191
Check Oil Level in Hydraulic Tank, Add Oil…193
Check Dust Indicator…194
Check for Water and Sediment in Water Separator, Drain Water…195
Check Electric Wiring…197
Check Working Lamp Switch…197
Check Function of Horn…197
Adjustments…198
Seat Adjustment…198
Rear View Mirrors…199
Wind-in Type Seat Belt…201
Operations Before Starting Engine…202
STARTING ENGINE…205
Normal Starting…205
Starting Engine in Cold Weather…207
Turbo protect function…209
Breaking-in the New Machine…209
AFTER STARTING ENGINE…210
Checking Engine Startability and Noise…210
Checking Engine Acceleration and Deceleration…210
Engine Warm Up…211
Hydraulic Equipment Warm Up…213
Operation After Completion of Warm-Up Operation…219
STOPPING THE ENGINE…221
MACHINE OPERATION…222
Preparations for Moving the Machine…222
Moving Machine Forward…223
Moving Machine Backward…224
Stopping Machine…225
STEERING THE MACHINE…226
Steering…226
Steering the Machine When Stopped…226
Changing Direction of the Machine…227
Counter-rotation Turn (Spin Turn)…227
SWINGING…228
WORK EQUIPMENT CONTROLS AND OPERATIONS…229
WORKING MODE…231
PROHIBITED OPERATIONS…233
Operations Using Swing Force…233
Operations Using Travel Force…233
Prohibition of Operations Using Hydraulic Cylinders to Stroke Ends…233
Operations Using Bucket Dropping Force…234
Operations Using Machine Dropping Force…234
Digging Hard Rocky Ground…234
Prohibition of Lifting Operation…235
Sudden Lever or Pedal Shifting High Speed Travel…235
Support Blade on Both Sides…235
GENERAL OPERATION INFORMATION…236
Traveling…236
High Speed Travel…236
Folding in Work Equipment…236
Avoid Hitting Blade…237
Blade During Backhoe Operations…237
Permissible Water Depth…237
TRAVELING ON SLOPES…238
Traveling Downhill…239
Engine Stopped on Slope…239
Cab Doors on Slope…239
ESCAPE FROM MUD…240
Track on One Side Stuck…240
Tracks on Both Sides Stuck…240
RECOMMENDED APPLICATIONS…241
Backhoe Work…241
Shovel Work…241
Ditching Work…241
Loading Work…242
Refill and Finishing Work…242
Side Ditching Work…242
BUCKET REPLACEMENT AND INVERSION…243
Replacement…243
Inversion…244
PARKING MACHINE…247
MACHINE INSPECTION AFTER DAILY WORK…249
Before Stopping Engine…249
After Stopping Engine…249
LOCKING…249
ROAD LINERS AND RUBBER SHOES…250
Road Liners and Rubber Shoes Information…250
Warranty for Road Liners and Rubber Shoes…250
Using Road Liners and Rubber Shoes…251
Prohibited Works…251
Long Life Operations…251
MACHINE READY FOR ATTACHMENT…255
Locations…255
Selector Valve…255
1st-Line Attachment Proportional Switch…256
Breaker Operation Switch…256
Breaker Circuit Additional Oil Filter…256
Accumulator (For Low Pressure)…256
Hydraulic Circuit…257
Hydraulic Circuit Connection…257
Attachment Removal And Installation…259
Attachment Installation…259
Attachment Removal…261
Attachment Operations…263
When Using Breaker…263
When Using General Attachment Such As Crusher…265
Long Term Storage…265
Hydraulic Specifications…265
TRANSPORTATION…265
Transportation Procedure…265
Loading and Unloading with Trailer…266
Loading…267
Securing Machine…268
Unloading…269
LIFTING MACHINE…272
COLD WEATHER OPERATION…273
Fuel and Lubricants…273
Cooling System Coolant…273
Battery…274
After Daily Work Completion…275
After Cold Weather Season…275
LONG TERM STORAGE…276
Before Storage…276
During Storage…276
After Storage…276
Starting Machine After Long-term Storage…276
TROUBLES AND ACTIONS…277
Running Out of Fuel…277
Phenomena That Are Not Failures…277
Towing the Machine…278
Severe Job Condition…278
Discharged Battery…279
Battery Removal and Installation…280
Battery Charges…281
Starting Engine with Booster Cables…282
Connecting and Disconnecting Booster Cables…282
Booster Cable Connection…283
Starting the Engine…283
Booster Cable Disconnection…283
TROUBLESHOOTING…285
Electrical System…285
Chassis…286
Engine…287
Electronic Control System…289
Point of Contact to Telephone when Error Occurs…289
MAINTENANCE…290
GUIDES TO MAINTENANCE…291
Check Service Meter…291
Komatsu Genuine Replacement Parts…291
Komatsu Genuine Oils…291
Always Use Clean Washer Fluid…291
Always Use Clean Oil and Grease…291
Checking Foreign Materials in Drained Oil and on Filters…291
Fueling…291
Welding Instructions…291
Do Not Drop Things Inside Machine:…291
Dusty Work Sites…292
Avoid Mixing Oil…292
Locking Inspection Covers…292
Bleeding Air From Hydraulic Circuit…292
Precautions When Installing Hydraulic Hoses…292
Checks After Inspection and Maintenance…292
OUTLINES OF SERVICE…293
Handling Oil, Fuel, Coolant, and Performing Oil Clinic…293
Oil…293
Fuel…293
Coolant and Water for Dilution…294
Grease…294
Performing KOWA (Komatsu Oil Wear Analysis)…295
Storing Oil and Fuel…296
Filters…296
Outline of Electric System…296
WEAR PARTS LIST…297
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…298
USE OF FUEL, COOLANT AND LUBRICANTS…299
Selection According to Ambient Temperature…299
Recommended Brands, Recommended Quality for Products other than Komatsu Genuine Oil…300
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…301
Torque List…301
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…303
Safety Critical Parts…303
REGULAR SCHEDULED MAINTENANCE…305
Maintenance Schedule Chart…305
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…306
WHEN REQUIRED…307
Check, Clean and Replace Air Cleaner Element…307
Checking…307
Cleaning Outer Element…307
Replacing Element…309
Clean Inside of Cooling System…311
Mixing Rate of Water and Antifreeze…312
Check and Tighten Track Shoe Bolts…314
Method for Further Tightening of Steel Shoe…314
Method for Further Tightening of Road Liner…314
Order for tightening…314
Check and Adjust Track Tension…315
Checking…315
Adjustment…315
Increasing Track Tension…315
Loosening Track Tension…316
Check Road Liners or Rubber Shoes…317
Lug Height…317
Rubber Shoe Steel Code Cuts…317
Rubber Shoe Core Separations…318
Rubber Shoe Tension…318
Rubber Shoe Cracks…318
Check and Adjust Rubber Shoe Tension…319
Checking…319
Adjustment…319
Increasing Track Tension…319
Loosening Track Tension…320
Replace Road Liners…320
Replace Rubber Shoes…321
Rubber Shoes Removal…321
Rubber Shoes Installation…322
Change Steel Shoes or Road Liner to Rubber Shoes…323
Changing from Steel Shoes or Road Liners to Rubber Shoes…323
Changing from Rubber Shoes to Steel Shoes or Road Liners…323
Replace Bucket Teeth (Vertical Pin Type)…324
Replace Bucket Teeth (Horizontal Pin Type)…327
Adjust Bucket Clearance…329
Check Window Washer Fluid Level, Add Fluid…330
Check and Maintenance of Air Conditioner…331
Check Level of Refrigerant (Gas)…331
Inspection During Off Season…331
Inspection and Maintenance Items…331
Check, Clean and Lubricate Cab Slide Door Rail and Roller…332
Checking…332
Cleaning…332
Greasing…332
Replace Breaker Circuit Additional Oil Filter Element…333
Wash Washable Floor…334
Method of Washing…334
Method of Setting Machine at Angle…335
Check Gas Spring…337
Bleeding Air From Hydraulic System…338
CHECK BEFORE STARTING…341
EVERY 100 HOURS MAINTENANCE…342
Lubricating…342
Check Swing Machinery Case Oil, Add Oil…343
EVERY 250 HOURS MAINTENANCE…344
Check Oil Level in Final Drive Case, Add Oil…344
Check Level of Battery Electrolyte…344
When Checking Electrolyte Level from Side of Battery…345
When it is Impossible to Check Electrolyte Level from Side of Battery…346
When it is Possible to Use Indicator to Check Electrolyte Level…346
Check and Adjust Cooling Fan Belt Tension…347
Checking…347
Adjustment…348
Check Air Conditioner Compressor Belt Tension, Adjust…349
Checking…349
Adjustment…350
EVERY 500 HOURS MAINTENANCE…351
Lubricating…351
Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge…353
Replace Fuel Pre-Filter Cartridge…354
Check Swing Pinion Grease Level, Add Grease…356
Lubricate Swing Circle…356
Clean and Inspect Radiator Fins, Oil Cooler Fins, After Cooler Fins, Fuel Cooler Fins, and Air Conditioner Condenser Fins…357
Clean Air Conditioner Fresh/Recirc Filters…358
Cleaning Recirculated Air Filter…358
Cleaning Fresh Air Filter…358
Replace Breather Element In Hydraulic Tank…359
EVERY 1000 HOURS MAINTENANCE…360
Change Oil in Swing Machinery Case…360
Change Oil in Final Drive Case…361
Replace Hydraulic Oil Filter Element…362
Replace Fuel Main Filter Cartridge…364
Check All Tightening Points of Engine Exhaust Pipe Clamps…366
Check Oil Level in PTO Gear Case, Add Oil…366
EVERY 2000 HOURS MAINTENANCE…367
Check Alternator, Starting Motor…367
Check Engine Valve Clearance, Adjust…367
Checking Charge Pressure of Nitrogen Gas in Accumulator (For Control Circuit)…367
Function of Accumulator…367
Checking Function of Accumulator…368
Method of Releasing Pressure In Hydraulic Circuit…370
EVERY 4000 HOURS MAINTENANCE…371
Check Water Pump…371
Replace Accumulator (For Control Circuit)…371
EVERY 5000 HOURS MAINTENANCE…372
Change Oil in Hydraulic Tank, Clean Strainer…372
SPECIFICATIONS…376
SPECIFICATIONS…377
OPTIONS, ATTACHMENTS…380
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…381
Safety First…381
Attachment Installation…382
BUCKET WITH HOOK…383
Hook Condition…383
Prohibited Operations…383
Operations with Care…383
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…384
Control Pattern Change Procedure…384
Machine Control Patterns…385
HYDRAULIC QUICK COUPLER PIPING…386
Locations…386
Operation…387
To Release a Bucket or Attachment…387
To Pick Up a New Bucket or Attachment…387
POWER ANGLE BLADE…388
Blade Control Lever…388
Lifting Control…388
Angling Control…388
Maintenance…389
When Required…389
Every 500 Hours Service…389
Wear Parts List…390
Specifications…390
ATTACHMENT GUIDE…391
Attachment Combinations…391
Track Shoes Selection…392
RECOMMENDED ATTACHMENT OPERATIONS…393
Hydraulic Breaker…393
Main Applications…393
Prohibited Works…395
Greasing…398
Crusher…399
Main Applications…399
Prohibited Works…399
HANDLING MACHINES EQUIPPED WITH KOMTRAX…403
Basic Precautions…403
CEBM007301 – Hydraulic Excavator PC88MR-8 Shop Manual…404
CEBM007301 – PC88MR-8 sn A90001-up…0
CONTENTS…405
REVISED PAGES…406
SAFETY…422
Safety Notice…422
Important Safety Notice…422
General Precautions…422
Preparations For Work…422
Precautions During Work…422
GENERAL…425
HOW TO READ THE SHOP MANUAL…426
Volumes…426
Distribution And Updating…426
Filing Method…426
Revised Edition Mark…426
Revisions…426
Symbols…426
HOISTING INSTRUCTIONS…427
Hoisting…427
Wire Ropes…427
PUSH PULL COUPLER…428
Type 1…428
Disconnection…428
Connection…428
Type 2…429
Disconnection…429
Connection…429
Type 3…430
Disconnection…430
Connection…430
EXPLANATION OF MAINTENANCE STANDARD TERMS…431
STANDARD TIGHTENING TORQUE…433
Bolts And Nuts…433
Tightening Torque Of Hose Nuts…434
Tightening Torque Of Split Flange Bolts…434
Tightening Torque For Flared Nuts…434
Tightening Torques For O-ring Boss Piping Joints…435
Table Of Tightening Torques For O-ring Boss Plugs…435
Torque Table For Hoses (Taper Seal Type And Face Seal Type)…435
ELECTRIC WIRE CODE…436
Classification By Thickness…436
Classification By Color And Code…436
How To Read Electric Wire Code…437
CONVERSION TABLES…440
Method Of Using The Conversion Table…440
COATING MATERIALS…446
01 GENERAL…448
SPECIFICATIONS DIMENSION DRAWING…449
Working Range Diagram…450
Specifications…451
Weight Table…455
TABLE FOR FUEL, COOLANT AND LUBRICANTS…457
Selection According to Ambient Temperature…457
Mixing Rate of Water and Antifreeze…458
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…460
ENGINE AND COOLING SYSTEM…465
Engine Mount…465
Cooling System…467
Power Take Off (PTO)…469
POWER TRAIN…470
Power Train…470
Swing Circle…471
Swing Machinery…473
UNDERCARRIAGE AND FRAME…475
Track Frame…475
Idler Cushion…476
Idler…477
Track Roller…479
Carrier Roller…480
Sprocket…481
Track Shoe…483
City Pad Shoe, Road Liner, Triple Grouser Shoe…483
City Pad Shoe, Triple Grouser Shoe…486
Road Liner…487
HYDRAULIC SYSTEM…489
Hydraulic Equipment Layout Drawing…489
Valve Control…490
Hydraulic Tank and Filter…491
Oil Filler Cap Breather…492
Hydraulic Pump…493
Model: LPD45+45…493
Operation of Pump…498
Servo Valve…499
Control of Delivery…501
LS Valve…502
PC Valve…502
Action of Spring…503
When Pump Pressure (PAVE) is Low…503
When Pump Pressure (PAVE) is High…503
When Swing Gear Pump Pressure Increases or Decreases…503
When PC-EPC Valve Operates…503
When Load is Light…504
When Load is Heavy…505
When Balanced…506
Control Valve…507
10-Spool Valve (EU Specification)…507
Sectional Views…509
9-Spool Valve (North America Specification)…521
CLSS…523
Outline of CLSS…523
Features…523
Composition…523
Basic principle…524
Pump swash plate angle control…524
LS differential pressure (rPLS) and pump swash plate angle…524
Pressure compensation control…525
Functions and Operation by Valve…527
Hydraulic Circuit Diagram and the Name of Valves…527
9-Spool Valve (North America Specification)…528
Unload Valve…529
Merge-Divider Valve…539
Introduction of LS Pressure…541
Travel Valve…542
LS Bypass Valve…543
LS Select Valve…545
Boom RAISE Merge Valve…547
Pressure compensation valve…550
Boom hydraulic drift prevention valve…551
Boom regeneration circuit…554
Travel junction valve…557
Travel LS Bleed Circuit and Travel Junction Valve…561
PPC Valve…565
Work Equipment and Swing PPC Valve…565
Travel PPC Valve…571
Blade and Boom Swing PPC Valve…575
Swing Motor…577
Brake Valve…581
Modulating Relief Valve…583
Swing Holding Brake…584
Reverse Prevention Valve…585
Travel Motor…588
Center Swivel Joint…596
Solenoid Valve…597
4-Spool Solenoid Valve…597
Check Valve…598
Solenoid Valve…599
EPC Valve…601
PPC Accumulator…604
Anti-Drop Valve…606
Multi-Control Valve…611
WORK EQUIPMENT…612
Dimensions of Components…615
Arm…615
Bucket…619
Work Equipment Cylinder…621
Boom Cylinder…621
Arm Cylinder…621
Bucket Cylinder…621
Boom Swing Cylinder…622
Blade Cylinder…622
AIR CONDITIONER…625
Air Conditioner Piping Diagram…625
Refrigerant Circuit Diagram…627
Air Conditioner Unit…629
Air Conditioner Controller…632
Compressor…633
Condenser…634
Receiver…635
Sensors…636
Sunlight Sensor…636
Ambient Air Temperature Sensor…636
ELECTRICAL SYSTEM…637
Electrical Control System…637
Machine Control System Diagram…637
Engine Control Function…639
Engine and Pump Mutual Control Function…641
Auto-Deceleration Function…645
Engine Automatic Warm-Up Function…647
Turbocharger Protection Function…649
Swing Control Function…651
Travel Control Function…653
PPC Lock Function…655
Oil Flow Adjuster Function for Attachment…656
System Components…657
Engine Controller…657
Pump Controller…659
Fuel control dial…661
Resistor…662
Engine Oil Pressure Switch…663
PPC Oil Pressure Switch…664
Monitor System…665
Machine monitor…667
Display…669
Switches…673
Operator Mode Function…677
Service Mode Function…679
KOMTRAX System…680
KOMTRAX terminal…681
Input and Output Signals…681
Sensor…682
Atmospheric Pressure Sensor…682
Boost Pressure and Temperature Sensor…682
Coolant Temperature Sensor…683
Crankshaft Speed Sensor…683
Camshaft Speed Sensor…683
Common Rail Pressure Sensor…684
Hydraulic Oil Temperature Sensor…684
Fuel Level Sensor…685
Pump Oil Pressure Sensor…686
Boom Cylinder Bottom Oil Pressure Sensor…686
PPC Oil Pressure Sensor…687
20 STANDARD VALUE TABLES…688
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…689
STANDARD VALUE TABLE FOR CHASSIS…690
30 TESTING AND ADJUSTING…698
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…701
ENGINE SPEED…706
EXHAUST TEMPERATURE…707
EXHAUST GAS COLOR…709
VALVE CLEARANCE…711
COMPRESSION PRESSURE…713
BLOW-BY PRESSURE…715
ENGINE OIL PRESSURE…717
HANDLING FUEL SYSTEM PARTS…719
Releasing Residual Pressure From Fuel System…719
Testing Fuel Pressure…720
Testing Fuel Return Rate And Fuel Leakage…721
Bleeding Air From Fuel Circuit…723
Checking Fuel Circuit for Leakage…725
ALTERNATOR BELT TENSION…727
Testing…727
Adjusting…728
AIR CONDITIONER COMPRESSOR BELT TENSION…729
Checking…729
Adjusting…729
SWING CIRCLE BEARING CLEARANCE…730
TRACK SHOE TENSION…731
Checking…731
Adjusting…731
Increasing tension…731
Decreasing tension…732
OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS…733
Testing…733
Adjusting…735
SWING AND BLADE CIRCUIT OIL PRESSURE…737
Testing…737
CONTROL CIRCUIT BASIC PRESSURE…741
OIL PRESSURE IN PUMP PC CONTROL CIRCUIT…743
PC-EPC SOLENOID OUTPUT PRESSURE…746
LS DIFFERENTIAL PRESSURE AND LS VALVE…747
Testing LS Differential Pressure…747
Adjusting LS Valve…748
SOLENOID VALVE OUTPUT PRESSURE…749
PPC VALVE OUTPUT PRESSURE…751
PLAY OF WORK EQUIPMENT AND SWING PPC VALVES…753
PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT…755
TRAVEL DEVIATION…757
Inspection…757
Adjusting…758
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT…759
OIL LEAKAGE…761
Bleeding Air from Each Part…765
MIRRORS…767
SPECIAL FUNCTIONS OF MACHINE MONITOR…769
Upper Section of Machine Monitor (Display Section)…770
Upper Section of Machine Monitor (Switch Section)…770
Lower Section of Machine Monitor (Switch Section)…770
Ordinary and Special Functions of Machine Monitor…771
Operator Mode (Outline)…772
Service Mode…785
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER…823
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM…824
Machine Monitor…824
Engine Controller…825
Pump Controller…825
KOMTRAX Communication Module…826
Engine Ne Speed Sensor (Crank Sensor)…826
Engine Bkup Speed Sensor (Cam Sensor)…826
Engine Oil Pressure Switch (Oil Pressure Switch)…826
Boost Pressure and Temperature Sensor (Boost Press and Imt)…827
Supply Pump IMV Solenoid (Fuel Regulator)…827
Common Rail Pressure Sensor (Fuel Rail Press)…828
Engine Coolant Temperature Sensor (Coolant Temp)…828
PROCEDURE FOR TESTING DIODES…829
When Using Digital Circuit Tester…829
When Using Analog Circuit Tester…830
PM CLINIC SERVICE…831
Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge…831
Check sheet (PC88MR-8)…832
Engine…832
Work equipment speed…832
Hydraulic drift of work equipment…832
Hydraulic circuit…833
* Gauge changing work: Change hoses of gauges [3] and [4]…833
* Gauge changing work: Change [3] and [4] to 60K and change hoses of [3], [4], and [5]…834
40 TROUBLESHOOTING…836
GENERAL INFORMATION ON TROUBLESHOOTING…841
Points to Remember When Troubleshooting…841
Sequence of Events in Troubleshooting…843
Checks Before Troubleshooting…844
Classification and Procedures for Troubleshooting…845
Procedure for Troubleshooting…845
Phenomena Looking Like Troubles and Troubleshooting Nos…847
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…850
T-ADAPTER TABLE…873
FAILURE CODE TABLE…877
FUSE LOCATIONS…879
TROUBLESHOOTING BY FAILURE CODE…882
Failure Code [989L00] Engine Controller Lock Caution 1…882
Failure Code [989M00] Engine Controller Lock Caution 2…883
Failure Code [989N00] Engine Controller Lock Caution 3…884
Failure Code [AB00KE] Charge Voltage Low…885
Failure Code [B@BAZG] Eng Oil Press. Low…887
Failure Code [B@BCNS] Eng Coolant Overheat…887
Failure Code [B@HANS] Hyd. Oil Overheat…888
Failure Code [CA111] ECM Critical Internal Failure…889
Failure Code [CA115] Eng. Ne and Bkup Speed Sensor Error…892
Failure Code [CA122] Charge Air Press Sensor High Error…893
Failure Code [CA123] Charge Air Press Sensor Low Error…895
Failure Code [CA131] Throttle Sensor High Error…897
Failure Code [CA132] Throttle Sensor Low Error…899
Failure Code [CA144] Coolant Temp. Sensor High Error…901
Failure Code [CA145] Coolant Temp. Sensor Low Error…903
Failure Code [CA153] Charge Air Temp. Sensor High Error…905
Failure Code [CA154] Charge Air Temp. Sensor Low Error…907
Failure Code [CA187] Sensor Sup. 2 Volt. Low Error…908
Failure Code [CA221] Ambient Air Press. Sensor High Error…909
Failure Code [CA227] Sensor Sup. 2 Volt. High Error…912
Failure Code [CA234] Eng. Overspeed…913
Failure Code [CA238] Ne Speed Sensor Sup. Volt. Error…915
Failure Code [CA272] IMV/PCV1 Open Error…919
Failure Code [CA322] Injector #1 (L #1) System Open/Short Error…921
Failure Code [CA324] Injector #3 (L #3) System Open/Short Error…923
Failure Code [CA331] Injector #2 (L #2) System Open/Short Error…925
Failure Code [CA332] Injector #4 (L #4) System Open/Short Error…927
Failure Code [CA351] Inj. Drive Circuit Error…929
Failure Code [CA352] Sensor Sup. 1 Volt. Low Error…932
Failure Code [CA386] Sensor Sup. 1 Volt. High Error…933
Failure Code [CA435] Abnormality in Engine Oil Pressure Switch…935
Failure Code [CA441] Battery Voltage Low Error…936
Failure Code [CA442] Battery Voltage High Error…937
Failure Code [CA449] Rail Press. Very High Error…938
Failure Code [CA451] Rail Press. Sensor High Error…939
Failure Code [CA452] Rail Press. Sensor Low Error…941
Failure Code [CA553] Rail Press. High Error…941
Failure Code [CA559] Rail Press. Low Error…942
Failure Code [CA731] Eng. Bkup Speed Sensor Phase Error…947
Failure Code [CA757] All Persistent Data Lost Error…948
Failure Code [CA778] Eng. Bkup Speed Sensor Error…949
Failure Code [CA1633] KOMNET Datalink Timeout Error…951
Failure Code [CA2185] Throttle Sens. Sup. Volt. High Error…953
Failure Code [CA2186] Throttle Sens. Sup. Volt. Low Error…955
Failure Code [CA2249] Rail Press. Very Low Error…956
Failure Code [CA2311] Abnormality in IMV Solenoid…957
Failure Code [D110KB] Battery Relay Drive Short…959
Failure Code [D19JKZ] Personal Code Relay Abnormality…961
Failure Code [D862KA] GPS Antenna Discon…963
Failure Code [DA22KK] Pump Solenoid Power Low Error…965
Failure Code [DA25KP] 5 V Sensor 1 Power Abnormality…967
Failure Code [DA26KP] 5 V Sensor 2 Power Abnormality…970
Failure Code [DA2RMC] CAN Discon (Pump Controller Detected)…971
Failure Code [DAFGMC] GPS Module Error…973
Failure Code [DAFRMC] CAN Discon (Monitor Detected)…975
Failure Code [DFB1KZ] Service Lever Pot. 1 Abnormality…977
Failure Code [DFB2KZ] Service Lever Pot. 2 Abnormality…979
Failure Code [DFB3L8] Service Lever 1 Potentio Error…981
Failure Code [DFB4L8] Service Lever 2 Potentio Error…983
Failure Code [DFB5KZ] Service Lever sPot. 1 Abnormality…985
Failure Code [DFB6KZ] Service Lever sPot. 2 Abnormality…987
Failure Code [DGH2KB] Hydr Oil Sensor Short…989
Failure Code [DHPAMA] Pump Press Sensor Abnormality…991
Failure Code [DHS5KX] Travel PPC Sensor Abnormality…993
Failure Code [DHSAMA] Swing RH PPC Press Sensor Abnormality…995
Failure Code [DHSBMA] Swing LH PPC Press Sensor Abnormality…997
Failure Code [DHX1MA] Overload Sensor Abnormality…999
Failure Code [DV20KB] Travel Alarm Short Circuit…1001
Failure Code [DW43KA] Travel Speed Sol Discon…1003
Failure Code [DW43KB] Travel Speed Sol Short…1004
Failure Code [DW45KA] Swing Brake Sol Discon…1005
Failure Code [DW45KB] Swing Brake Sol Short…1007
Failure Code [DWJ0KA] Merge-Divider Sol Discon…1009
Failure Code [DWJ0KB] Merge-Divider Sol Short…1010
Failure Code [DXA8KA] PC-EPC Sol Discon…1011
Failure Code [DXA8KB] PC-EPC Sol Short…1013
Failure Code [DXE7KA] Service Current EPC2 Open Circuit…1015
Failure Code [DXE7KB] Service Current EPC2 Short Circuit…1017
Failure Code [DXE8KA] Service Current EPC3 Open Circuit…1019
Failure Code [DXE8KB] Service Current EPC3 Short Circuit…1021
Failure Code [DXE9KA] Service Current EPC4 Open Circuit…1023
Failure Code [DXE9KB] Service Current EPC4 Short Circuit…1025
Failure Code [DXEAKA] Service Current EPC1 Open Circuit…1027
Failure Code [DXEAKB] Service Current EPC1 Short Circuit…1029
Failure Code [DY20KA] Wiper Working Abnormality…1031
Failure Code [DY20MA] Wiper Parking Abnormality…1033
Failure Code [DY2CKA] Washer Drive Open Circuit…1035
Failure Code [DY2CKB] Washer Drive Short Circuit…1037
Failure Code [DY2DKB] Wiper Drive (FWD) Short Circuit…1039
Failure Code [DY2EKB] Wiper Drive (REV) Short Circuit…1041
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…1043
Before Carrying Out Troubleshooting of Electrical System…1043
Connection table of fuse box…1043
Locations of fusible links…1044
Location of fuse box and fuse numbers…1044
Information in Troubleshooting Table…1045
E-1 When Starting Switch is Turned On, Machine Monitor Displays Nothing…1047
E-2 Engine Does Not Start (Engine Does Not Turn)…1049
E-3 Preheater Does Not Operate…1052
E-5 All Work Equipment, Swing, and Travel Mechanism Does Not Move or Cannot Be Locked…1055
E-6 Precaution Lights Up While Engine Is Running…1057
E-7 Emergency Stop Item Lights Up While Engine Is Running…1060
E-8 Engine Coolant Temperature Gauge Does Not Indicate Normally…1061
E-9 Hydraulic oil temperature gauge does not indicate normally…1063
E-10 Fuel Level Gauge Does Not Indicate Normally…1066
E-11 Contents of Display by Machine Monitor are Different From Applicable Machine…1068
E-12 Machine Monitor Does Not Display Some Items…1068
E-13 Function Switch Does Not Work…1068
E-14 Auto-decelerator Does Not Operate Normally…1069
E-15 Working Mode Does Not Change…1070
E-16 Travel Speed Does Not Change…1071
E-17 Alarm Buzzer Cannot Be Stopped…1072
E-18 Windshield Wiper And Window Washer Do Not Operate…1073
E-19 Swing Holding Brake Does Not Operate Normally…1077
E-20 Travel Alarm Does Not Sound Or Does Not Stop Sounding…1079
E-21 Air Conditioner Does Not Operate Normally (Including Air Conditioner Abnormality Record)…1080
E-22 While Starting Switch is in Off Position, Service Meter is not Displayed…1093
E-25 Komtrax System Does Not Operate Normally…1115
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…1118
Information Contained in Troubleshooting Table…1118
System Chart for Hydraulic and Mechanical Systems…1120
H-1 Speed or Power of all Work Equipment, Swing, and Travel are Low…1122
H-2 Engine Speed Sharply Drops or Engine Stalls…1123
H-3 No Work Equipment, Travel and Swing Move…1124
H-4 Abnormal Noise is Heard from Around Hydraulic Pump…1124
H-5 Fine Control Performance or Response of Work Equipment and Travel is Low…1125
H-6 Speed or Power of Boom is Low…1126
H-7 Speed or Power of Arm is Low…1127
H-8 Speed or Power of Bucket is Low…1128
H-9 Speed or Power of Boom Swing is Low…1129
H-10 Speed or Power of Blade is Low…1130
H-11 Work Equipment Does Not Move in its Single Operation…1131
H-12 Hydraulic Drift of Work Equipment is Large…1132
H-13 Time Lag of Work Equipment is Large…1134
H-14 Work Equipment Loaded More is Slower During Compound Operation…1134
H-15 Boom RAISE Speed is Low in Compound Operation of Swing + Boom Raise…1134
H-16 Travel Speed Lowers Significantly During Compound Operation of Work Equipment/Swing + Travel…1135
H-17 Machine Deviates During Travel…1136
H-18 Travel Speed is Low…1137
H-19 Machine Cannot be Steered Easily or Steering Power is Low…1138
H-20 Travel Speed Does Not Change or it is Kept Low or High…1139
H-21 Track Does Not Move (Only Either Side)…1139
H-22 Machine Does Not Swing…1140
H-23 Swing Acceleration, Swing Speed and Swing Power are Low…1142
H-24 Excessive Overrun when Stopping Swing…1144
H-25 When Upper Structure Stops Swinging, it Makes Large Shock…1145
H-26 When Upper Structure Stops Swinging, it Makes Large Sound…1145
H-27 Hydraulic Drift of Swing is Large…1146
H-28 Flow Rate in Attachment Circuit Cannot Be Adjusted…1147
50 DISASSEMBLY AND ASSEMBLY…1148
HOW TO READ THIS MANUAL…1153
Removal and Installation of Assemblies…1153
Special Tools…1153
Removal…1153
Installation…1153
Disassembly and Assembly of Assemblies…1154
Special Tools…1154
Disassembly…1154
Assembly…1155
COATING MATERIALS LIST…1157
SPECIAL TOOLS LIST…1161
SKETCHES OF SPECIAL TOOLS…1165
CONNECTOR REPAIR PROCEDURES…1170
Stripping Insulation…1170
Wire Inspection…1170
Contact Terminal Removal (HD30 Type)…1171
Crimping Contact Terminal (HD30 Type)…1172
Insertion of Contact Terminal (HD30 Type)…1173
Contact Terminal Removal (DT Type)…1174
Crimping Contact Terminal (DT Type)…1175
Insertion of Contact Terminal (DT Type)…1176
ENGINE AND COOLING SYSTEM…1177
Fuel Supply Pump Assembly…1177
Removal…1177
Installation…1181
Fuel Injector Assembly…1183
Removal…1183
Installation…1187
Engine Front Seal…1189
Removal…1189
Installation…1190
Engine Rear Seal…1191
Removal…1191
Installation…1193
Cylinder Head Assembly…1194
Removal…1194
Installation…1204
Radiator Assembly…1209
Removal…1209
Installation…1212
Aftercooler Assembly…1213
Removal…1213
Installation…1216
Hydraulic Oil Cooler Assembly…1217
Removal…1217
Installation…1220
Engine and Hydraulic Pump Assembly…1221
Removal…1221
Installation…1233
Fuel Tank Assembly…1237
Removal…1237
Installation…1239
POWER TRAIN…1241
Travel Motor and Final Drive Assembly…1241
Removal…1241
Installation…1242
Swing Motor and Swing Machinery Assembly…1243
Installation…1244
Swing Machinery…1245
Disassembly…1245
Assembly…1251
Swing Circle Assembly…1257
Removal…1257
Installation…1258
UNDERCARRIAGE AND FRAME…1259
Track Roller Assembly…1259
Disassembly…1259
Assembly…1261
Idler Assembly…1265
Disassembly…1265
Assembly…1266
Recoil Spring Assembly…1269
Disassembly…1269
Assembly…1271
Track Shoe Assembly…1273
Spreading…1273
Installation…1274
Sprocket…1275
Removal…1275
Installation…1275
Revolving Frame Assembly…1277
Removal…1277
Installation…1279
Counterweight Assembly…1281
Removal…1281
Installation…1286
HYDRAULIC SYSTEM…1287
Center Swivel Joint Assembly…1287
Removal…1287
Installation…1288
Disassembly…1289
Assembly…1290
Hydraulic Tank Assembly…1291
Removal…1291
Installation…1294
Hydraulic Pump Assembly…1295
Removal…1295
Installation…1300
Control Valve Assembly…1301
Removal…1301
Disassembly…1311
Assembly…1311
Work Equipment PPC Valve Assembly…1319
Disassembly…1319
Assembly…1319
Travel PPC Valve Assembly…1321
Assembly…1321
Boom Swing Cylinder Assembly…1323
Removal…1323
Installation…1326
Hydraulic Cylinder Assembly…1327
Disassembly…1328
Assembly…1331
WORK EQUIPMENT…1335
Work Equipment Assembly (Machine With Boom Hydraulic Drift Prevention Valve)…1335
Removal…1335
Installation…1338
Boom Swing Bracket…1339
Removal…1339
Installation…1342
Blade Assembly…1343
Removal…1343
Installation…1344
CAB AND ITS ATTACHMENTS…1345
Operator Cab Assembly…1345
Removal…1345
Installation…1351
Operator’s Cab Glass (Stuck glass)…1353
Removal…1354
Installation…1355
Front Window Assembly…1364
Removal…1364
Installation…1364
Floor Frame Assembly…1365
Removal…1365
Installation…1372
Air Conditioner Compressor Assembly…1373
Removal…1373
Installation…1374
Air Conditioner Condenser Assembly…1375
Removal…1375
Installation…1375
Air Conditioner Unit Assembly…1377
Removal…1377
Installation…1382
ELECTRICAL SYSTEM…1383
Machine Monitor Assembly…1383
Removal…1383
Installation…1384
Pump Controller Assembly…1385
Removal…1385
Installation…1387
Engine Controller Assembly…1389
Removal…1389
Installation…1392
KOMTRAX Terminal Assembly…1393
Removal…1393
Installation…1393
90 DIAGRAMS AND SCHEMATICS…1394
HYDRAULIC SYSTEM…1396
Hydraulic Circuit Diagram…1396
ELECTRICAL SYSTEM…0
Electrical Circuit Diagram (2/6)…1398
Electrical Circuit Diagram (3/6)…1399
Electrical Circuit Diagram (4/6)…1400
Electrical Circuit Diagram (5/6)…1401
Electrical Circuit Diagram (6/6)…1402
Electrical Circuit Diagram for Air Conditioner…1403
Connector List and Stereogram…1404
SEN04329-11 – Hydraulic Excavator PC88MR-8 Shop Manual…1405
COVER…1405
00 Index and foreword…0
100 Index…1407
Composition of shop manual…1408
Table of contents…1410
200 Foreword and general information…1419
Safety notice…1420
How to read the shop manual…1425
Explanation of terms for maintenance standard…1427
Handling of electric equipment and hydraulic component…1429
Handling of connectors newly used for engines…1438
How to read electric wire code…1441
Precautions when carrying out operation…1444
Method of disassembling and connecting push-pull type coupler…1447
Standard tightening torque table…1450
Conversion table…1454
01 Specification…0
100 Specification and technical data…1461
Specification dimension drawing…1462
Working range diagram…1463
Specifications…1464
Weight table…1467
Table of fuel, coolant and lubricants…1469
10 Structure, function and maintenance standard…0
100 Engine and cooling system…1471
Engine mount…1472
PTO…1473
Cooling system…1474
200 Power train…1477
Power train…1478
Swing circle…1480
Swing machinery…1482
300 Undercarriage and frame…1485
Track frame…1486
Idler cushion…1487
Idler…1488
Track roller…1489
Carrier roller…1490
Sprocket…1491
Track shoe…1492
410 Hydraulic system, Part 1…1499
Hydraulic equipment layout drawing…1500
Valve control…1502
Hydraulic tank and filter…1504
Hydraulic pump…1506
420 Hydraulic system, Part 2…1521
Control valve…1523
CLSS…1540
Functions and operation by valve…1544
430 Hydraulic system, Part 3…1575
PPC valve…1577
Swing motor…1589
Travel motor…1599
Center swivel joint…1607
Solenoid valve…1608
PPC accumulator…1615
Anti-drop valve…1618
Multi-control valve…1623
500 Work equipment…1625
Work equipment…1626
Dimensions of components…1628
Work equipment cylinder…1634
600 Cab and its attachments…1639
Air conditioner…1640
700 Electrical system…1653
Electrical control system…1654
Monitor system…1688
KOMTRAX system…1702
Sensor…1653
20 Standard value table…0
100 Standard service value table…1711
Standard value table for engine related parts…1712
Standard value table for chassis…1713
30 Testing and adjusting…0
110 Testing and adjusting, Part 1…1723
Tools for testing, adjusting, and troubleshooting…1725
Testing engine speed…1730
Testing exhaust temperature…1731
Checking exhaust gas color…1732
Adjusting valve clearance…1733
Testing compression pressure…1735
Testing blow-by pressure…1737
Testing engine oil pressure…1738
Handling fuel system parts…1739
Releasing residual pressure from fuel system…1739
Testing fuel pressure…1740
Testing fuel return rate and fuel leakage…1741
Bleeding air from fuel circuit…1743
Checking fuel circuit for leakage…1745
Testing and adjusting alternator belt tension…1746
Checking and adjusting air conditioner compressor belt tension…1748
Testing swing circle bearing clearance…1749
Checking and adjusting track shoe tension…1750
Testing and adjusting oil pressure in work equipment and travel circuits…1752
Testing and adjusting swing and blade circuit oil pressure…1754
Testing control circuit basic pressure…1757
Testing and adjusting oil pressure in pump PC control circuit…1758
Testing PC-EPC solenoid output pressure…1761
Testing LS differential pressure and adjusting LS valve…1762
Testing solenoid valve output pressure…1764
Testing PPC valve output pressure…1765
Adjusting play of work equipment and swing PPC valves…1767
Checking parts which cause hydraulic drift of work equipment…1768
Testing and adjusting travel deviation…1770
Releasing residual pressure from hydraulic circuit…1772
Testing oil leakage…1773
Bleeding air from each part…1776
Adjusting mirrors…1778
Testing and adjusting hood catch…1779
120 Testing and adjusting, Part 2…1783
Special functions of machine monitor…1784
130 Testing and adjusting, Part 3…1835
Handling voltage circuit of engine controller…1836
Preparation work for troubleshooting of electrical system…1837
Procedure for testing diodes…1842
Pm Clinic service…1843
40 Troubleshooting…0
100 Failure code table and fuse locations…1849
Failure code table…1850
Fuse locations…1853
200 General information on troubleshooting…1857
Points to remember when troubleshooting…1858
Sequence of events in troubleshooting…1859
Checks before troubleshooting…1860
Classification and procedures for troubleshooting…1861
Information in troubleshooting table…1862
Phenomena looking like troubles and troubleshooting Nos…1864
Connection table for connector pin numbers…1867
T- branch box and T- branch adapter table…1903
310 Troubleshooting by failure code, Part 1…1907
Failure code [989L00] Engine controller lock caution 1…1909
Failure code [989M00] Engine controller lock caution 2…1910
Failure code [989N00] Engine controller lock caution 3…1911
Failure code [AB00KE] Charge voltage low…1912
Failure code [B@BAZG] Eng oil press. low…1915
Failure code [B@BCNS] Eng coolant overheat…1916
Failure code [B@HANS] Hydr. oil overheat…1916
Failure code [CA111] ECM critical internal failure…1917
Failure code [CA115] Eng. Ne and Bkup speed sensor error…1920
Failure code [CA122] Charge air press sensor high error…1922
Failure code [CA123] Charge air press sensor low error…1924
Failure code [CA131] Throttle sensor high error…1926
Failure code [CA132] Throttle sensor low error…1928
Failure code [CA144] Coolant temp. sensor high error…1930
Failure code [CA145] Coolant temp. sensor low error…1932
Failure code [CA153] Charge air temp. sensor high error…1934
Failure code [CA154] Charge air temp. sensor low error…1936
Failure code [CA187] Sensor sup. 2 volt. low error…1937
Failure code [CA221] Ambient air press. sensor high error…1938
Failure code [CA222] Ambient air press. sensor low error…1940
Failure code [CA227] Sensor sup. 2 volt. high error…1941
Failure code [CA234] Eng. overspeed…1942
Failure code [CA238] Ne speed sensor sup. volt. error…1944
Failure code [CA271] IMV/PCV1 short error…1946
Failure code [CA272] IMV/PCV1 open error…1947
Failure code [CA322] Injector #1 (L #1) system open/short error…1948
Failure code [CA324] Injector #3 (L #3) system open/short error…1950
Failure code [CA331] Injector #2 (L #2) system open/short error…1952
Failure code [CA332] Injector #4 (L #4) system open/short error…1954
320 Troubleshooting by failure code, Part 2…1957
Failure code [CA351] Inj. drive circuit error…1959
Failure code [CA352] Sensor sup. 1 volt. low error…1962
Failure code [CA435] Abnormality in engine oil pressure switch…1966
Failure code [CA441] Battery voltage low error…1967
Failure code [CA442] Battery voltage high error…1968
Failure code [CA449] Rail press. very high error…1969
Failure code [CA451] Rail press. sensor high error…1970
Failure code [CA452] Rail press. sensor low error…1972
Failure code [CA553] Rail press. high error…1972
Failure code [CA559] Rail press. low error…1973
Failure code [CA689] Eng. Ne speed sensor error…1976
Failure code [CA731] Eng. Bkup speed sensor phase error…1978
Failure code [CA757] All persistent data lost error…1979
Failure code [CA778] Eng. Bkup speed sensor error…1980
Failure code [CA1633] KOMNET datalink timeout error…1982
Failure code [CA2185] Throttle sens. sup. volt. high error…1984
Failure code [CA2186] Throttle sens. sup. volt. low error…1986
Failure code [CA2249] Rail press. very low error…1987
Failure code [CA2311] Abnormality in IMV solenoid…1988
Failure code [D110KB] Battery relay drive short…1989
Failure code [D19JKZ] Personal code relay abnormality…1993
Failure code [D862KA] GPS antenna discon…1996
Failure code [DA22KK] Pump solenoid power low error…1997
Failure code [DA25KP] 5 V sensor 1 power abnormality…1999
Failure code [DA26KP] 5 V sensor 2 power abnormality…2002
330 Troubleshooting by failure code, Part 3…2005
Failure code [DA2RMC] CAN discon (Pump controller detected)…2006
Failure code [DAFGMC] GPS module error…2008
Failure code [DAFRMC] CAN discon (Monitor detected)…2010
Failure code [DFB1KZ] Service lever pot. 1 abnormality…2012
Failure code [DFB2KZ] Service lever pot. 2 abnormality…2014
Failure code [DFB3L8] Service lever1 potentio error…2016
Failure code [DFB4L8] Service lever2 potentio error…2018
Failure code [DFB5KZ] Service lever sPot. 1 abnormality…2020
Failure code [DFB6KZ] Service lever sPot. 2 abnormality…2022
Failure code [DGH2KB] Hydr oil sensor short…2024
Failure code [DHPAMA] Pump press sensor abnormality…2026
Failure code [DHS5KX] Travel PPC sensor abnormality…2028
Failure code [DHSAMA] Swing RH PPC press sensor abnormality…2030
Failure code [DHSBMA] Swing LH PPC press sensor abnormality…2032
Failure code [DHX1MA] Overload sensor abnormality…2034
Failure code [DV20KB] Travel alarm short circuit…2035
Failure code [DW43KA] Travel speed sol discon…2036
Failure code [DW43KB] Travel speed sol short…2037
Failure code [DW45KA] Swing brake sol discon…2038
Failure code [DW45KB] Swing brake sol short…2040
Failure code [DWJ0KA] Merge-divider sol discon…2042
Failure code [DWJ0KB] Merge-divider sol short…2043
340 Troubleshooting by failure code, Part 4…2045
Failure code [DXA8KA] PC-EPC sol discon…2046
Failure code [DXA8KB] PC-EPC sol short…2048
Failure code [DXE7KA] Service current EPC2 open circuit…2050
Failure code [DXE7KB] Service current EPC2 short circuit…2052
Failure code [DXE8KA] Service current EPC3 open circuit…2054
Failure code [DXE8KB] Service current EPC3 short circuit…2056
Failure code [DXE9KA] Service current EPC4 open circuit…2058
Failure code [DXE9KB] Service current EPC4 short circuit…2060
Failure code [DXEAKA] Service current EPC1 open circuit…2062
Failure code [DXEAKB] Service current EPC1 short circuit…2064
Failure code [DY20KA] Wiper working abnormality…2066
Failure code [DY20MA] Wiper parking abnormality…2068
Failure code [DY2CKA] Washer drive open circuit…2070
Failure code [DY2CKB] Washer drive short circuit…2072
Failure code [DY2DKB] Wiper drive (fwd) short circuit…2074
Failure code [DY2EKB] Wiper drive (rev) short circuit…2076
400 Troubleshooting of electrical system (E-mode)…2079
Before carrying out troubleshooting of electrical system…2081
Information in troubleshooting table…2084
E-1 When starting switch is turned ON, machine monitor displays nothing…2086
E-2 Engine does not start (Engine does not turn)…2088
E-3 Preheater does not operate…2092
E-4 Automatic warm-up system does not operate (in cold season)…2095
E-5 All work equipment, swing, and travel mechanism do not move or cannot be locked…2096
E-6 Precaution lights up while engine is running…2098
E-7 Emergency stop item lights up while engine is running…2102
E-8 Engine coolant temperature gauge does not indicate normally…2103
E-9 Hydraulic oil temperature gauge does not indicate normally…2104
E-10 Fuel level gauge does not indicate normally…2107
E-11 Contents of display by machine monitor are different from applicable machine…2109
E-12 Machine monitor does not display some items…2109
E-13 Function switch does not work…2109
E-14 Auto-decelerator does not operate normally…2110
E-15 Working mode does not change…2111
E-16 Travel speed does not change…2112
E-17 Alarm buzzer cannot be stopped…2113
E-18 Windshield wiper and window washer do not operate…2114
E-19 Swing holding brake does not operate normally…2118
E-20 Travel alarm does not sound or does not stop sounding…2120
E-21 Air conditioner does not operate normally (including air conditioner abnormality record)…2121
E-22 While starting switch is in OFF position, service meter is not displayed…2134
E-23 Machine monitor cannot be set in service mode…2135
E-24 Monitoring function does not display lever control signal normally…2136
E-25 KOMTRAX system does not operate normally…2156
500 Troubleshooting of hydraulic and mechanical system (H-mode)…2159
Information contained in troubleshooting table…2161
System chart for hydraulic and mechanical systems…2162
H-1 Speed or power of all work equipment, swing, and travel are low…2164
H-2 Engine speed sharply drops or engine stalls…2165
H-3 No work equipment, travel and swing move…2166
H-4 Abnormal noise is heard from around hydraulic pump…2166
H-5 Fine control performance or response of work equipment and travel is low…2167
H-6 Speed or power of boom is low…2168
H-7 Speed or power of arm is low…2169
H-8 Speed or power of bucket is low…2170
H-9 Speed or power of boom swing is low…2171
H-10 Speed or power of blade is low…2172
H-11 Work equipment does not move in its single operation…2173
H-12 Hydraulic drift of work equipment is large…2174
H-13 Time lag of work equipment is large…2176
H-14 Work equipment loaded more is slower during compound operation…2176
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE…2176
H-16 Travel speed lowers significantly during compound operation of work equipment/swing + travel…2177
H-17 Machine deviates during travel…2178
H-18 Travel speed is low…2179
H-19 Machine cannot be steered easily or steering power is low…2180
H-20 Travel speed does not change or it is kept low or high…2181
H-21 Track does not move (only either side)…2181
H-22 Machine does not swing…2182
H-23 Swing acceleration, swing speed and swing power are low…2183
H-24 Excessive overrun when stopping swing…2185
H-25 When upper structure stops swinging, it makes large shock…2186
H-26 When upper structure stops swinging, it makes large sound…2186
H-27 Hydraulic drift of swing is large…2187
H-28 Flow rate in attachment circuit cannot be adjusted…2188
600 Troubleshooting of engine (S-mode)…2191
Method of using troubleshooting chart…2192
S-1 Starting performance is poor…2196
S-2 Engine does not start…2197
S-3 Engine does not pick up smoothly…2200
S-4 Engine stops during operations…2201
S-5 Engine does not rotate smoothly…2202
S-6 Engine lacks output (or lacks power)…2203
S-7 Exhaust smoke is black (incomplete combustion)…2204
S-8 Oil consumption is excessive (or exhaust smoke is blue)…2205
S-9 Oil becomes contaminated quickly…2206
S-10 Fuel consumption is excessive…2207
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…2208
S-12 Oil pressure drops…2209
S-13 Oil level rises (Entry of coolant or fuel)…2210
S-14 Coolant temperature becomes too high (overheating)…2211
S-15 Abnormal noise is made…2212
S-16 Vibration is excessive…2213
50 Disassembly and assembly…0
100 General information on disassembly and assembly…2215
How to read this manual…2216
Coating materials list…2218
Special tool list…2221
Sketches of special tools…2225
200 Engine and cooling system…2231
Removal and installation of fuel supply pump assembly…2232
Removal and installation of fuel injector assembly…2236
Removal and installation of engine front seal…2240
Removal and installation of engine rear seal…2241
Removal and installation of cylinder head assembly…2243
Removal and installation of radiator assembly…2254
Removal and installation of aftercooler assembly…2257
Removal and installation of hydraulic oil cooler assembly…2259
Removal and installation of engine and hydraulic pump assembly…2262
Removal and installation of fuel tank assembly…2272
Removal and installation of fuel tank assembly…2273
300 Power train…2277
Removal and installation of travel motor and final drive assembly…2279
Disassembly and assembly of travel motor and final drive assembly…2281
Removal and installation of swing motor and swing machinery assembly…2319
Disassembly and assembly of swing machinery…2321
Removal and installation of swing circle assembly…2330
400 Undercarriage and frame…2333
Disassembly and assembly of track roller assembly…2334
Disassembly and assembly of idler assembly…2337
Disassembly and assembly of recoil spring assembly…2340
Spreading and installation of track shoe assembly…2342
Removal and installation of sprocket…2344
Removal and installation of revolving frame assembly…2345
Removal and installation of counterweight assembly…2348
500 Hydraulic system…2353
Removal and installation of center swivel joint assembly…2354
Disassembly and assembly of center swivel joint assembly…2356
Removal and installation of hydraulic tank assembly…2358
Removal and installation of hydraulic pump assembly…2361
Removal and installation of control valve assembly…2365
Disassembly and assembly of control valve assembly…2373
Disassembly and assembly of work equipment PPC valve assembly…2379
Disassembly and assembly of travel PPC valve assembly…2381
Removal and installation of boom swing cylinder assembly…2383
Disassembly and assembly of hydraulic cylinder assembly…2386
600 Work equipment…2393
Removal and installation of work equipment assembly…2394
Removal and installation of boom swing bracket…2397
Removal and installation of blade assembly…2401
700 Cab and its attachments…2405
Removal and installation of operator cab assembly…2406
Removal and installation of operator’s cab glass (Stuck glass)…2411
Removal and installation of front window assembly…2421
Removal and installation of floor frame assembly…2422
800 Electrical system…2429
Removal and installation of air conditioner compressor assembly…2430
Removal and Installation of air conditioner condenser assembly…2431
Removal and installation of air conditioner unit assembly…2432
Removal and installation of machine monitor assembly…2436
Removal and installation of pump controller assembly…2438
Removal and installation of engine controller assembly…2440
Removal and installation of KOMTRAX terminal assembly…2442
90 Diagrams and drawings…0
100 Hydraulic diagrams and drawings…2445
Hydraulic circuit diagram…2447
200 Electrical diagrams and drawings…2452
Electrical circuit diagram…2454
Electrical circuit diagram of the air conditioner unit…2466
Connector list and stereogram…2467
SEN06467-02 – Hydraulic Excavator PC88MR-10 Shop Manual…2470
Cover…2470
00 Index and foreword …2472
Index …2473
Foreword, safety and general information …2484
Important safety notice …2484
How to read the shop manual …2491
Explanation of terms for maintenance standard …2493
Handling equipment of fuel system devices …2495
Handling of intake system parts …2496
Handling of hydraulic equipment …2497
Method of disconnecting and connecting of push-pull type coupler …2499
Handling of electrical equipment …2502
How to read electric wire code …2510
Precautions when performing operation …2513
Practical use of KOMTRAX …2518
Standard tightening torque table …2519
List of abbreviation …2525
Conversion table …2530
01 Specification …2536
Table of contents …2537
Specifications …2538
Specification drawing …2538
Working range drawings …2539
Specifications …2540
Weight table …2544
Table of fuel, coolant, and lubricants …2546
10 Structure and function …2548
Table of contents …2549
Engine and cooling system …2550
Engine related parts …2550
PTO …2552
VFT …2553
EGR system piping drawing …2557
EGR system circuit diagram …2559
EGR valve …2560
EGR cooler …2562
KCCV layout drawing …2564
KCCV ventilator …2567
KDOC muffler …2569
Cooling system …2571
Power train …2574
Power train system …2574
Swing circle …2576
Swing machinery …2578
Undercarriage and frame …2580
Track frame …2580
Idler cushion …2582
Hydraulic system …2583
Hydraulic component layout …2583
Valve control …2585
Hydraulic tank …2587
CLSS …2591
Main pump …2595
Control valve …2607
Swing motor …2655
Travel motor …2666
Work equipment and swing PPC valve …2677
Travel PPC valve …2684
Blade PPC valve …2690
Boom swing PPC valve …2692
Solenoid valve …2694
Multi-control valve …2698
Center swivel joint …2699
Accumulator …2700
Work equipment …2702
Work equipment …2702
Work equipment shim …2703
Bucket play adjustment shim …2704
Cab and its attachments …2705
Cab mount and cab tipping stopper …2705
ROPS cab …2707
Electrical system …2709
Electrical control system …2709
Machine monitor system …2754
KOMTRAX system …2776
KOMTRAX terminal …2776
Sensor …2778
20 Standard value tables …2786
Table of contents …2787
Standard service value table …2788
Standard value table for engine …2788
Standard value table for machine …2790
Standard value table for electrical system …2806
30 Testing and adjusting …2812
Table of contents …2813
Related information on testing and adjusting …2814
Tools for testing and adjusting …2814
Sketch of tools for testing and adjusting …2817
Engine and cooling system …2819
Testing engine speed …2819
Testing exhaust gas color …2820
Testing and adjusting valve clearance …2821
Testing compression pressure …2823
Testing blowby pressure …2825
Testing engine oil pressure …2826
Testing fuel pressure …2827
Testing fuel return rate and leakage …2828
Bleeding air from fuel system …2831
Testing fuel circuit for leakage …2833
Handling cylinder cutout mode operation …2834
Handling no-injection cranking operation …2835
Testing and adjusting air conditioner compressor belt tension …2836
Replacing fan belt …2837
Writing compensation values at replacement of injector and engine controller …2839
Power train …2843
Testing swing circle bearing clearance …2843
Undercarriage and frame …2844
Testing and adjusting track tension …2844
Hydraulic system …2845
Releasing remaining pressure from hydraulic circuit …2845
Testing and adjusting oil pressure in work equipment and travel circuits …2847
Testing and adjusting swing and blade circuit oil pressure …2850
Testing oil pressure of control circuit …2853
Testing and adjusting oil pressure in pump PC control circuit …2854
Testing and adjusting oil pressure in pump LS control circuit …2857
Testing outlet pressure of solenoid valve …2860
Testing PPC valve outlet pressure …2861
Adjusting play of work equipment and swing PPC valves …2862
Isolating the parts causing hydraulic drift in work equipment …2863
Testing and adjusting travel deviation …2864
Testing oil leakage …2866
Bleeding air from hydraulic circuit …2870
Cab and its attachments …2873
Testing, cleaning and lubricating slide door rail and roller …2873
Adjusting mirrors …2874
Testing and adjusting hood catcher …2876
Electrical system …2878
Special functions of machine monitor …2878
KOMTRAX terminal start-up procedure …2926
Adjusting rearview camera angle …2930
Handling voltage circuit of engine controller …2932
Handling battery disconnect switch …2933
Testing diodes …2934
Pm clinic …2935
Pm Clinic service …2935
40 Troubleshooting …2944
Table of contents …2945
Related information on troubleshooting …2951
Troubleshooting points …2951
Sequence of events in troubleshooting …2953
Checks before troubleshooting …2955
Inspection procedure before troubleshooting …2957
Preparation for troubleshooting of electrical system …2974
Classification and procedures for troubleshooting …2979
Symptom and troubleshooting numbers …2982
Information in troubleshooting table …2985
Troubleshooting method for open circuit in wiring harness of pressure sensor system …2987
Connector list and layout …2989
Connector contact identification …2998
T-branch box and T-branch adapter table …3036
Fuse location table …3041
Failure codes table …3043
Troubleshooting by failure code (Display of code) …3049
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit …3049
Failure code [879AKB] A/C Recirc Air Temp Sens Short …3050
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit …3051
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit …3052
Failure code [879CKA] Ventilating Sensor Open Circuit …3053
Failure code [879CKB] Ventilating Sensor Short Circuit …3054
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit …3055
Failure code [879EMC] Ventilation Damper Malfunction …3056
Failure code [879FMC] Air Mix Damper Malfunction …3057
Failure code [879GKX] Refrigerant Press Input Sig Out of Range …3058
Failure code [989L00] Engine Controller Lock Caution 1 …3059
Failure code [989M00] Engine Controller Lock Caution 2 …3060
Failure code [989N00] Engine Controller Lock Caution 3 …3061
Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3 …3062
Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1 …3063
Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2 …3064
Failure code [AB00KE] Charge Voltage Low …3065
Failure code [B@BAZG] Eng Oil Press Low …3067
Failure code [B@BCNS] Eng Water Overheat …3068
Failure code [CA115] Eng Ne and Bkup Speed Sens Error …3069
Failure code [CA122] Charge Air Pressure Sensor High Error …3070
Failure code [CA123] Charge Air Pressure Sensor Low Error …3072
Failure code [CA131] Throttle Sensor High Error …3074
Failure code [CA132] Throttle Sensor Low Error …3076
Failure code [CA144] Coolant Temperature Sensor High Error …3078
Failure code [CA145] Coolant Temperature Sensor Low Error …3080
Failure code [CA153] Charge Air Temperature Sensor High Error …3082
Failure code [CA154] Charge Air Temperature Sensor Low Error …3084
Failure code [CA187] Sensor 2 Supply Voltage Low Error …3086
Failure code [CA221] Ambient Pressure Sensor High Error …3088
Failure code [CA222] Ambient Pressure Sensor Low Error …3090
Failure code [CA227] Sensor 2 Supply Voltage High Error …3092
Failure code [CA234] Engine Overspeed …3093
Failure code [CA238] NE Speed Sensor Supply Voltage Error …3094
Failure code [CA239] NE Speed Sensor Supply Voltage High Error …3095
Failure code [CA271] PCV1 Short Circuit Error …3096
Failure code [CA272] PCV1 Open Circuit Error …3097
Failure code [CA322] Injector #1 (L#1) Open or Short Circuit …3098
Failure code [CA324] Injector #3 (L#3) Open or Short Circuit …3100
Failure code [CA331] Injector #2 (L#2) Open or Short Circuit …3102
Failure code [CA332] Injector #4 (L#4) Open or Short Circuit …3104
Failure code [CA343] Engine Controller Internal Failure …3106
Failure code [CA351] Injectors Drive Circuit Error …3107
Failure code [CA352] Sensor1 Supply Voltage Low Error …3108
Failure code [CA356] MAF Sensor High Error …3110
Failure code [CA357] MAF Sensor Low Error …3112
Failure code [CA386] Sensor1 Supply Voltage High Error …3114
Failure code [CA435] Engine Oil Pressure SW Error …3115
Failure code [CA441] Battery Voltage Low Error …3116
Failure code [CA442] Battery Voltage High Error …3118
Failure code [CA449] Common Rail Pressure High Error 2 …3119
Failure code [CA451] Common Rail Pressure Sensor High Error …3120
Failure code [CA452] Common Rail Pressure Sensor Low Error …3122
Failure code [CA466] KVGT Motor Driver Position Error …3124
Failure code [CA515] Rail Pressure Sensor Sup Volt High Error …3126
Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error …3128
Failure code [CA553] Common Rail Pressure High Error 1 …3130
Failure code [CA555] Crankcase Pressure High Error 1 …3131
Failure code [CA556] Crankcase Pressure High Error 2 …3132
Failure code [CA559] Common Rail Pressure Low Error 1 …3133
Failure code [CA689] Engine NE Speed Sensor Error …3136
Failure code [CA691] Intake Air Temperature Sensor High Error …3138
Failure code [CA692] Intake Air Temperature Sensor Low Error …3140
Failure code [CA697] Engine Con Internal Temp Sens High Error …3142
Failure code [CA698] Engine Con Internal Temp Sens Low Error …3143
Failure code [CA731] Engine Backup Speed Sensor Phase Error …3144
Failure code [CA778] Engine Backup Speed Sensor Error …3146
Failure code [CA1117] Engine Controller Partial Data Lost Error …3150
Failure code [CA1695] Sensor 5 Supply Voltage High Error …3151
Failure code [CA1696] Sensor 5 Supply Voltage Low Error …3152
Failure code [CA1843] Crankcase Pressure Sensor High Error …3153
Failure code [CA1844] Crankcase Pressure Sensor Low Error …3155
Failure code [CA1896] EGR Valve Stuck Error …3157
Failure code [CA1942] Crankcase Pressure Sensor In Range Error …3158
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error …3159
Failure code [CA2185] Throttle Sensor Supply Voltage High Error …3160
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error …3162
Failure code [CA2249] Common Rail Pressure Low Error 2 …3164
Failure code [CA2272] EGR Valve Position Sensor Low Error …3165
Failure code [CA2311] IMV Solenoid Error …3167
Failure code [CA2349] EGR Valve Solenoid Open Circuit Error …3168
Failure code [CA2353] EGR Valve Solenoid Short Circuit Error …3170
Failure code [CA2357] EGR Valve Servo Error …3172
Failure code [CA2765] Injector Trim Data Mismatch …3173
Failure code [CA3419] MAF Sensor Supply Voltage High Error …3174
Failure code [CA3421] MAF Sensor Supply Voltage Low Error …3176
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error …3178
Failure code [CA3918] KVGT Stuck Error …3180
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error …3181
Failure code [CA3921] KVGT Servo Error 2 …3182
Failure code [CA3922] KVGT Motor Driver Open Error …3183
Failure code [CA3923] KVGT Motor Driver Short Error …3185
Failure code [D110KB] Battery Relay Output Short Circuit …3187
Failure code [D19JKZ] Personal Code Relay Open or Short …3189
Failure code [D811MC] KOMTRAX Malfunction …3192
Failure code [D862KA] GPS Antenna Open Circuit …3193
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) …3194
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) …3196
Failure code [D8AQKR] CAN 2 Defective Communication (KOMTRAX) …3197
Failure code [DA20MC] Pump Controller Malfunction …3199
Failure code [DA22KK] Pump Con Solenoid Power Volt Low Error …3200
Failure code [DA25KP] 5V Sensor 1 Power Voltage Low Error …3202
Failure code [DA29KQ] Model Selection Sig Mismatch (Pump Con) …3204
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) …3206
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) …3208
Failure code [DA2QKR] CAN 2 Defective Communication (Pump Con) …3209
Failure code [DA2RKR] CAN 1 Defective Communication (Pump Con) …3211
Failure code [DAF0MB] Monitor ROM Abnormality …3212
Failure code [DAF0MC] Monitor Malfunction …3213
Failure code [DAF8KB] Camera Power Supply Short Circuit …3214
Failure code [DAF9KQ] Model Selection Signal Mismatch (Monitor) …3215
Failure code [DAFGMC] GPS Module Malfunction …3216
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) …3217
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) …3219
Failure code [DAFQKR] CAN 2 Defective Communication (Monitor) …3220
Failure code [DAZ9KQ] Model Selection Sig Mismatch (A/C) …3221
Failure code [DAZQKR] CAN2 Defective Communication (A/C ECU) …3222
Failure code [DB2QKR] CAN2 Defective Communication (Engine Con) …3226
Failure code [DB2RKR] CAN1 Defective Communication (Engine Con) …3230
Failure code [DDNRKA] WE Lever Lock SW Open Circuit …3234
Failure code [DDNRKY] WE Lever Lock SW Short Circuit …3236
Failure code [DDNS00] Lock Lever Auto Lock Release SW On …3238
Failure code [DGH2KB] Hydraulic Oil Temp Sensor Ground Fault …3240
Failure code [DHPAMA] Front Pump Press Sens Defective Function …3242
Failure code [DHS3MA] Arm IN PPC Press Sensor Def Function …3244
Failure code [DHS4MA] Bucket CURL PPC Press Sens Def Function …3246
Failure code [DHS5MA] Travel PPC Sensor Abnormality …3248
Failure code [DHS8MA] Boom Raise PPC Press Sens Def Function …3250
Failure code [DHS9MA] Boom Lower PPC Press Sens Def Function …3252
Failure code [DHSAMA] Swing Right PPC Press Sens Def Function …3254
Failure code [DHSBMA] Swing Left PPC Press Sensor Def Function …3256
Failure code [DHSCMA] Arm OUT PPC Press Sens Def Function …3258
Failure code [DHSDMA] Bucket DUMP PPC Press Sens Def Function …3260
Failure code [DHSPMA] Boom Swing LH PPC Press Sensor Abnormality …3262
Failure code [DHSQMA] Boom Swing RH PPC Press Sensor Abnormality …3264
Failure code [DKULKA] PPC Lock Relay Open Circuit …3266
Failure code [DKULKB] PPC Lock Relay Short Circuit …3268
Failure code [DKULKY] PPC Lock Relay Hot Short Circuit …3270
Failure code [DV20KB] Travel Alarm Short Circuit …3272
Failure code [DW43KA] Travel Speed Solenoid Open Circuit …3274
Failure code [DW43KB] Travel Speed Solenoid Short Circuit …3276
Failure code [DW43KY] Travel Speed Sol Hot Short Circuit …3278
Failure code [DW45KA] Swing Parking Brake Solenoid Open Circuit …3279
Failure code [DW45KB] Swing Parking Brake Solenoid Short Circuit …3282
Failure code [DW45KY] Swing Brake Sol Hot Short Circuit …3284
Failure code [DW4CKY] PPC lock Sol Hot Short Circuit …3286
Failure code [DWJ0KA] Merge-divider Sol Open Circuit …3288
Failure code [DWJ0KB] Merge-divider Sol Short Circuit …3290
Failure code [DWJ0KY] Merge-divider Sol Short Circuit …3292
Failure code [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit …3293
Failure code [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit …3295
Failure code [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit …3297
Failure code [DXE7KB] Att Flow Regulating EPC 2 Short Circuit …3299
Failure code [DXE7KY] Attachment Flow Regulating EPC 2 Solenoid Hot Short Circuit …3301
Failure code [DXEAKA] Att Flow Regulating EPC 5 Open Circuit …3303
Failure code [DXEAKB] Att Flow Regulating EPC 5 Short Circuit …3305
Failure code [DXEAKY] Service Current EPC5 Hot Short Circuit …3307
Failure code [DY20KA] Wiper Motor Open Circuit …3309
Failure code [DY20MA] Wiper Motor Defective Function …3311
Failure code [DY2CKB] Washer Motor Short Circuit …3313
Failure code [DY2DKB] Wiper Motor (Normal) Short Circuit …3315
Failure code [DY2EKB] Wiper Motor (Reverse) Short Circuit …3317
Troubleshooting of electrical system (E-mode) …3319
E-1 Engine does not start (Engine does not crank) …3319
E-2 Manual preheating system does not work …3325
E-3 While preheating is working, preheating monitor does not light up …3328
E-4 When starting switch is turned to ON position, machine monitor displays nothing …3330
E-5 Engine coolant temperature monitor lights up in white while engine is running …3333
E-6 Hydraulic oil temperature monitor lights up in white while engine is running …3334
E-7 Charge level monitor lights up while engine is running …3335
E-8 Fuel level monitor lights up in red while engine is running …3336
E-9 Engine coolant temperature monitor lights up in red while engine is running …3337
E-10 Hydraulic oil temperature monitor lights up in red while engine is running …3338
E-11 Engine oil pressure monitor lights up in red while engine is running …3339
E-12 Fuel gauge display does not move from minimum or maximum …3340
E-13 Fuel gauge indicates incorrect amount (indicates neither full nor empty) …3341
E-14 Engine coolant temperature gauge display does not move from minimum or maximum …3342
E-15 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full nor empty) …3343
E-16 Hydraulic oil temperature gauge does not move from minimum or maximum …3344
E-17 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor empty) …3346
E-18 Some areas of machine monitor screen are not displayed …3347
E-19 Function switch does not work …3348
E-20 Automatic warm-up system does not operate (in cold season) …3349
E-21 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated …3350
E-22 Auto-deceleration function does not operate or is not canceled while lever is operated …3351
E-23 Working mode selection screen is not displayed while working mode selector switch is operated …3353
E-24 Setting of engine and hydraulic pump is not changed while working mode is changed …3354
E-25 Travel speed monitor does not change when travel speed switch is operated …3355
E-26 Travel speed does not change while travel speed selection is changed …3356
E-27 Alarm buzzer does not stop sounding …3357
E-28 Service meter is not displayed, while starting switch is in OFF position …3358
E-29 Service mode cannot be selected …3359
E-30 Any of work equipment, swing and travel does not work …3360
E-31 Any of work equipment, swing and travel cannot be locked …3362
E-32 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position …3364
E-33 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position …3366
E-34 Work equipment does not operate while lock lever automatic release switch is in release position …3368
E-35 Alarm does not sound during travel …3370
E-36 Alarm does not stop sounding while machine is stopped …3371
E-37 Horn does not sound …3372
E-38 Horn does not stop sounding …3374
E-39 Wiper monitor does not light up, or does not go out, while wiper switch is operated …3375
E-40 Wiper does not operate while wiper switch is operated …3376
E-41 Window washer does not operate while window washer switch is operated …3378
E-42 Boom LOWER is not displayed correctly with monitoring function …3379
E-43 Arm OUT is not displayed correctly with monitoring function …3380
E-44 Arm IN is not displayed correctly with monitoring function …3381
E-45 Boom RAISE is not displayed correctly with monitoring function …3382
E-46 Bucket CURL is not displayed correctly with monitoring function …3383
E-47 Bucket DUMP is not displayed correctly with monitoring function …3384
E-48 Boom swing left is not displayed correctly with monitoring function …3385
E-49 Boom swing right is not displayed correctly with monitoring function …3386
E-50 Swing is not displayed correctly with monitoring function …3387
E-51 Travel is not displayed correctly with monitoring function …3388
E-52 Blade RAISE ON is not displayed correctly with monitoring function …3389
E-53 Blade LOWER ON is not displayed correctly with monitoring function …3391
E-54 KOMTRAX system does not operate normally …3393
Troubleshooting of hydraulic and mechanical system (H-mode) …3395
Information described in troubleshooting table (H-mode) …3395
System chart of hydraulic and mechanical systems …3396
Failure mode and cause table …3398
H-1 All of work equipments, swing and travel operations lack speed or power …3406
H-2 Engine speed drops significantly or engine stalls …3408
H-3 Any of work equipment, swing and travel does not work …3409
H-4 Unusual sound is heard from around hydraulic pump …3410
H-5 Fine control performance or response is poor …3411
H-6 Boom speed or power is low …3412
H-7 Arm speed or power is low …3415
H-8 Bucket speed or power is low …3417
H-9 Boom swing speed or power is low …3419
H-10 Blade speed or power is low …3421
H-11 Work equipment does not move in single operation …3423
H-12 Hydraulic drift of boom is large …3424
H-13 Hydraulic drift of arm is large …3425
H-14 Hydraulic drift of bucket is large …3426
H-15 Hydraulic drift of blade is large …3427
H-16 Time lag of work equipment is large …3428
H-17 In combined operation of work equipment , equipment having heavier load moves slower …3430
H-18 In combined operation of swing and boom RAISE, boom rising speed is low …3431
H-19 In combined operation of work equipment or swing and travel, travel speed drops largely …3432
H-20 Machine does not travel straight …3434
H-21 Travel speed is slow …3436
H-22 Machine is hard to steer or travel power is low …3438
H-23 Travel speed does not change, or travel speed is too slow or fast …3441
H-24 One of tracks does not run …3442
H-25 Upper structure does not swing to the right or left …3444
H-26 Upper structure swing only to the right or left …3445
H-27 Swing acceleration or swing speed is low in both directions (right and left) …3446
H-28 Swing acceleration performance is poor or swing speed is slow in only one direction …3447
H-29 Upper structure overruns excessively when it stops swinging (both right and left) …3448
H-30 Upper structure overruns excessively when it stops swinging (either right or left) …3449
H-31 Shock is large when upper structure stops swinging …3450
H-32 Large unusual noise is heard when upper structure stops swinging …3451
H-33 Swing drift on a slope is large while swing parking brake is applied …3452
H-34 Swing drift on a slope is large while swing parking brake is released …3453
H-35 Oil flow in attachment circuit cannot be controlled …3454
Troubleshooting of engine (S-mode) …3455
Information mentioned in troubleshooting table (S mode) …3455
S-1 Engine does not crank when starting switch is turned to START position …3456
S-2 Engine cranks but no exhaust smoke comes out …3457
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) …3458
S-4 Engine startability is poor …3459
S-5 Engine does not pick up smoothly …3461
S-6 Engine stops during operation …3463
S-7 Engine runs rough or is unstable …3465
S-8 Engine lacks power …3466
S-9 Exhaust smoke is black …3468
S-10 Engine oil consumption is excessive …3470
S-11 Oil becomes contaminated quickly …3471
S-12 Fuel consumption is excessive …3472
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) …3473
S-14 Oil pressure drops …3474
S-15 Fuel mixes into engine oil …3475
S-16 Water mixes into engine oil (milky) …3476
S-17 Coolant temperature rises too high (overheating) …3477
S-18 Unusual noise is heard …3478
S-19 Vibration is excessive …3479
S-20 Air cannot be bled from fuel circuit …3480
50 Disassembly and assembly …3482
Table of contents …3483
Related information on disassembly and assembly …3485
How to read this manual …3485
Coating materials list …3487
Special tools list …3491
Sketches of special tools …3496
Engine and cooling system …3498
Removal and installation of supply pump assembly …3498
Removal and installation of injector assembly …3501
Removal and installation of cylinder head assembly …3508
Removal and installation of radiator assembly …3520
Removal and installation of hydraulic oil cooler assembly …3524
Removal and installation of aftercooler assembly …3527
Removal and installation of engine and main pump assembly …3530
Removal and installation of engine front oil seal …3538
Removal and installation of engine rear oil seal …3539
Removal and installation of fuel cooler assembly …3541
Removal and installation of fuel tank assembly …3542
Removal and installation of engine hood assembly …3544
Removal and installation of KDOC muffler …3545
Removal and installation of KCCV ventilator …3548
Removal and installation of air cleaner assembly …3550
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly …3552
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly …3554
Removal and installation of fan belt …3555
Power train system …3556
Removal and installation of travel motor and final drive assembly …3556
Disassembly and assembly of travel motor and final drive assembly …3558
Removal and installation of swing motor and swing machinery assembly …3591
Disassembly and assembly of swing machinery assembly …3593
Removal and installation of swing circle assembly …3601
Undercarriage and frame …3602
Separation and connection of track …3602
Removal and installation of sprocket …3603
Removal and installation of idler and idler cushion assembly …3604
Disassembly and assembly of idler assembly …3605
Disassembly and assembly of idler cushion assembly …3608
Disassembly and assembly of track roller assembly …3611
Removal and installation of revolving frame assembly …3614
Removal and installation of counterweight assembly [For machines with additional counterweight] …3616
Hydraulic system …3618
Removal and installation of center swivel joint assembly …3618
Disassembly and assembly of center swivel joint assembly …3620
Removal and installation of hydraulic tank assembly …3621
Removal and installation of main pump assembly …3624
Removal and installation of control valve assembly …3628
Disassembly and assembly of control valve assembly …3632
Disassembly and assembly of work equipment PPC valve assembly …3635
Disassembly and assembly of travel PPC valve assembly …3637
Disassembly and assembly of work equipment cylinder assembly …3638
Work equipment …3642
Removal and installation of work equipment assembly …3642
Removal and installation of boom swing bracket …3645
Removal and installation of blade assembly …3646
Cab and its attachments …3648
Removal and installation of operator’s cab assembly …3648
Removal and installation of operator’s cab door …3652
Removal and installation of operator’s cab glass (adhered glass) …3655
Removal and installation of front window assembly …3666
Removal and installation of floor frame assembly …3667
Removal and installation of air conditioner unit assembly …3672
Removal and installation of air conditioner compressor assembly …3677
Removal and installation of air conditioner condenser assembly …3679
Removal and installation of operator’s seat …3681
Removal and installation of seat belt …3682
Removal and installation of front wiper assembly …3683
Electrical system …3689
Removal and installation of starting motor assembly …3689
Removal and installation of engine controller assembly …3690
Removal and installation of pump controller assembly …3691
Removal and installation of machine monitor assembly …3692
Removal and installation of mass air flow and temperature sensor …3694
Removal and installation of KOMTRAX terminal assembly …3695
60 Maintenance standard …3696
Table of contents …3697
Engine and cooling system …3698
Engine mount …3698
PTO …3699
Cooling system …3700
Power train system …3702
Swing circle …3702
Swing machinery …3704
Sprocket …3706
Undercarriage and frame …3707
Track frame …3707
Idler cushion …3708
Idler …3709
Track roller …3710
Carrier roller …3711
Track shoe …3712
Hydraulic system …3718
Hydraulic tank …3718
Main pump …3719
Control valve …3723
Swing motor …3732
Travel motor …3734
PPC valve …3735
Work equipment and swing PPC valve …3735
Travel PPC valve …3738
Blade PPC valve …3740
Boom swing PPC valve …3742
Solenoid valve …3744
Center swivel joint …3746
Cab and its attachments …3747
Cab mount and cab tipping stopper …3747
Work equipment …3748
Work equipment …3748
Boom cylinder …3759
Arm cylinder …3760
Bucket cylinder …3761
Boom swing cylinder …3762
Blade cylinder …3763
80 Appendix …3764
Table of contents …3765
Air conditioner components …3766
Precautions for refrigerant …3766
Air conditioner component …3767
Configuration and function of refrigeration cycle …3770
Outline of refrigeration cycle …3771
Air conditioner unit …3773
Dual pressure switch …3778
Air conditioner controller …3779
Compressor …3780
Condenser …3781
Sunlight sensor …3783
Outer temperature sensor (outside air temperature sensor) …3784
Procedure for testing and troubleshooting …3785
Circuit diagram and arrangement of connector pins …3787
System diagram …3789
Input and output signals of the air conditioner controller …3790
Air conditioner unit …3792
Parts and connectors layout …3794
Testing air leakage (duct) …3800
Testing with self-diagnosis function …3802
Testing vent (mode) changeover …3805
Testing FRESH/RECIRC air changeover …3806
Testing sunlight sensor …3807
Testing (dual) pressure switch for refrigerant …3808
Testing relays …3810
Troubleshooting chart 1 …3811
Troubleshooting chart 2 …3812
Information in troubleshooting table …3815
Failure code list related to air conditioner …3816
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit …3817
Failure code [879AKB] A/C Recirc Air Temp Sens Short …3818
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit …3819
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit …3821
Failure code [879CKA] Ventilating Sensor Open Circuit …3823
Failure code [879CKB] Ventilating Sensor Short Circuit …3824
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit …3825
Failure code [879EMC] Ventilation Damper Malfunction …3827
Failure code [879FMC] Air Mix Damper Malfunction …3828
Failure code [879GKX] Refrigerant Press Input Sig Out of Range …3829
A-1 Troubleshooting for power supply system (Air conditioner does not operate) …3830
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) …3832
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) …3835
A-4 Troubleshooting for FRESH/RECIRC air changeover …3837
Troubleshooting with gauge pressure …3839
Connection of service tool …3842
Precautions for disconnecting and connecting refrigerant piping …3844
Handling of compressor oil …3846
90 Diagrams and drawings …3848
Table of contents …3849
Hydraulic circuit diagram …3850
Symbols in hydraulic circuit diagram …3850
Hydraulic circuit diagram …3854
Electric circuit diagram …3855
Symbols in electric circuit diagram …3855
Electrical circuit diagram …3858
Electrical circuit diagram of air conditioner unit …3863
INDEX…3864
TEN00287-06 – Hydraulic Excavator PC88MR-8 Operation & Maintenance Manual…3874
COVER…3874
FOREWORD…3875
BEFORE READING THIS MANUAL…3876
SAFETY INFORMATION…3877
INTRODUCTION…3878
USE OF MACHINE…3878
DIRECTIONS OF MACHINE…3878
VISIBILITY FROM OPERATOR’S SEAT…3878
PRODUCT INFORMATION…3879
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…3879
EPA REGULATIONS, ENGINE NUMBER PLATE…3879
SERVICE METER LOCATION…3880
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…3880
CONTENTS…3881
SAFETY…3885
SAFETY…3886
SAFETY LABELS…3889
LOCATION OF SAFETY LABELS…3890
SAFETY LABELS…3891
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…3898
PRECAUTIONS BEFORE STARTING OPERATION…3898
PREPARATIONS FOR SAFE OPERATION…3898
FIRE PREVENTION…3900
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…3901
DO NOT GET CAUGHT IN WORK EQUIPMENT…3903
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…3903
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…3904
UNAUTHORIZED MODIFICATION…3904
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…3904
PRECAUTIONS RELATED TO CAB GLASS…3904
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…3905
PRECAUTIONS FOR OPERATION…3906
PRECAUTIONS FOR JOBSITE…3906
STARTING ENGINE…3908
OPERATION…3910
TRANSPORTATION…3918
TOWING…3919
LIFTING OBJECTS WITH BUCKET…3920
PRECAUTIONS FOR MAINTENANCE…3921
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…3921
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…3925
OPERATION…3931
MACHINE VIEW ILLUSTRATIONS…3932
OVERALL MACHINE VIEW…3932
CONTROLS AND GAUGES…3933
DETAILED CONTROLS AND GAUGES…3935
MONITORING SYSTEM…3935
SWITCHES…3994
CONTROL LEVERS AND PEDALS…3999
SUN ROOF…4003
WINDSHIELD…4004
SLIDING DOOR…4010
EMERGENCY ESCAPE HAMMER…4011
COVER WITH LOCK…4012
ENGINE HOOD…4013
MUD COVER…4015
BATTERY INSPECTION COVER…4016
AIR CONDITIONER CONTROLS…4017
RADIO…4030
FUSE…4035
FUSIBLE LINK…4036
AUXILIARY ELECTRIC POWER…4037
CONTROLLERS…4038
OPERATION MANUAL STORAGE…4039
CUP HOLDER…4039
TOOL BOX…4039
GREASE PUMP HOLDER…4039
ASHTRAY…4040
FIRE EXTINGUISHER…4040
MACHINE OPERATIONS AND CONTROLS…4041
BEFORE STARTING ENGINE…4041
STARTING ENGINE…4060
AFTER STARTING ENGINE…4065
STOPPING THE ENGINE…4075
MACHINE OPERATION…4076
STEERING THE MACHINE…4080
SWINGING…4082
WORK EQUIPMENT CONTROLS AND OPERATIONS…4083
WORKING MODE…4085
PROHIBITED OPERATIONS…4087
GENERAL OPERATION INFORMATION…4090
TRAVELING ON SLOPES…4092
ESCAPE FROM MUD…4094
RECOMMENDED APPLICATIONS…4095
BUCKET REPLACEMENT AND INVERSION…4097
PARKING MACHINE…4100
MACHINE INSPECTION AFTER DAILY WORK…4102
LOCKING…4102
ROAD LINERS AND RUBBER SHOES…4103
MACHINE READY FOR ATTACHMENT…4108
TRANSPORTATION…4118
TRANSPORTATION PROCEDURE…4118
LOADING AND UNLOADING WITH TRAILER…4119
LIFTING MACHINE…4125
COLD WEATHER OPERATION…4127
COLD WEATHER OPERATION INFORMATION…4127
AFTER DAILY WORK COMPLETION…4129
AFTER COLD WEATHER SEASON…4129
LONG TERM STORAGE…4130
BEFORE STORAGE…4130
DURING STORAGE…4130
AFTER STORAGE…4130
STARTING MACHINE AFTER LONG-TERM STORAGE…4131
TROUBLES AND ACTIONS…4132
RUNNING OUT OF FUEL…4132
PHENOMENA THAT ARE NOT FAILURES…4133
TOWING THE MACHINE…4134
SEVERE JOB CONDITION…4134
DISCHARGED BATTERY…4135
OTHER TROUBLE…4140
MAINTENANCE…4145
MAINTENANCE INFORMATION…4146
OUTLINE OF SERVICE…4148
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…4148
ELECTRIC SYSTEM MAINTENANCE…4151
WEAR PARTS…4152
WEAR PARTS LIST…4152
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…4154
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…4155
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…4156
TIGHTENING TORQUE SPECIFICATIONS…4157
TIGHTENING TORQUE LIST…4157
SAFETY CRITICAL PARTS…4158
SAFETY CRITICAL PARTS LIST…4158
MAINTENANCE SCHEDULE…4160
MAINTENANCE SCHEDULE CHART…4160
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…4162
MAINTENANCE PROCEDURE…4163
WHEN REQUIRED…4163
CHECK BEFORE STARTING…4199
EVERY 100 HOURS MAINTENANCE…4200
EVERY 250 HOURS MAINTENANCE…4202
EVERY 500 HOURS MAINTENANCE…4209
EVERY 1000 HOURS MAINTENANCE…4220
EVERY 2000 HOURS MAINTENANCE…4230
EVERY 4000 HOURS MAINTENANCE…4234
EVERY 5000 HOURS MAINTENANCE…4235
SPECIFICATIONS…4239
SPECIFICATIONS…4240
ATTACHMENTS, OPTIONS …4243
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…4244
SAFETY FIRST…4244
ATTACHMENT INSTALLATION…4245
BUCKET WITH HOOK…4246
HOOK CONDITION…4246
PROHIBITED OPERATIONS…4246
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)…4247
CONTROL PATTERN CHANGE PROCEDURE…4247
MACHINE CONTROL PATTERNS…4248
HYDRAULIC QUICK COUPLER PIPING…4249
LOCATIONS…4249
OPERATION…4250
POWER ANGLE BLADE…4252
BLADE CONTROL LEVER…4252
WHEN REQUIRED…4253
EVERY 500 HOURS SERVICE…4253
WEAR PARTS LIST…4254
SPECIFICATIONS…4254
ATTACHMENT GUIDE…4255
ATTACHMENT COMBINATIONS…4255
TRACK SHOES SELECTION…4257
RECOMMENDED ATTACHMENT OPERATIONS…4258
HYDRAULIC BREAKER…4258
CRUSHER…4263
HANDLING MACHINES EQUIPPED WITH KOMTRAX…4266
BASIC PRECAUTIONS…4266
INDEX…4267
TEN00468-01 – Hydraulic Excavator PC88MR-8 Operation & Maintenance Manual…4271
COVER…4271
FOREWORD…4272
BEFORE READING THIS MANUAL…4273
SAFETY INFORMATION…4274
INTRODUCTION…4275
USE OF MACHINE…4275
DIRECTIONS OF MACHINE…4275
VISIBILITY FROM OPERATOR’S SEAT…4275
PROTECTIVE STRUCTURE…4275
PRODUCT INFORMATION…4276
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…4276
EPA REGULATIONS, ENGINE NUMBER PLATE…4276
SERVICE METER LOCATION…4277
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…4277
CONTENTS…4278
SAFETY…4282
SAFETY…4283
SAFETY LABELS…4286
LOCATION OF SAFETY LABELS…4287
SAFETY LABELS…4288
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…4295
PRECAUTIONS BEFORE STARTING OPERATION…4295
PREPARATIONS FOR SAFE OPERATION…4295
FIRE PREVENTION…4297
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…4298
DO NOT GET CAUGHT IN WORK EQUIPMENT…4300
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…4300
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…4301
UNAUTHORIZED MODIFICATION…4301
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…4301
PRECAUTIONS RELATED TO CAB GLASS…4301
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…4302
PRECAUTIONS FOR OPERATION…4303
PRECAUTIONS FOR JOBSITE…4303
STARTING ENGINE…4305
OPERATION…4307
TRANSPORTATION…4315
TOWING…4316
LIFTING OBJECTS WITH BUCKET…4317
PRECAUTIONS FOR MAINTENANCE…4318
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…4318
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…4322
OPERATION…4328
MACHINE VIEW ILLUSTRATIONS…4329
OVERALL MACHINE VIEW…4329
CONTROLS AND GAUGES…4330
DETAILED CONTROLS AND GAUGES…4332
MONITORING SYSTEM…4332
SWITCHES…4391
CONTROL LEVERS AND PEDALS…4396
SUN ROOF…4400
WINDSHIELD…4401
SLIDING DOOR…4407
EMERGENCY ESCAPE HAMMER…4408
COVER WITH LOCK…4409
ENGINE HOOD…4410
MUD COVER…4412
BATTERY INSPECTION COVER…4413
AIR CONDITIONER CONTROLS…4414
RADIO…4427
FUSE…4432
FUSIBLE LINK…4433
AUXILIARY ELECTRIC POWER…4434
CONTROLLERS…4435
OPERATION MANUAL STORAGE…4436
CUP HOLDER…4436
TOOL BOX…4436
GREASE PUMP HOLDER…4436
ASHTRAY…4437
FIRE EXTINGUISHER…4437
MACHINE OPERATIONS AND CONTROLS…4438
BEFORE STARTING ENGINE…4438
STARTING ENGINE…4457
AFTER STARTING ENGINE…4462
STOPPING THE ENGINE…4472
MACHINE OPERATION…4473
STEERING THE MACHINE…4477
SWINGING…4479
WORK EQUIPMENT CONTROLS AND OPERATIONS…4480
WORKING MODE…4482
PROHIBITED OPERATIONS…4484
GENERAL OPERATION INFORMATION…4487
TRAVELING ON SLOPES…4489
ESCAPE FROM MUD…4491
RECOMMENDED APPLICATIONS…4492
BUCKET REPLACEMENT AND INVERSION…4494
PARKING MACHINE…4497
MACHINE INSPECTION AFTER DAILY WORK…4499
LOCKING…4499
ROAD LINERS AND RUBBER SHOES…4500
MACHINE READY FOR ATTACHMENT…4505
TRANSPORTATION…4515
TRANSPORTATION PROCEDURE…4515
LOADING AND UNLOADING WITH TRAILER…4516
LIFTING MACHINE…4522
COLD WEATHER OPERATION…4524
COLD WEATHER OPERATION INFORMATION…4524
AFTER DAILY WORK COMPLETION…4526
AFTER COLD WEATHER SEASON…4526
LONG TERM STORAGE…4527
BEFORE STORAGE…4527
DURING STORAGE…4527
AFTER STORAGE…4528
STARTING MACHINE AFTER LONG-TERM STORAGE…4529
TROUBLES AND ACTIONS…4530
RUNNING OUT OF FUEL…4530
PHENOMENA THAT ARE NOT FAILURES…4531
TOWING THE MACHINE…4532
SEVERE JOB CONDITION…4532
DISCHARGED BATTERY…4533
OTHER TROUBLE…4538
MAINTENANCE…4544
MAINTENANCE INFORMATION…4545
OUTLINE OF SERVICE…4547
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…4547
ELECTRIC SYSTEM MAINTENANCE…4550
WEAR PARTS…4551
WEAR PARTS LIST…4551
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…4553
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…4554
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…4555
TIGHTENING TORQUE SPECIFICATIONS…4556
TIGHTENING TORQUE LIST…4556
SAFETY CRITICAL PARTS…4557
SAFETY CRITICAL PARTS LIST…4557
MAINTENANCE SCHEDULE…4559
MAINTENANCE SCHEDULE CHART…4559
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…4561
MAINTENANCE PROCEDURE…4562
WHEN REQUIRED…4562
CHECK BEFORE STARTING…4598
EVERY 100 HOURS MAINTENANCE…4599
EVERY 250 HOURS MAINTENANCE…4601
EVERY 500 HOURS MAINTENANCE…4608
EVERY 1000 HOURS MAINTENANCE…4620
EVERY 2000 HOURS MAINTENANCE…4630
EVERY 4000 HOURS MAINTENANCE…4634
EVERY 5000 HOURS MAINTENANCE…4635
SPECIFICATIONS…4638
SPECIFICATIONS…4639
ATTACHMENTS, OPTIONS…4642
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…4643
SAFETY FIRST…4643
ATTACHMENT INSTALLATION…4644
BUCKET WITH HOOK…4645
HOOK CONDITION…4645
PROHIBITED OPERATIONS…4645
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) …4646
CONTROL PATTERN CHANGE PROCEDURE…4646
MACHINE CONTROL PATTERNS…4647
HYDRAULIC QUICK COUPLER PIPING…4648
LOCATIONS…4648
OPERATION…4649
POWER ANGLE BLADE…4651
BLADE CONTROL LEVER…4651
WHEN REQUIRED…4652
EVERY 500 HOURS SERVICE…4652
WEAR PARTS LIST…4653
SPECIFICATIONS…4653
ATTACHMENT GUIDE…4654
ATTACHMENT COMBINATIONS…4654
TRACK SHOES SELECTION…4656
RECOMMENDED ATTACHMENT OPERATIONS…4657
HYDRAULIC BREAKER…4657
CRUSHER…4662
FALLING LOAD PROTECTIVE DEVICE (FALLING LOAD PREVENTIVE VALVE)…4665
HANDLING MACHINES EQUIPPED WITH KOMTRAX…4666
BASIC PRECAUTIONS…4666
INDEX…4668
WEAM009700 – Hydraulic Excavator PC80MR-3 Operation & Maintenance Manual…4672
1.1 FOREWORD…4674
1.2 INFORMATION ON SAFETY…4675
1.3 INTRODUCTION…4677
1.3.1 INTENDED USE OF THE MACHINE…4677
1.3.2 IMPROPER OR UNAUTHORIZED USES…4677
1.3.2.1 MAIN CHARACTERISTICS…4677
1.3.3 RUNNING-IN…4678
1.3.4 POSITIONS AND DIRECTIONS OF THE MACHINE…4679
1.4 PRODUCT IDENTIFICATION…4680
1.4.1 MACHINE SERIAL NUMBER…4680
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)…4680
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE…4681
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER…4681
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER…4681
1.4.6 CAB SERIAL NUMBER…4681
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS…4682
1.5 KOMTRAX SYSTEM…4683
1.5.1 GENERAL PRECAUTIONS…4683
TABLE OF CONTENTS…4684
2.1 SAFETY, NOISE AND VIBRATION PLATES…4693
2.1.1 POSITION OF THE SAFETY PLATES…4693
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS…4694
2.1.3 POSITION OF THE NOISE PLATES…4701
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED…4701
2.2 GENERAL PRECAUTIONS…4702
2.2.1 SAFETY RULES…4702
2.2.2 HOW TO BEHAVE IN CASE OF ANOMALIES…4702
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS…4702
2.2.4 FIRE EXTINGUISHERS AND FIRST AID KIT…4703
2.2.5 SAFETY DEVICES AND GUARDS…4703
2.2.6 CLEANING THE MACHINE…4703
2.2.7 INSIDE OF THE CAB…4704
2.2.8 LEAVING THE OPERATOR SEAT…4704
2.2.9 GETTING ON AND OFF THE MACHINE…4705
2.2.10 IT IS FORBIDDEN TO CLIMB ON THE EQUIPMENT…4705
2.2.11 ARTICULATED PARTS…4705
2.2.12 PREVENTING BURNS…4706
2.2.13 PREVENTING FIRES DUE TO FUEL AND OIL…4706
2.2.14 HOW TO BEHAVE IN CASE OF FIRE…4707
2.2.15 DETERGENT FOR THE WINDOWS…4707
2.2.16 PROTECTION AGAINST FALLING OBJECTS, FLYING OBJECTS, FOREIGN BODIES…4707
2.2.17 PRECAUTIONS CONCERNING THE EQUIPMENT…4707
2.2.18 COMBINING THE WORK EQUIPMENT…4707
2.2.19 WORK LIGHT AND CAB LIGHTS…4708
2.2.20 CAB WINDOWS…4708
2.2.21 PRECAUTIONS CONCERNING THE CAB STRUCTURE…4708
2.2.22 UNAUTHORIZED MODIFICATIONS…4708
2.2.23 SAFETY AT THE WORKPLACE…4708
2.2.24 WORKING ON LOOSE GROUND…4708
2.2.25 PREVENTING ELECTROCUTION…4709
2.2.26 VISIBILITY…4710
2.2.27 ROOM VENTILATION…4710
2.2.28 CHECKING THE SIGNALS OF THE SIGNALMAN AND THE FIXED SIGNS…4710
2.2.29 HAND SIGNALS…4711
2.2.30 EMERGENCY EXIT…4716
2.2.31 PREVENTING DAMAGE DUE TO ASBESTOS POWDER…4716
2.3 PRECAUTIONS FOR USE…4717
2.3.1 BEFORE STARTING THE ENGINE…4717
2.3.1.1 CHECKS AND ADJUSTMENTS TO BE CARRIED OUT BEFORE STARTING THE ENGINE…4717
2.3.1.2 PRECAUTIONS TO BE TAKEN DURING THE START PROCEDURE…4717
2.3.1.3 PRECAUTIONS TO BE TAKEN IN COLD AREAS…4718
2.3.2 PRECAUTIONS TO BE TAKEN WHEN WORKING…4719
2.3.2.1 CHECKS AFTER STARTING THE ENGINE…4719
2.3.2.2 PRECAUTIONS TO BE TAKEN WHEN CHANGING DIRECTION…4719
2.3.2.3 PRECAUTIONS TO BE TAKEN DURING TRAVEL…4720
2.3.2.4 MOVING ON SLOPES…4721
2.3.2.5 WORKING ON SLOPES…4722
2.3.2.6 UNAUTHORIZED OPERATIONS…4722
2.3.2.7 WORKING ON ICY OR SNOW-COVERED SURFACES…4724
2.3.2.8 PARKING THE MACHINE…4724
2.3.3 TRANSPORTING THE MACHINE…4725
2.3.3.1 LOADING AND UNLOADING THE MACHINE…4725
2.3.3.2 TRANSPORTING THE MACHINE…4725
2.3.4 BATTERY…4726
2.3.4.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY…4726
2.3.4.2 STARTING WITH BOOSTER CABLES…4727
2.3.5 REMOVAL…4728
2.3.5.1 PRECAUTIONS FOR THE REMOVAL…4728
2.4 PRECAUTIONS FOR MAINTENANCE…4729
2.4.1 WARNING PLATES…4729
2.4.2 KEEP THE WORK PLACE CLEAN AND ORDERLY…4729
2.4.3 APPOINT A SUPERVISOR WHEN WORKING WITH OTHER PEOPLE…4729
2.4.4 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION…4730
2.4.5 MAINTENANCE OPERATIONS TO BE CARRIED OUT WITH THE ENGINE RUNNING REQUIRE THE PRESENCE OF TWO OPERATORS…4731
2.4.6 TOOLS…4731
2.4.7 HYDRAULIC ACCUMULATOR…4731
2.4.8 MAINTENANCE STAFF…4732
2.4.9 EQUIPMENT…4732
2.4.10 WORKING UNDER THE MACHINE…4732
2.4.11 NOISE…4732
2.4.12 PRECAUTIONS TO BE TAKEN WHEN USING THE HAMMER…4733
2.4.13 REPAIR WELDS…4733
2.4.14 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL…4733
2.4.15 CHECKING THE COOLANT LEVEL IN THE RADIATOR…4734
2.4.16 USING LAMPS…4734
2.4.17 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR…4735
2.4.18 PRECAUTIONS CONCERNING THE STARTER…4735
2.4.19 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE TRACK TENSION…4736
2.4.20 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT…4736
2.4.21 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL…4737
2.4.22 HANDLING HIGH-PRESSURE HOSES…4737
2.4.23 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE…4737
2.4.24 COOLING FAN AND BELT…4738
2.4.25 WASTE MATERIALS…4738
2.4.26 SERVICING THE AIR CONDITIONER…4738
2.4.27 COMPRESSED AIR…4738
2.4.28 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY…4738
2.4.29 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS…4739
2.4.30 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE HEES…4739
3.1 DESCRIPTION AND USE OF THE MACHINE…4741
3.1.1 GENERAL VIEW OF THE MACHINE WITH MONOBOOM…4741
3.1.2 GENERAL VIEW OF THE MACHINE WITH TWO-PIECE BOOM…4742
3.1.3 CONTROLS AND INDICATORS…4743
3.2 INSTRUMENTS AND CONTROLS…4744
3.2.1 DASHBOARD…4744
3.2.1.1 WARNING LIGHTS…4745
3.2.1.2 EMERGENCY WARNING LIGHTS…4747
3.2.1.3 WARNING LIGHTS AND INDICATORS DISPLAY…4749
3.2.1.4 SWITCHES…4753
3.2.2 SWITCHES AND PUSH BUTTONS…4755
3.2.3 CONTROL LEVERS AND PEDALS…4762
3.2.4 CAB…4767
3.2.4.1 WINDSHIELD…4768
3.2.4.2 SLIDING DOOR…4772
3.2.4.3 SIDE WINDOW…4773
3.2.4.4 EMERGENCY EXIT HAMMER…4775
3.2.5 COVERS WITH LOCK…4776
3.2.6 ENGINE HOOD…4777
3.2.7 TANK COVER…4778
3.2.8 FUSES AND RELAY…4779
3.2.8.1 CONTROL UNIT FUSES AND RELAYS…4779
3.2.8.2 VENTILATION RELAYS…4782
3.2.8.3 AIR CONDITIONER FUSE AND RELAY…4783
3.2.8.4 ENGINE LINE FUSES AND RELAYS…4783
3.2.8.5 MAIN FUSE…4784
3.2.9 CONTROLLER…4784
3.2.10 VENTILATION AND HEATING…4785
3.2.10.1 HEATING AND DEFROSTING CONTROL PANEL…4785
3.2.11 AIR CONDITIONER (if installed)…4788
3.2.11.1 AIR CONDITIONER CONTROL PANEL…4789
3.2.12 TECHNICAL DOCUMENTATION COMPARTMENT…4792
3.2.13 TOOL BOX…4792
3.2.14 GREASING PUMP SUPPORT…4792
3.2.15 ASHTRAY…4793
3.2.16 FIRE EXTINGUISHERS…4793
3.2.17 FIRST AID KIT…4793
3.3 USE OF THE MACHINE…4794
3.3.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE…4794
3.3.1.1 VISUAL CHECKS…4794
3.3.2 DAILY CHECKS…4796
3.3.2.1 CHECKING THE COOLANT LEVEL AND TOPPING UP…4796
3.3.2.2 CHECKING THE ENGINE OIL LEVEL AND TOPPING UP…4797
3.3.2.3 CHECKING THE FUEL LEVEL AND REFUELLING…4798
3.3.2.4 CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK AND TOPPING UP…4799
3.3.2.5 AIR FILTER CLOGGING CHECK…4801
3.3.2.6 CHECKING THE WATER SEPARATOR…4801
3.3.2.7 CHECK THE WIRING SYSTEMS…4802
3.3.2.8 HORN OPERATION CHECK…4802
3.3.3 ADJUSTMENTS…4803
3.3.3.1 ADJUSTING THE SEAT…4803
3.3.3.2 REAR-VIEW MIRRORS…4804
3.3.4 SEAT BELT…4805
3.3.4.1 FASTENING AND UNFASTENING THE SEAT BELT…4805
3.3.4.2 ADJUSTING THE SEAT BELT…4806
3.3.4.3 RETRACTABLE SEAT BELT (if provided)…4807
3.3.5 OPERATIONAL CHECKS…4808
3.3.6 STARTING THE ENGINE…4810
3.3.6.1 STARTING THE ENGINE IN NORMAL OPERATING CONDITIONS…4810
3.3.6.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES…4812
3.3.7 AFTER STARTING THE ENGINE…4815
3.3.7.1 RUNNING-IN…4815
3.3.7.2 WARMING-UP PROCEDURE…4816
3.3.8 STOPPING THE ENGINE…4818
3.3.9 CHECKS TO BE CARRIED OUT AFTER STOPPING THE ENGINE…4818
3.3.10 OPERATING THE MACHINE…4819
3.3.10.1 HOW TO MOVE THE MACHINE…4819
3.3.10.2 MOVING THE MACHINE FORWARD…4820
3.3.10.3 REVERSE…4821
3.3.10.4 HOW TO STOP THE MACHINE…4822
3.3.11 STEERING THE MACHINE…4823
3.3.11.1 STEERING (CHANGING DIRECTION)…4823
3.3.12 SWINGING THE TURRET…4825
3.3.13 WORK EQUIPMENT CONTROLS AND FUNCTIONS…4826
3.3.14 WORK MODE…4828
3.3.15 UNAUTHORIZED OPERATIONS…4829
3.3.16 IGENERAL INFORMATION ON THE OPERATION OF THE MACHINE…4831
3.3.17 MOVING ON SLOPES…4833
3.3.18 GETTING THE MACHINE OUT OF MUD…4835
3.3.19 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR…4836
3.3.20 CHANGING THE BUCKET…4838
3.3.21 PARKING THE MACHINE…4839
3.3.22 CHECKS TO BE CARRIED OUT ON THE MACHINE AT THE END OF THE WORK DAY…4840
3.3.23 LOCKING THE MACHINE…4840
3.3.24 ROAD LINERS AND RUBBER TRACKS…4841
3.3.24.1 INFORMATION ON THE ROAD LINERS AND THE RUBBER TRACKS…4841
3.3.24.2 WARRANTY ON THE ROAD LINERS AND THE RUBBER TRACKS…4841
3.3.24.3 USING THE ROAD LINERS AND THE RUBBER TRACKS…4841
3.3.24.4 HOW TO PRESERVE THE ROAD LINERS AND THE RUBBER TRACKS OVER TIME…4842
3.4 TRANSPORTING THE MACHINE…4846
3.4.1 TRANSPORT PROCEDURE…4846
3.4.2 LOADING AND UNLOADING THE MACHINE…4846
3.4.2.1 LOADING THE MACHINE…4847
3.4.2.2 HOW TO SECURE THE MACHINE…4849
3.4.2.3 UNLOADING THE MACHINE…4850
3.4.3 HOW TO LIFT THE MACHINE…4852
3.5 USING THE MACHINE IN COLD CLIMATES…4854
3.5.1 PRECAUTIONS TO BE TAKEN WHEN USING THE MACHINE IN THE COLD SEASON…4854
3.5.1.1 FUEL AND LUBRICANTS…4854
3.5.1.2 COOLANT…4854
3.5.1.3 BATTERY…4855
3.5.2 AT THE END OF THE WORK DAY…4856
3.5.3 AT THE END OF THE COLD SEASON…4856
3.6 LONG PERIODS OF INACTIVITY…4857
3.6.1 BEFORE A PERIOD OF INACTIVITY…4857
3.6.2 DURING A PERIOD OF INACTIVITY…4857
3.6.3 AFTER A PERIOD OF INACTIVITY…4858
3.7 TROUBLESHOOTING…4859
3.7.1 IF FUEL RUNS OUT COMPLETELY…4859
3.7.2 OCCURRENCES THAT ARE NOT FAILURES…4859
3.7.3 REMOVING THE MACHINE…4859
3.7.4 DEMANDING OPERATING CONDITIONS…4860
3.7.5 IF THE BATTERY IS DOWN…4860
3.7.6 REMOVING AND INSTALLING THE BATTERY…4861
3.7.7 CHARGING THE BATTERY…4862
3.7.8 STARTING WITH BOOSTER CABLES…4863
3.7.8.1 CONNECTING AND DISCONNECTING THE BOOSTER CABLES…4863
3.7.8.2 CONNECTING THE BOOSTER CABLES…4864
3.7.8.3 STARTING THE ENGINE…4864
3.7.8.4 REMOVING THE BOOSTER CABLES…4864
3.7.9 LOWERING THE WORK EQUIPMENT WHEN THE ENGINE STOPS BECAUSE OF A FAILURE…4865
3.7.10 OTHER TROUBLES…4866
3.7.10.1 ELECTRICAL SYSTEM…4866
3.7.10.2 FRAME…4867
3.7.10.3 ENGINE…4868
3.7.10.4 ELECTRONIC CONTROL SYSTEM…4870
4.1 GUIDE TO MAINTENANCE…4873
4.2 MAINTENANCE NOTES…4875
4.2.1 OIL, FUEL AND COOLANT…4875
4.2.1.1 OIL…4875
4.2.1.2 FUEL…4876
4.2.1.3 COOLANT…4876
4.2.1.4 KOWA (KOMATSU OIL WEAR ANALYSIS)…4877
4.2.1.5 STORING OIL AND FUEL…4878
4.2.1.6 FILTERS…4878
4.2.2 NOTES ON THE MAINTENANCE OF THE ELECTRICAL SYSTEM…4879
4.2.3 NOTES ON THE MAINTENANCE OF THE HYDRAULIC SYSTEM…4879
4.2.4 MAINTENANCE NOTES REGARDING LUBRICATION…4879
4.3 PARTS SUBJECT TO WEAR…4880
4.3.1 LIST OF THE PARTS SUBJECT TO WEAR…4880
4.4 FUEL, COOLANT AND LUBRICANTS…4881
4.4.1 COOLANT…4882
4.4.2 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES…4883
4.5 TIGHTENING TORQUES…4884
4.5.1 STANDARD TIGHTENING TORQUES FOR SCREWS AND NUTS…4884
4.5.2 STANDARD TIGHTENING TORQUES FOR HOSES WITH ORFS…4885
4.6 LUBRICATION…4886
4.6.1 LUBRICATION DIAGRAM…4886
4.7 PERIODICAL CHANGE OF SAFETY-RELATED COMPONENTS…4887
4.7.1 SAFETY-RELATED PARTS…4888
4.8 MAINTENANCE PLAN…4889
4.8.1 MAINTENANCE PLAN…4889
4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER…4892
4.9 MAINTENANCE PROCEDURES…4893
4.9.1 WHEN REQUIRED…4893
4.9.1.a CHECKING, CLEANING OR CHANGING THE AIR FILTER CARTRIDGE…4893
4.9.1.b CLEANING THE WATER SEPARATOR FILTER…4896
4.9.1.c CHECKING THE TIGHTENING OF THE TRACKS…4897
4.9.1.d CHECKING AND ADJUSTING THE TRACK TENSION…4898
4.9.1.e CHECKING THE ROAD LINERS OR THE RUBBER TRACKS…4900
4.9.1.f CHECKING AND ADJUSTING THE RUBBER TRACK TENSION…4902
4.9.1.g CHANGING THE ROAD LINERS…4903
4.9.1.h CHANGING THE RUBBER TRACKS…4904
4.9.1.i REPLACING THE ROAD LINERS OR STEEL TRACKS WITH RUBBER TRACKS…4907
4.9.1.j ADJUSTING THE BUCKET CLEARANCE…4908
4.9.1.k CHECKING THE WINDSHIELD FLUID LEVEL AND TOPPING UP…4909
4.9.1.l CHECKING, CLEANING AND LUBRICATING THE GUIDE OF THE CAB SLIDING DOOR…4910
4.9.1.m WASHING THE FLOOR…4911
4.9.1.n BLEEDING THE HYDRAULIC SYSTEM…4913
4.9.2 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE…4916
4.9.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)…4916
4.9.4 MAINTENANCE EVERY 50 HOURS OF OPERATION…4916
4.9.4.a COOLANT LEVEL CHECK IN THE RADIATOR…4916
4.9.5 MAINTENANCE EVERY 100 HOURS OF OPERATION…4917
4.9.5.a LUBRICATION…4917
4.9.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION…4917
4.9.7 MAINTENANCE EVERY 250 HOURS OF OPERATION…4918
4.9.7.a LUBRICATION…4918
4.9.7.b CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR AND TOPPING UP…4920
4.9.7.c CHECKING THE OIL LEVEL IN THE FINAL REDUCTION GEARS AND TOPPING UP…4920
4.9.7.d BATTERY ELECTROLYTE LEVEL CHECK…4921
4.9.7.e CHECKING AND ADJUSTING THE FAN BELT TENSION…4922
4.9.7.f CHECKING AND ADJUSTING THE AIR CONDITIONER COMPRESSOR BELT TENSION (if installed)…4923
4.9.7.g DRAINING THE FUEL TANK…4924
4.9.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)…4925
4.9.9 MAINTENANCE EVERY 500 HOURS OF OPERATION…4925
4.9.9.a CHANGING THE FUEL FILTER CARTRIDGE…4925
4.9.9.b CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER CARTRIDGE…4927
4.9.9.c CHANGING THE HYDRAULIC OIL FILTER CARTRIDGE…4929
4.9.9.d CLEANING THE INSIDE AND OUTSIDE FILTERS OF THE AIR CONDITIONER…4931
4.9.9.e RADIATOR, EXCHANGER AND AIR CONDITIONER CONDENSER (if fitted) CHECK AND EXTERIOR CLEANING…4933
4.9.9.f LUBRICATING THE SWING BALL- BEARING RING…4934
4.9.9.g CHECKING THE GREASE LEVEL IN THE BALL-BEARING RING PINION AND TOPPING UP…4934
4.9.9.h DRAINING THE HYDRAULIC OIL TANK (Only for machines in which synthetic biodegradable oil type HEES is used)…4935
4.9.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION…4936
4.9.10.a CHANGING THE OIL IN THE SWING REDUCTION GEAR…4936
4.9.10.b CHANGING THE OIL IN THE FINAL REDUCTION GEARS…4937
4.9.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION…4938
4.9.11.a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER (Only for machines in which synthetic biodegradable oil HEES is used)…4938
4.9.11.b CHANGING THE COOLANT…4940
4.9.11.c CHECKING THE ALTERNATOR AND THE STARTER…4942
4.9.11.d CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE…4942
4.9.11.e CHECKING THE A/C REFRIGERANT GAS QUANTITY ((only for machines with air conditioner)…4942
4.9.12 MAINTENANCE EVERY 4000 HOURS OF OPERATION…4943
4.9.12.a CHANGING THE A/C FILTER DRIER (only for machines with air conditioner)…4943
4.9.12.b CHECKING THE OPERATING CONDITIONS OF THE A/C COMPRESSOR (only for machines with air conditioner)…4943
4.9.12.c CHECKING THE WATER PUMP…4943
4.9.13 MAINTENANCE EVERY 5000 HOURS OF OPERATION…4944
4.9.13.a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER…4944
5.1 TECHNICAL DATA…4947
5.2 LIFTING CAPACITIES…4949
5.2.1 LIFTING CAPACITIES WITH MONOBOOM…4949
6.1 AUTHORIZED OPTIONAL EQUIPMENT…4955
6.1.1 PRECAUTIONS REGARDING SAFETY…4955
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT…4956
6.1.3 AUTHORISED TOOLS CHARACTERISTICS…4957
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER…4958
6.2.1 DESCRIPTION AND CONTROL…4958
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED…4959
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER…4964
6.2.3.1 INSTALLATION…4964
6.2.3.2 REMOVING THE HAMMER…4965
6.2.4 MAINTENANCE…4965
6.3 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET SWING SYSTEM (second hydraulic line)…4966
6.4 ARRANGEMENT FOR THE INSTALLATION OF THE BUCKET QUICK COUPLING SYSTEM (Third hydraulic line)…4969
6.5 INSTALLING AND REMOVING THE ADDITIONAL COUNTERWEIGHT…4971

Komatsu Hydraulic Excavator PC80MR Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC78UU, PC78US, PC78US, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavators PC78UU-6, PC78US-6, PC78US-8 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEBM025118 – Hydraulic Excavator PC78UU-6, PC78US-6 Shop Manual.pdf
SEN04543-10 – Hydraulic Excavator PC78US-8 Shop Manual.pdf
SEAM044600T – Hydraulic Excavator PC78US-6 Operation & Maintenance Manual.pdf
SEAM044601 – Hydraulic Excavator PC78US-6 Operation & Maintenance Manual.pdf
SEAM044602T – Hydraulic Excavator PC78US-6 Operation & Maintenance Manual.pdf
SEAM046100T – Hydraulic Excavator PC78US-5 Operation & Maintenance Manual.pdf
TEN00004-00 – Hydraulic Excavator GALEO PC78US-6 Operation & Maintenance Manual.pdf
TEN00072-01 – Hydraulic Excavator GALEO PC78US-6 Operation & Maintenance Manual.pdf
TEN00200-00 – Hydraulic Excavator GALEO PC78US-6 Operation & Maintenance Manual.pdf
TEN00307-05 – Hydraulic Excavator PC78US-8 Operation & Maintenance Manual.pdf
TEN00466-01 – Hydraulic Excavator PC78US-8 Operation & Maintenance Manual.pdf

Total Pages: 4,842 pages
File Format: PDF
Language: English

SEAM044600T – Hydraulic Excavator PC78US-6 Operation & Maintenance Manual….2
COVER….2
FOREWORD….3
FOREWORD….4
SAFETY INFORMATION….7
INTRODUCTION….9
DIRECTIONS OF MACHINE….9
PRODUCT INFORMATION….10
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION….10
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….10
SERVICE METER LOCATION….11
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….11
CONTENTS….12
SAFETY….15
SAFETY INFORMATION….16
WARNING LABELS AND PICTOGRAMS….18
WARNING LABELS AND PICTOGRAMS-LOCATION….19
WARNING LABELS AND PICTOGRAMS-ACTUAL….20
SAFETY INFORMATION….25
SAFETY RULES….25
IF ABNORMALITIES ARE FOUND….25
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….25
FIRE EXTINGUISHER AND FIRST AID KIT….25
SAFETY EQUIPMENT….25
KEEP MACHINE CLEAN….26
KEEP OPERATOR'S COMPARTMENT CLEAN….26
LEAVING OPERATOR'S SEAT WITH LOCK….26
HANDRAILS AND STEPS….27
MOUNTING AND DISMOUNTING….27
NO PERSONS ON ATTACHMENTS….27
DO NOT GET CAUGHT IN ARTICULATED PORTION….27
BURN PREVENTION….28
FIRE PREVENTION AND EXPLOSION PREVENTION….28
ACTION IF FIRE OCCURS….29
WINDSHIELD WASHER FLUID….29
FALLING OBJECTS,FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….29
ATTACHMENT INSTALLATION….30
ATTACHMENT COMBINATIONS….30
CAB WINDOW GLASSES….30
UNAUTHORIZED MODIFICATIONS….30
SAFETY AT JOBSITE….30
WORKING ON LOOSE GROUND….30
DISTANCE TO HIGH VOLTAGE CABLES….31
ENSURE GOOD VISIBILITY….31
VENTILATION FOR ENCLOSED AREA….31
SIGNALMAN'S SIGNAL AND SIGNS….32
EMERGENCY EXIT FROM OPERATOR'S CAB….32
ASBESTOS DUST HAZARD PREVENTION….32
SAFETY MACHINE OPERATION….33
STARTING ENGINE….33
CHECKS BEFORE STARTING ENGINE….33
SAFETY RULES FOR STARTING ENGINE….33
STARTING ENGINE IN COLD WEATHER….34
OPERATION….35
CHECKS BEFORE OPERATION….35
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….35
SAFETY RULES FOR TRAVELING….36
TRAVELING ON SLOPES….37
OPERATIONS ON SLOPES….38
PROHIBITED OPERATIONS….38
OPERATIONS ON SNOW….39
PARKING MACHINE….40
TRANSPORTATION….41
LOADING AND UNLOADING….41
SHIPPING THE MACHINE….41
BATTERY….42
BATTERY HAZARD PREVENTION….42
STARTING ENGINE WITH BOOSTER CABLES….43
TOWING….44
SAFETY RULES FOR TOWING….44
LIFTING OBJECTS WITH BUCKET….45
SAFETY RULES FOR LIFTING OBJECTS….45
SAFETY MAINTENANCE INFORMATION….46
WARING TAG….46
KEEP WORK PLACE CLEAN AND TIDY….46
APPOINT LEADER WHEN WORKING WITH OTHERS….46
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….46
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….47
PROPER TOOLS….48
PERSONNEL….48
ATTACHMENTS….48
WORK UNDER THE MACHINE….48
NOISE….48
WHEN USING HAMMER….49
WELDING WORKS….49
REMOVING BATTERY TERMINALS….49
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….49
DO NOT DISASSEMBLE RECOIL SPRINGS….49
SAFETY RULES FOR HIGH-PRESSURE OIL….50
SAFETY HANDLING HIGH-PRESSURE HOSES….50
WASTE MATERIALS….50
AIR CONDITIONER MAINTENANCE….50
COMPRESSED AIR….51
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….51
OPERATION….52
MACHINE VIEW ILLUSTRATIONS….53
OVERALL MACHINE VIEW….53
CONTROLS AND GAUGES….54
DETAILED CONTROLS AND GAUGES….55
MONITORING SYSTEM….55
SWITCHES….66
CONTROL LEVERS AND PEDALS….71
SUN ROOF….75
WINDSHIELD….76
SLIDING DOOR….81
EMERGENCY ESCAPE HAMMER….82
CAP WITH LOCK….83
ENGINE HOOD….84
MUD COVER….85
BATTERY INSPECTION COVER….86
FUSE….87
FUSIBLELINK….88
AUXILIARY ELECTRIC POWER….88
CONTROLLERS….88
HEATER AND DEFROSTAR CONTROLS….89
AIR CONDITIONER CONTROLS….94
RADIO….100
OPERATION MANUAL STORAGE….105
TOOL BOX….105
GREASE PUMP HOLDER….105
ASHTRAY….105
FIRE EXTINGUISHER….106
MACHINE OPERATIONS AND CONTROLS….107
BEFORE STARTING ENGINE….107
STARTING ENGINE….122
AFTER STARTING ENGINE….126
STOPPING THE ENGINE….129
CHECK AFTER SHUT OFF ENGINE….129
MACHINE OPERATION….130
STEERING THE MACHINE….134
SWINGING….136
WORK EQUIPMENT CONTROLS AND OPERATIONS….137
WORKING MODE….139
PROHIBITED OPERATIONS….140
GENERAL OPERATION INFORMATION….142
TRAVELING ON SLOPES….144
ESCAPE FROM MUD….146
RECOMMENDED APPLICATIONS….147
BUCKET REPLACEMENT AND INVERSION….149
PARKING MACHINE….151
MACHINE INSPECTION AFTER DAILY WORK….152
LOCKING….152
ROAD LINERS AND RUBBER SHOES….153
TRANSPORTATION….158
TRANSPORTATION PROCEDURE….158
LOADING AND UNLOADING WITH TRAILER….158
LIFTING MACHINE….164
COLD WEATHER OPERATION….166
COLD WEATHER OPERATION INFORMATION….166
AFTER DAILY WORK COMPLETION….168
AFTER COLD WEATHER SEASON….168
LONG TERM STORAGE….169
BEFORE STORAGE….169
DURING STORAGE….169
AFTER STORAGE….169
TROUBLES AND ACTIONS….170
RUNNING OUT OF FUEL….170
PHENOMENA THAT ARE NOT FAILURES….170
TOWING THE MACHINE….170
SEVERE JOB CONDITION….171
DISCHARGED BATTERY….171
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY….175
OTHER TROUBLE….176
MAINTENANCE….181
MAINTENANCE INFORMATION….182
LUBRICANTS, COOLANT AND FILTERS….184
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….184
ELECTRIC SYSTEM MAINTENANCE….187
WEAR PARTS….188
WEAR PARTS LIST….188
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….189
PROPER SELECTION….189
TIGHTENING TORQUE SPECIFICATIONS….193
TIGHTENING TORQUE LIST….193
SAFETY CRITICAL PARTS….194
SAFETY CRITICAL PARTS LIST….194
MAINTENANCE SCHEDULE….195
MAINTENANCE SCHEDULE CHART….195
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….196
MAINTENANCE PROCEDURE….197
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….197
WHEN REQUIRED….198
AIR CLEANER ELEMENT-CHECK/CLEAN/REPLACE….198
COOLING SYSTEM COOLANT-CLEAN/CHANGE….202
WATER SEPARATOR ELEMENT-REPLACE….204
FUEL TANK-CLEAN….205
TRACK SHOE BOLTS-CHECK/TIGHTEN….206
TRACK TENSION-CHECK/ADJUST….207
ROAD LINERS OR RUBBER SHOES-CHECK….209
RUBBER SHOE TENSION-CHECK/ADJUST….211
ROAD LINERS-REPLACE….212
RUBBER SHOES-REPLACE….213
STEEL SHOES OR ROAD LINERS TO RUBBER SHOES-CHANGE….215
BUCKET TEETH(VERTICAL PIN TYPE)-REPLACE….216
BUCKET TEETH(HORIZONTAL PIN TYPE)-REPLACE….219
BUCKET CLEARANCE-ADJUST….220
WINDSHIELD WASHER FLUID LEVEL-CHECK/ADD….221
AIR CONDITIONER-CHECK/MAINTENANCE….222
CAB SLIDE DOOR RAIL AND ROLLER-CHECK/CLEAN/LUBRICATE….223
BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT-REPLACE….224
WASH WASHABLE FLOOR….225
HYDRAULIC SYSTEM-BLEED AIR….226
CHECK BEFORE STARTING….229
EVERY 50 HOURS MAINTENANCE….230
FUEL TANK-DRAIN….230
EVERY 100 HOURS MAINTENANCE….231
LUBRICATING….231
EVERY 250 HOURS MAINTENANCE….232
LUBRICATING….232
FINAL DRIVE CASE OIL LEVEL-CHECK/ADD….234
BATTERY ELECTROLYTE LEVEL-CHECK….235
COOLING FAN BELT TENSION-INSPECT/ADJUST….237
AIR CONDITIONER COMPRESSOR BELT TENSION-INSPECT/ADJUST….239
EVERY 500 HOURS MAINTENANCE….240
FUEL FILTER CARTRIDGE-REPLACE….240
CHANGE OIL ENGINE OIL PAN,REPLACE ENGINE OIL FILTER CARTRIDGE….241
AIR CONDITIONER AIR FILTER(IF EQUIPPED)-CLEAN….242
RADIATOR FINS,OIL COOLER FINS,CONDENSOR FINS-CLEAN/REPLACE….244
SWING CIRCLE-LUBRICATE….246
SWING PINION GEAR OIL LEVEL-CHECK/ADD….246
EVERY 1000 HOURS MAINTENANCE….247
HYDRAULIC FILTER ELEMENT-REPLACE….247
SWING MACHINERY CASE OIL-CHANGE….249
FINAL DRIVE CASE OIL-CHANGE….250
EVERY 2000 HOURS MAINTENANCE….251
PTO GEAR CASE OIL LEVEL-CHECK/ADD….251
ALTERNATOR AND STARTING MOTOR-INSPECT….251
ENGINE VALVE CLEARANCES-INSPECT….251
EVERY 4000 HOURS MAINTENANCE….252
WATER PUMP-INSPECT….252
EVERY 5000 HOURS MAINTENANCE….253
CHANGE OIL IN HYDRAULIC TANK,CLEAN STRAINER….253
SPECIFICATIONS….255
SPECIFICATIONS….256
ATTACHMENTS, OPTIONS….258
ATTACHMENTS AND OPTIONS-GENERAL INFORMATION….259
SAFETY FIRST….259
ATTACHMENT INSTALLATION….260
BUCKET WITH HOOK….261
HOOK CONDITION….261
PROHIBITED OPERATIONS….261
MACHINE READY FOR ATTACHMENT….262
LOCATIONS….262
HYDRAULIC CIRCUIT….264
ATTACHMENT OPERATIONS….265
LONG TERM STORAGE….267
SPECIFICATIONS….267
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED) ….268
CONTROL PATTERN CHANGE PROCEDURE….268
MACHINE CONTROL PATTERNS….269
ATTACHMENT GUIDE….270
OTHER ATTACHMENTS….270
ATTACHMENT COMBINATIONS….271
RECOMMENDED ATTACHMENT OPERATIONS….272
HYDRAULIC BREAKER….272
INDEX….277
SEAM044601 – Hydraulic Excavator PC78US-6 Operation & Maintenance Manual….280
COVER….280
FOREWORD….281
FOREWORD….282
SAFETY INFORMATION….285
INTRODUCTION….287
DIRECTIONS OF MACHINE….287
PRODUCT INFORMATION….288
MACHINE SERIAL NUMBER PLATE AND ITS POSITION….288
ENGINE SERIAL NUMBER PLATE AND ITS POSITION….288
SERVICE METER LOCATION….289
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….289
CONTENTS….290
SAFETY….293
SAFETY INFORMATION….294
WARNING LABELS AND PICTOGRAMS….296
WARNING LABELS AND PICTOGRAMS-LOCATION….297
WARNING LABELS AND PICTOGRAMS-ACTUAL….298
SAFETY INFORMATION….303
SAFETY RULES….294
IF ABNORMALITIES ARE FOUND….294
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….294
FIRE EXTINGUISHER AND FIRST AID KIT….294
SAFETY EQUIPMENT….303
KEEP MACHINE CLEAN….304
KEEP OPERATOR'S COMPARTMENT CLEAN….304
LEAVING OPERATOR'S SEAT WITH LOCK….304
HANDRAILS AND STEPS….305
MOUNTING AND DISMOUNTING….305
NO PERSONS ON ATTACHMENTS….305
CRUSHING OR CUTTING PREVENTION….305
BURN PREVENTION….306
FIRE PREVENTION AND EXPLOSION PREVENTION….306
ACTION IF FIRE OCCURS….307
WINDSHEILD WASHER FLUID….307
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….307
ATTACHMENT INSTALLATION….308
ATTACHMENT COMBINATIONS….308
CAB WINDOW GLASSES….308
UNAUTHORIZED MODIFICATIONS….308
SAFETY AT JOBSITE….308
WORKING ON LOOSE GROUND….309
DISTANCE TO HIGH VOLTAGE CABLES….309
ENSURE GOOD VISIBILTY….309
VENTILATION FOR ENCLOSED AREA ….310
SIGNALMAN'S SIGNAL AND SIGNS….310
EMERGENCY EXIT FROM OPERATOR'S CAB….310
ASBESTOS DUST HAZARD PREVENTION….310
SAFETY MACHINE OPERATION….311
STARTING ENGINE….311
CHECKS BEFORE STARTING ENGINE….311
SAFETY RULES FOR STARTING ENGINE….311
STARTING ENGINE INCOLD WEATHER….312
OPERATION….313
CHECKS BEFORE OPERATION….313
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….313
SAFETY RULES FOR TRAVELING ….314
TRAVELING ON SLOPES….315
OPERATIONS ON SLOPES….316
PROHIBITED OPERATIONS….316
OPERATION ON SNOW….317
PARKING MACHINE….318
TRANSPORTATION….319
LOADING AND UNLOADING….319
SHIPPING THE MACHINE….319
BATTERY….320
BATTERY HAZARD PREVENTION….320
STARTING ENGINE WITH BOOSTER CABLES….321
TOWING….322
SAFETY RULES FOR TOWING….322
LIFTING OBJECTS WITH BUCKET….323
SAFETY RULES FOR LIFTING OBJECTS….323
SAFETY MAINTENANCE INFORMATION….324
WARNING TAG….324
KEEP WORK PLACE CLEAN AND TIDY….324
APPOINT LEADER WHEN WORKING WITH OTHERS….324
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….324
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….325
PROPER TOOLS….326
PERSONNEL….326
ATTACHMENTS….326
WORK UNDER THE MACHINE….326
NOISE ….326
WHEN USING HAMMER….327
WELDING WORKS….327
REMOVING BATTERY TERMINALS….327
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….327
DO NOT DISASSEMBLE RECOIL SPRINGS….327
SAFETY RULES FOR HIGH-PRESSURE OIL….328
SAFETY HANDLING HIGH-PRESSURE HOSES….328
WASTE MATERIALS….328
AIR CONDITIONER MAINTENANCE ….328
COMPRESSED AIR….329
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….329
OPERATION….331
MACHINE VIEW ILLUSTRATIONS….332
OVERALL MACHINE VIEW….332
CONTROLS AND GAUGES….333
DETAILED CONTROLS AND GAUGES….334
MONITORING SYSTEM….334
SWITCHES….345
CONTROL LEVERS AND PEDALS….350
SUN ROOF….354
WINDSHEILD….355
SLIDING DOOR….361
EMERGENCY ESCAPE HAMMER….361
MACHINE OPERATIONS AND CONTROLS….387
BEFORE STARTING ENGINE….387
STARTING ENGINE….403
AFTER STARTING ENGINE….407
STOPPING ENGINE….410
CHECK AFTER STOPPING ENGINE….410
MACHINE OPERATION….411
STEERING THE MACHINE….415
SWINGING….417
WORK EQUIPMENT CONTROLS AND OPERATIONS….418
WORKING MODE….420
PROHIBITED OPERATIONS….421
GENERAL OPERATION INFORMATION….423
TRAVELING ON SLOPES….425
ESCAPE FROM MUD….427
RECOMMENDED APPLICATIONS….428
BUCKET REPLACEMENT AND INVERSION….430
PARKING MACHINE….432
MACHINE INSPECTION AFTER DAILY WORK….433
LOCKING….433
ROAD LINERS AND RUBBER SHOES….434
TRANSPORTATION….439
TRANSPORTATION PROCEDURE….439
LOADING AND UNLOADING WITH TRAILER….439
LIFTING MACHINE….445
COLD WEATHER OPERATION….447
COLD WEATHER OPERATION INFORMATION….447
AFTER DAILY WORK COMPLETION….449
AFTER COLD WEATHER SEASON….449
LONG TERM STORAGE….450
BEFORE STORAGE….450
DURING STORAGE….450
AFTER STORAGE….450
TROUBLES AND ACTIONS….451
RUNNING OUT OF FUEL….451
PHENOMENA THAT ARE NOT FAILURES….451
TOWING THE MACHINE….451
SEVERE JOB CONDITION….452
DISCHARGED BATTERY….452
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY….456
OTHER TROUBLE….457
MAINTENANCE….463
MAINTENANCE INFORMATION….464
LUBRICANTS, COOLANT AND FILTERS….466
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….466
ELECTRIC SYSTEM MAINTENANCE….468
WEAR PARTS ….469
WEAR PARTS LIST….469
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….470
PROPER SELECTION….470
TIGHTENING TORQUES SPECIFICATIONS….474
TIGHENING TORQUE LIST….474
SAFETY CRITICAL PARTS….475
SAFETY CRITICAL PARTS LIST….475
MAINTENANCE SCHEDULE….476
MAINTENANCE SCHEDULE CHART….476
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….477
MAINTENANCE PROCEDURE….478
INITIAL 250 HOURS SERVICE (ONLY AFETR THE FIRST 250 HOURS)….478
WHEN REQUIRED….479
AIR CLEANER ELEMENT-CHECK/CLEAN/REPLACE….479
COOLING SYSTEM COOLANT – CLEAN/CHANGE….483
WATER SEPARATOR ELEMENT-ELEMENT….485
FUEL TANK – CLEAN….486
TRACK SHOE BOLTS – CHECK /TIGHTEN….487
TRACK TENSION – CHECK/ADJUST….488
ROAD LINERS OR RUBBER SHOES – CHECK….490
RUBBER SHOE TENSION – CHECK/ADJUST….492
ROAD LINERS – REPLACE….493
RUBBER SHOES – REPLACE….494
STEEL SHOES OR ROAD LINERS TO RUBBER SHOES – CHANGE….496
BUCKET TEETH (VERTICAL OIN TYPE) – REPLACE….497
BUCKET TEETH (HORIZONTAL OIN TYPE) – REPLACE….500
BUCKET CLEARANCE – ADJUST….501
WINDSHIELD WASHER FLUID LEVEL – CHECK/ADD….502
AIR CONDITIONER – CHECK/MAINTENANCE….503
CAB SLIDE DOOR RAIL AND ROOLER – CHECK/CLEAN/LUBRICATE….504
BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT – REPLACE….505
WASH WASHABLE FLOOR….506
HYDRAULIC SYSTEM – BLEED AIR….507
CHECK BEFORE STARTING….510
EVERY 50 HOURS MAINTENANCE….511
FUEL TANK – DRAIN….511
EVERY 100 HOURS MAINTENANCE….512
LUBRICATING….512
EVERY 250 HOURS MAINTENANCE….513
LUBRICATING….513
FINAL DRIVE CASE OIL LEVEL – CHECK/ADD….515
BATTERY ELECTROLYTE LEVEL – CHECK….516
COOLING FAN BELT TENSION – INSPECT/ADJUST….518
AIR CONDITIONER COMPRESSOR BELT TENSION – INSPECT/ADJUST….520
EVERY 500 HOURS MAINTENANCE….521
FUEL FILTER CARTRIDGE – REPLACE….521
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….522
AIR CONDITIONER AIR FILTER (IF EQUIPPED) – CLEAN….523
RADITOR FINS, OIL COOLER FINS AND CONDENSOR FINS – CLEAN/CHECK….525
SWING CIRCLE – LUBRICATE….526
SWING PINION GEAR OIL LEVEL – CHECK/ADD….527
EVERY 1000 HOURS MAINTENANCE….528
HYDRAULIC OIL FILTER ELEMENT – REPLACE….528
SWING MACHINERY CASE OIL – CHANGE….530
FINAL DRIVE CASE OIL-CHANGE….531
EVERY 2000 HOURS MAINTENANCE….532
PTO GEAR CASE OIL LEVEL – CHECK/ADD….532
ALTERNATOR AND STARTER MOTOR – INSPECT….532
ENGINE VALVE CLEARANCES – INSPECT….532
EVERY 4000 HOURS MAINTENENCE….533
WATER PUMP – INSPECT….533
EVERY 5000 HOURS MAINTENENCE….534
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….534
SPECIFICATIONS….537
SPECIFICATIONS….538
ATTACHMENTS, OPTIONS….541
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….542
SAFETY FIRST….542
ATTACHMENT INSTALLATION….543
BUCKET WITH HOOK….544
HOOK CONDITION….544
PROHIBITED OPERATIONS….544
MACHINE READY FOR ATTACHMENT….545
LOCATIONS….545
HYDRAULIC CIRCUIT….547
ATTACHMENT OPERATIONS….548
LONG TERM STORAGE….550
SPECIFICATIONS….550
METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT….551
CHANGING MACHINE CONTROL PATTERN (IF PATERN CHANGE VALVE EQUIPPED)….553
CONTROL PATTERN CHANGE PROCEDURE….553
MACHINE CONTROL PATTERNS….554
ATTACHMENT GUIDE….555
OTHER ATTACHMENTS….555
ATTACHMENT COMBINATIONS….556
RECOMMENDED ATTACHMENT OPERATIONS….557
HYDRAULIC BREAKER….557
INDEX….563
SEAM044602T – Hydraulic Excavator PC78US-6 Operation & Maintenance Manual….567
COVER….567
FOREWORD….568
FOREWORD….569
SAFETY INFORMATION….572
INTRODUCTION….574
DIRECTIONS OF MACHINE….574
PRODUCT INFORMATION….575
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION….575
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….575
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION….576
SERVICE METER LOCATION….576
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….577
CONTENTS….578
SAFETY….581
SAFETY INFORMATION….582
SAFETY LABELS….584
LOCATION OF SAFETY LABELS….585
SAFETY LABELS….586
SAFETY INFORMATION….592
SAFETY RULES….592
IF ABNORMALITIES ARE FOUND….592
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….592
FIRE EXTINGUISHER AND FIRST AID KIT….592
SAFETY EQUIPMENT….592
KEEP MACHINE CLEAN….593
KEEP OPERATOR'S COMPARTMENT CLEAN….593
LEAVING OPERATOR'S SEAT WITH LOCK….593
HANDRAILS AND STEPS….594
MOUNTING AND DISMOUNTING….594
NO PERSONS ON ATTACHMENTS….594
DO NOT GET CAUGHT IN ARTICULATED PORTION….594
BURN PREVENTION….595
FIRE PREVENTION AND EXPLOSION PREVENTION….595
ACTION IF FIRE OCCURS….596
WINDSHIELD WASHER FLUID….596
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….596
ATTACHMENT INSTALLATION….597
ATTACHMENT COMBINATIONS….597
CAB WINDOW GALSSES….597
UNAUTHORIZED MODIFICATIONS….597
SAFETY AT JOBSITE….597
WORKING ON LOOSE GROUND….597
DISTANCE TO HIGH VOLTAGE CABLES….598
ENSURE GOOD VISIBILITY….598
VENTILATION FOR ENCLOSED AREA….599
SIGNALMAN'S SIGNAL AND SIGNS….599
EMERGENCY EXIT FORM OPERATOR'S CAB….599
ASBESTOS DUST HAZARD PREVENTION….599
SAFETY MACHINE OPERATION….600
STARTING ENGINE….600
CHECKS BEFORE STARTING ENGINE….600
SAFETY RULES FOR STARTING ENGINE….601
STARTING ENGINE IN COLD WEATHER….601
OPERATION….602
CHECKS BEFORE OPERATION….602
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….602
SAFETY RULES FOR TRAVELING….603
TRAVELING ON SLOPES….604
OPERATIONS ON SLOPES….605
PROHIBITED OPERATIONS….605
OPERATIONS ON SNOW….606
PARKING MACHINE….607
TRANSPORTATION….608
LOADING AND UNLOADING….608
SHIPPING THE MACHINE….608
BATTERY….609
BATTERY HAZARD PREVENTION….609
STARTING ENGINE WITH BOOSTER CABLES….610
TOWING….611
SAFETY RULES FOR TOWING….611
LIFTING OBJECTS WITH BUCKET….612
SAFETY RULES FOR LIFTING OBJECTS….612
SAFETY MAINTENANCE INFORMATION….613
WARNING TAG….613
KEEP WORK PLACE CLEAN AND TIDY….613
APPOINT LEADER WHEN WORKING WITH OTHERS….613
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….613
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….614
PROPER TOOLS….615
PERSONNEL….615
ATTACHMENTS….615
WORK UNDER THE MACHINE….615
NOISE….615
WHEN USING HAMMER….616
WELDING WORKS….616
REMOVING BATTERY TERMINALS….616
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….616
DO NOT DISASSEMBLE RECOIL SPRINGS….616
SAFETY RULES FOR HIGH-PRESSURE OIL….617
SAFETY HANDLING HIGH-PRESSURE HOSES….617
WASTE MATERIALS….617
AIR CONDITIONER MAINTENANCE….617
COMPRESSED AIR….618
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….618
OPERATION….619
MACHINE VIEW ILLUSTRATIONS….620
OVERALL MACHINE VIEW….620
CONTROLS AND GAUGES….621
DETAILED CONTROLS AND GAUGES….622
MONITORING SYSTEM….622
SWITCHES….633
CONTROL LEVERS AND PEDALS….638
SUN ROOF….642
WINDSHIELD….643
SLIDING DOOR….648
EMERGENCY ESCAPE HAMMER….648
CAP WITH LOCK….650
ENGINE HOOD….651
MUD COVER….652
BATTERY INSPECTION COVER….653
FUSE….654
FUSIBLELINK….655
AUXILIARY ELECTRIC POWER….655
CONTROLLERS….655
HEATER AND DEFROSTAR CONTROLS….656
AIR CONDITIONER CONTROLS….661
RADIO….667
OPERATION MANUAL STORAGE….672
TOOL BOX….672
GREASE PUMP HOLDER….672
ASHTRAY….672
FIRE EXTINGUISHER….673
MACHINE OPERATIONS AND CONTROLS….674
BEFORE STARTING ENGINE….674
STARTING ENGINE….690
AFTER STARTING ENGINE….695
STOPPING THE ENGINE….698
CHECK AFTER SHUT OFF ENGINE….698
MACHINE OPERATION….699
STEERING THE MACHINE….703
SWINGING….705
WORK EQUIPMENT CONTROLS AND OPERATIONS….706
WORK MODE….707
PROHIBITED OPERATIONS….708
GENERAL OPERATION INFORMATION….710
TRAVELING ON SLOPES….712
ESCAPE FROM MUD….714
RECOMMENDED APPLICATIONS….715
BUCKET REPLACEMENT AND INVERSION….717
PARKING MACHINE….719
MACHINE INSPECTION AFTER DAILY WORK….720
LOCKING….720
ROAD LINERS AND RUBBER SHOES….721
TRANSPORTATION….726
TRANSPORTATION PROCEDURE….726
LOADING AND UNLOADING WITH TRAILER….726
LIFTING MACHINE….732
COLD WEATHER OPERATION….734
COLD WEATHER OPERATION INFORMATION….734
AFTER DAILY WORK COMPLETION….736
AFTER COLD WEATHER SEASON….736
LONG TERM STORAGE….737
BEFORE STORAGE….737
DURING STORAGE….737
AFTER STORAGE….737
TROUBLES AND ACTIONS….738
RUNNING OUT OF FUEL….738
PHENOMENA THAT ARE NOT FAILURES….738
TOWING THE MACHINE….738
SEVERE JOB CONDITION….739
DISCHARGED BATTERY….740
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY….745
OTHER TROUBLE….746
MAINTENANCE….751
MAINTENANCE INFORMATION….752
LUBRICANTS, COOLANT AND FILTERS….754
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….754
ELECTRIC SYSTEM MAINTENANCE….756
WEAR PARTS….757
WEAR PARTS LIST….757
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….758
PROPER SELECTION….758
TIGHTENING TORQUE SPECIFICATIONS….762
TIGHTENING TORQUE LIST….762
SAFETY CRITICAL PARTS….763
SAFETY CRITICAL PARTS LIST….763
MAINTENANCE SCHEDULE….764
MAINTENANCE SCHEDULE CHART….764
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….765
MAINTENANCE PROCEDURE….766
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….766
WHEN REQUIRED….767
CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT….767
CLEAN INSIDE OF COOLING SYSTEM….771
REPLACE WATER SEPARATOR ELEMENT….773
CLEAN FUEL TANK….774
CHECK AND TIGHTEN TRACK SHOE BOLTS….775
CHECK AND ADJUST TRACK TENSION….776
CHECK ROAD LINERS OR RUBBER SHOES….778
CHECK AND ADJUST RUBBER SHOE TENSION….780
REPLACE ROAD LINERS….781
REPLACE RUBBER SHOES….782
CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES….784
REPLACE BUCKET TEETH(VERTICAL PIN TYPE)….785
REPLACE BUCKET TEETH(HORIZONTAL PIN TYPE)….788
ADJUST BUCKET CLEARANCE….789
CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID….790
CHECK AND ADJUST AIR CONDITIONER….791
CHECK,CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER….792
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT….793
WASH WASHABLE FLOOR….794
BLEEDING AIR FROM HYDRAULIC SYSTEM….795
CHECK BEFORE STARTING….798
EVERY 50 HOURS MAINTENANCE….799
DRAIN WATER FROM FUEL TANK….799
EVERY 100 HOURS MAINTENANCE….800
LUBRICATING….800
EVERY 250 HOURS MAINTENANCE….801
LUBRICATING….801
CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL….803
CHECK LEVEL OF BATTERY ELECTROLYTE….804
CHECK AND ADJUST COOLING FAN BELT TENSION….806
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION,ADJUST….808
EVERY 500 HOURS MAINTENANCE….809
REPLACE FUEL FILTER CARTRIDGE….809
CHANGE OIL IN ENGINE OIL PAN,REPLACE ENGINE OIL FILTER CARTRIDGE….810
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER….811
CLEAN,CHECK RADIATOR FINS,OIL COOLER FINS AND CONDENSER FINS….813
LUBRICATE SWING CIRCLE….815
CHECK SWING PINION GREASE LEVEL,ADD GREASE….815
EVERY 1000 HOURS MAINTENANCE….816
REPLACE HYDRAULIC OIL FILTER ELEMENT….816
CHANGE OIL IN SWING MACHINERY CASE….818
CHANGE OIL IN FINAL DRIVE CASE….819
EVERY 2000 HOURS MAINTENANCE….820
CHECK PTO GEAR CASE,ADD OIL….820
CLEAN,CHECK TURBOCHARGER….820
CHECK ALTERNATOR,STARTING MOTOR….820
CHECK ENGINE VALVE CLEARANCE,ADJUST….820
EVERY 4000 HOURS MAINTENANCE….821
CHECK WATER PUMP….821
EVERY 5000 HOURS MAINTENANCE….822
CHANGE OIL IN HYDRAULIC TANK,CLEAN STRAINER….822
SPECIFICATIONS….824
SPECIFICATIONS….825
ATTACHMENTS, OPTIONS….827
ATTACHMENTS AND OPTIONS-GENERAL INFORMATION….828
SAFETY FIRST….828
ATTACHMENT INSTALLATION….829
BUCKET WITH HOOK….830
HOOK CONDITION….830
PROHIBITED OPERATIONS….830
MACHINE READY FOR ATTACHMENT….831
LOCATIONS….831
HYDRAULIC CIRCUIT….833
ATTACHMENT OPERATIONS….834
LONG TERM STORAGE….836
SPECIFICATIONS….836
METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT….837
CHANGING MACHINE CONTROL PATTERN(IF PATTERN CHANGE VALVE EQUPPED)….839
CONTROL PATTERN CHANGE PROCEDURE….839
MACHINE CONTROL PATTERNS….840
ATTACHMENT GUIDE….841
OTHER ATTACHMENTS….841
ATTACHMENT COMBINATIONS….842
RECOMMENDED ATTACHMENT OPERATIONS….843
HYDRAULIC BREAKER….843
INDEX….848
SEAM046100T – Hydraulic Excavator PC78US-5 Operation & Maintenance Manual….851
COVER….851
FOREWORD….852
FOREWORD….853
SAFETY INFORMATION….856
INTRODUCTION….858
DIRECTIONS OF MACHINE….858
PRODUCT INFORMATION….859
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION….859
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….859
SERVICE METER LOCATION….860
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….860
CONTENTS….861
SAFETY….866
SAFETY INFORMATION….867
POSITION FOR ATTACHING SAFETY LABELS….869
POSITION FOR ATTACHING SAFETY LABELS….870
SAFETY LABELS….871
SAFETY INFORMATION….875
SAFETY RULES….875
IF ABNORMALITIES ARE FOUND….875
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….875
FIRE EXTINGUISHER AND FIRST AID KIT….875
SAFETY EQUIPMENT….876
KEEP MACHINE CLEAN….876
KEEP OPERATOR'S COMPARTMENT CLEAN….876
LEAVING OPERATOR'S SEAT WITH LOCK….876
HANDRAILS AND STEPS….877
CRUSHING OR CUTTING PREVENTION….878
MOUNTING AND DISMOUNTING….878
NO PERSONS ON ATTACHMENTS….878
BURN PREVENTION….878
FIRE PREVENTION AND EXPLOSION PREVENTION….879
ACTION IF FIRE OCCURS….880
WINDSHIELD WASHER FLUID….880
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….880
ATTACHMENT INSTALLATION….880
ATTACHMENT COMBINATIONS….881
CAB WIDOW GLASSES….881
UNAUTHORIZED MODIFICATIONS….881
SAFETY AT JOBSITE….881
WORKING ON LOOSE GROUND….881
DISTANCE TO HIGH VOLTAGE CABLES….882
ENSURE GOOD VISIBILITY….882
VENTILATION FOR ENCLOSED AREA….883
SIGNALMAN'S SIGNAL AND SIGNS….883
EMERGENCY EXIT FROM OPERATOR'S CAB….883
ASBESTOS DUST HAZARD PREVENTION….883
SAFETY MACHINE OPERATION….884
STARTING ENGINE….884
CHECKS BEFORE STARTING ENGINE….884
SAFETY RULES FOR STARTING ENGINE….885
STARTING ENGINE IN COLD WEATHER….885
OPERATION….886
CHECKS AFTER STARTING ENGINE….886
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….886
SAFETY RULES FOR TRAVELING….887
TRAVELING ON SLOPES….888
OPERATIONS ON SLOPES….889
PROHIBITED OPERATIONS….889
OPERATIONS ON SNOW….891
PARKING MACHINE….891
TRANSPORTATION….892
LOADING AND UNLOADING….892
SHIPPING THE MACHINE….893
BATTERY….894
BATTERY HAZARD PREVENTION….894
STARTING ENGINE WITH BOOSTER CABLES….895
TOWING….896
SAFETY RULES FOR TOWING….896
LIFTING OBJECTS WITH BUCKET….897
SAFETY RULES FOR LIFTING OBJECTS….897
SAFETY MAINTENANCE INFORMATION….898
WARNING TAG….898
KEEP WORK PLACE CLEAN AND TIDY….898
APPOINT LEADER WHEN WORKING WITH OTHERS….898
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….899
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….900
PROPER TOOLS….900
PERSONNEL….900
ATTACHMENTS….901
WORK UNDER THE MACHINE….901
NOISE….901
WHEN USING HAMMER….901
WELDING WORKS….902
REMOVING BATTERY TERMINALS….902
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….902
DO NOT DISASSEMBLE RECOIL SPRINGS….902
SAFETY RULES FOR HIGH-PRESSURE OIL….903
SAFETY HANDLING HIGH-PRESSURE HOSES….903
WASTE MATERIALS….903
AIR CONDITIONER MAINTENANCE….904
COMPRESSED AIR….904
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….904
OPERATION….906
GENERAL VIEW….907
GENERAL VIEW OF MACHINE….907
GENERAL VIEW CONTROLS AND GAUGES….908
EXPLANATION OF COMPONENTS….909
MACHINE MONITOR….909
SWITCHES….915
CONTROL LEVERS, PEDALS….920
CEILING WINDOW….923
FRONT WINDOW….924
SLIDING DOOR….927
REAR WINDOW….928
HAMMER FOR EMERGENCY ESCAPE….928
CAP, COVER WITH LOCK….929
ENGINE HOOD….930
RIGHT SIDE INSPECTION COVER….931
FUEL TANK FILLER COVER….932
FUSE….933
FUSIBLELINK….933
HANDLING AIR CONDITIONER….934
CAR RADIO….937
OPERATION AND MAINTENANCE MANUAL HOLDER….942
TOOL COMPARTMENT….942
GREASE GUN HOLDER….942
ASHTRAY….942
MACHINE OPERATIONS AND CONTROLS….943
BEFORE STARTING ENGINE….943
STARTING ENGINE….956
AFTER STARTING ENGINE….959
STOPPING THE ENGINE….962
CHECK AFTER SHUT OFF ENGINE….962
MACHINE OPERATION….963
STEERING THE MACHINE….967
SWINGING….969
WORK EQUIPMENT CONTROLS AND OPERATIONS….970
PROHIBITED OPERATIONS….972
GENERAL OPERATION INFORMATION….976
TRAVELING ON SLOPES….977
ESCAPE FROM MUD….979
RECOMMENDED APPLICATIONS….980
REPLACEMENT AND INVERSION OF BUCKET….982
PARKING MACHINE….986
CHECK AFTER FINISHING WORK….988
LOCKING….988
HANDLING RUBBER SHOE AND ROAD LINER….989
TRANSPORTATION….994
TRANSPORTATION PROCEDURE….994
LOADING AND UNLOADING WITH TRAILER….995
LIFTING MACHINE….1001
COLD WEATHER OPERATION….1003
COLD WEATHER OPERATION INFORMATION….1003
AFTER DAILY WORK COMPLETION….1005
AFTER COLD WEATHER SEASON….1006
LONG TERM STORAGE….1007
BEFORE STORAGE….1007
DURING STORAGE….1007
AFTER STORAGE….1008
TROUBLESHOOTING….1009
AFTER RUNNING OUT OF FUEL….1009
PHENOMENA THAT ARE NOT FAILURES….1009
TOWING THE MACHINE….1010
PRECAUTIONS ON PARTICULAR JOBSITES….1010
DISCHARGED BATTERY….1011
OTHER TROUBLE….1016
MAINTENANCE….1020
MAINTENANCE INFORMATION….1021
LUBRICANTS, COOLANT AND FILTERS….1024
OUTLINE OF OIL, FUEL, COOLANT….1024
ELECTRIC SYSTEM MAINTENANCE….1026
HANDLING HYDRAULIC SYSTEM….1026
WEAR PARTS LIST….1028
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1029
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS….1029
TIGHTENING TORQUE SPECIFICATIONS….1033
TIGHTENING TORQUE LIST….1033
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….1034
SAFETY CRITICAL PARTS….1034
MAINTENANCE SCHEDULE….1035
MAINTENANCE SCHEDULE CHART….1035
Initial 250 Hours Maintenance (Only after the first 250 hours)….1035
When Required….1035
Checks Before Starting….1036
Every 50 Hours Maintenance….1036
Every 100 Hours Maintenance….1036
Every 250 Hours Maintenance….1036
Every 500 Hours Maintenance….1036
Every 1000 Hours Maintenance….1036
Every 2000 Hours Maintenance….1036
Every 4000 Hours Maintenance….1036
Every 5000 Hours Maintenance….1036
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….1037
MAINTENANCE PROCEDURE….1038
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….1038
WHEN REQUIRED….1039
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….1039
CLEAN INSIDE OF COOLING SYSTEM….1041
WASH INSIDE OF FUEL TANK….1043
REPLACE FEED PUMP PRE-FILTER CARTRIDGE….1044
CHECK AND TIGHTEN TRACK SHOE BOLTS….1045
CHECK AND ADJUST TRACK TENSION….1046
Inspection….1046
Adjustment….1047
CHECK RUBBER SHOES, ROAD LINER….1049
CHECK AND ADJUST RUBBER SHOES TENSION….1051
Inspection….1051
Adjustment….1052
Adjustment….1052
REPLACE RUBBER SHOES….1053
REPLACE ROAD LINER….1056
CHANGE STEEL SHOES OR ROAD LINERS TO RUBBER SHOES….1056
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)….1057
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….1060
ADJUST BUCKET CLEARANCE….1061
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….1062
Mixture ratio of pure washer fluid and water….1062
CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)….1063
CHECK LEVEL OF REFRIGERANT (GAS)….1063
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER….1064
REPLACE ADDITIONAL BREAKER FILTER ELEMENT….1065
WASHING WASHABLE FLOOR….1066
Method of washing….1066
METHOD OF SETTING MACHINE ANGLE….1067
BLEEDING AIR FROM HYDRAULIC SYSTEM….1069
CHECK BEFORE STARTING….1072
EVERY 50 HOURS MAINTENANCE….1073
DRAIN WATER AND SEDIMENT FROM FUEL TANK….1073
EVERY 100 HOURS MAINTENANCE….1074
LUBRICATING….1074
EVERY 250 HOURS MAINTENANCE….1076
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….1076
CHECK LEVEL OF BATTERY ELECTROLYTE….1077
INSPECT AND ADJUST COOLING FAN BELT TENSION….1078
Inspection….1078
Adjustment….1078
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT….1080
Adjusting….1080
EVERY 500 HOURS MAINTENANCE….1081
REPLACE FUEL FILTER CARTRIDGE….1081
PROCEDURE FOR BLEEDING AIR….1082
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….1084
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM….1085
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS….1086
LUBRICATE SWING CIRCLE (2 POINTS)….1086
CHECK SWING PINION GREASE LEVEL, ADD GREASE….1087
REPLACE HYDRAULIC FILTER ELEMENT….1088
EVERY 1000 HOURS MAINTENANCE….1089
CHANGE OIL IN SWING MACHINERY CASE….1089
CHANGE OIL IN FINAL DRIVE CASE….1090
EVERY 2000 HOURS MAINTENANCE….1091
CHECK OIL LEVEL IN PTO GEAR CASE, ADD OIL….1091
CHECK ALTERNATOR, STARTING MOTOR….1091
CHECK ENGINE VALVE CLEARANCE, ADJUST….1091
EVERY 4000 HOURS MAINTENENCE….1092
CHECK WATER PUMP….1092
EVERY 5000 HOURS MAINTENANCE….1093
CHANGE OIL IN HYDRAULIC TANK….1093
SPECIFICATIONS….1096
SPECIFICATIONS….1097
ATTACHMENTS AND OPTIONS….1100
GENERAL PRECAUTIONS….1101
PRECAUTIONS RELATED TO SAFETY….1101
PRECAUTIONS WHEN INSTALLING ATTACHMENTS….1103
HANDLING BUCKET WITH HOOK….1104
CHECKING FOR DAMAGE TO BUCKET WITH HOOK….1104
PROHIBITED OPERATIONS….1104
PRECAUTIONS DURING OPERATIONS….1104
HANDLING CAR HEATER….1105
EXPLANATION OF COMPONENTS….1105
PREPARING CAR HEATER….1105
MACHINES READY FOR ATTACHMENTS….1106
EXPLANATION OF COMPONENTS….1106
STOP VALVE….1106
SELECTOR VALVE….1107
ATTACHMENT CONTROL PEDAL….1107
LOCK PIN….1107
ADDITIONAL FILTER FOR BREAKER….1107
HYDRAULIC CIRCUIT….1108
HYDRAULIC CIRCUIT CONNECTION….1108
OPERATION….1109
WHEN USING BREAKER….1109
WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER….1110
WHEN ADJUSTING OIL AMOUNT FOR ATTACHMENT….1110
LONG-TERM STORAGE….1111
SPECIFICATIONS….1111
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)….1112
CONTROL PATTERN CHANGE PROCEDURE….1112
MACHINE CONTROL PATTERNS….1113
INTRODUCTION OF ATTACHMENTS….1114
SPECIFICATION, USE….1114
INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS….1114
ATTACHMENT INSTALLATION COMBINATION TABLE….1115
ATTACHMENT COMBINATIONS….1115
RECOMMENDED ATTACHMENT OPERATIONS….1116
HYDRAULIC BREAKER….1116
MAIN APPLICATIONS….1116
PROHIBITED WORKS….1118
GREASING POSITION FOR HYDRAULIC BREAKER….1120
INDEX….1122
A….1122
B….1122
C….1122
D….1122
E….1122
F….1122
G….1122
H….1122
I….1122
L….1122
M….1122
O….1123
P….1123
R….1123
S….1123
T….1123
U….1123
W….1123
Y….1123
SEBM025118 – Hydraulic Excavator PC78UU-6, PC78US-6 Shop Manual….1126
COVER….1126
CONTENTS….1127
01 GENERAL….1155
SPECIFICATION DIMENSIONS DRAWING….1156
WORKING RANGE DRAWING….1158
SPECIFICATIONS….1159
WEIGHT TABLE….1171
LIST OF LUBRICANTS AND COOLANT….1175
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD….1176
PTO….1177
COOLING SYSTEM….1179
POWER TRAIN SYSTEM….1181
SWING CIRCLE….1183
SWING MACHINERY….1184
TRACK FRAME AND IDLER CUSHION….1188
IDLER….1190
TRACK ROLLER….1191
CARRIER ROLLER….1193
SPROCKET….1194
TRACK SHOE….1195
ARRANGEMENT OF HYDRAULIC COMPONENTS….1200
HYDRAULIC TANK AND OIL FILTER….1203
CENTER SWIVEL JOINT….1205
TRAVEL MOTOR….1207
WORK EQUIPMENT CYLINDER….1215
SOLENOID VALVE….1220
MULTI-CONTROL VALVE….1227
ACCUMULATOR FOR BRAKER….1228
HYDRAULIC PUMP….1229
CONTROL VALVE….1253
CLSS….1290
SWING MOTOR….1327
WORK EQUIPMENT AND SWING PPC VALVE….1335
TRAVEL PPC VALVE….1341
OFFSET PPC VALVE (PC78UU-6)ATTACHMENT PPC VALVE (PC78US-6)BLADE PPC VALVE (PC78UU,PC78US-6)….1345
WORK EQUIPMENT….1349
DIMENSIONS OF EACH PART OF WORK EQUIPMENT….1354
AIR CONDITIONER PIPING (OPTIONAL)….1360
ELECTRIC CONTROL SYSTEM….1362
SYSTEM COMPONENTS….1417
MONITOR SYSTEM….1430
SENSORS….1436
20 TESTING AND ADJUSTING….1440
STANDARD VALUE TABLE FOR ENGINE….1441
STANDARD VALUE TABLE FOR CHASSIS….1443
STANDARD VALUE TABLE FOR ELECTRIC PARTS….1452
TESTING AND ADJUSTING….1463
LIST OF DEVICES FOR TESTING, ADJUSTING, & TROUBLESHOOTING….1464
MEASURING ENGINE SPEED….1465
MEASURING EXHAUST GAS COLOR….1466
ADJUSTING VALVE CLEARANCE….1467
MEASURING COMPRESSION PRESSURE….1468
MEASURING BLOW-BY PRESSURE….1470
TESTING AND ADJUSTING FUEL INJECTION TIMING….1472
MEASURING ENGINE OIL PRESSURE….1476
ADJUSTING ENGINE STOP SOLENOID….1477
ADJUSTING FUEL CONTROL LINKAGE….1479
ADJUSTING ENGINE SPEED SENSOR….1481
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT,SWING,AND TRAVEL CIRCUITS….1482
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE….1485
ADJUSTING PC VALVE….1487
TESTING TVC-EPC SOLENOID OUTPUT PRESSURE….1487
MEASURING CONTROL CIRCUIT PRESSURE….1489
MEASURING PPC VALVE OUTPUT PRESSURE….1490
TESTING SOLENOID VALVE OUTPUT PRESSURE….1491
ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE….1493
TESTING TRAVEL DEVIATION….1494
TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT….1496
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTORS….1497
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT….1498
TESTING CLEARANCE OF SWING CIRCLE BEARING….1499
TESTING AND ADJUSTING TRACK SHOE TENSION….1500
BLEEDING AIR FROM HYDRAULIC CIRCUIT….1501
PROCEDURE FOR ADJUSTING INSTALLATION OF LONG ARM….1503
TESTING AND ADJUSTING HOOD CATCH….1504
REPLACEMENT PROCEDURE OF POTENTIOMETERS….1506
PROCEDURE FOR TESTING DIODE….1507
PM-CLINIC SERVICE….1508
TROUBLESHOOTING….1512
POINTS TO REMEMBER WHEN TROUBLESHOOTING….1513
SEQUENCE OF EVENTS IN TROUBLESHOOTING….1514
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE….1515
CHECKS BEFORE TROUBLESHOOTING….1523
CONNECTOR TYPES AND MOUNTING LOCATIONS….1524
CONNECTOR ARRANGEMENT DIAGRAM….1526
CONNECTOR TYPES AND MOUNTING LOCATIONS….1529
CONNECTOR ARRANGEMENT DIAGRAM….1531
CONNECTOR TYPES AND MOUNTING LOCATIONS….1534
CONNECTOR ARRANGEMENT DIAGRAM….1536
CONNECTOR TYPES AND MOUNTING LOCATIONS….1539
CONNECTOR ARRANGEMENT DIAGRAM….1541
CONNECTOR TYPES AND MOUNTING LOCATIONS….1544
CONNECTOR ARRANGENMENT DIAGRAM….1546
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….1549
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL MECHANISM….1572
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL….1576
TVC VALVE CURRENT ADJUSTMENT TABLE….1593
HOW TO READ FLOW OF TROUBLESHOOTING….1596
CONTENTS AND PROCEDURE OF TROUBLESHOOTING….1598
TROUBLESHOOTING OF COMMUNICATION SYSTEM (N MODE)….1599
N-1 DEFECTIVE COMMUNICATION….1600
TROUBLESHOOTING FOR CONTROLLER(GOVERNOR CONTROL SYSTEM)(E MODE)….1602
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (GOVERNOR CONTROL SYSTEM)….1603
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE….1604
JUDGMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE….1609
E-1 CONTROLLER POWER SUPPLY ID DEFECTIVE (LED OF CONTROLLER IS TURNED OFF)….1613
E-2 [E321] (SHORT CIRCUIT IN MOTOR DRIVE RELAY) IS DISPLAYED….1615
E-3 [E323] (SHORT CIRCUIT IN ACCELERATOR RELAY SYSTEM) IS DISPLAYED….1616
E-4 [E325] (SHORT CIRCUIT IN DECELERATOR REPLAY SYSTEM) IS DISPLAYED….1619
E-5 [E328] (STALL OF MOTOR) IS DISPLAYED….1622
E-6 [E227] (TROUBLE IN ENGINE SPEED SENSOR) IS DISPLAYED….1627
E-7 [E306] (TROUBLE IN GOVERNOR MOTOR FEEDBACK POTENTIOMETER) IS DISPLAYED….1629
E-8 [E308] (TROUBLE IN FUEL CONTROL DIAL SYSTEM) IS DISPLAYED….1630
E-9 ONE-TOUCH SLOW-DOWN MECHANISM DOES NOT WORK….1631
E-10 ENGINE DOES NOT START….1633
a) [E304] SHORT CIRCUIT IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED….1633
b) [E314] DISCONNECTION IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED….1633
c) ENGINE STOP SOLENOID SYSTEM….1635
d) STARTING SYSTEM….1640
E-11 ENGINE DOES NOT STOP….1647
TROUBLESHOOTING FOR CONTROLLER PUMP CONTROL SYSTEM (C MODE)….1650
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (PUMP CONTROL SYSTEM)….1651
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE….1652
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC EQUIPMENT….1658
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM….1662
C-1 [E232], C-2 [E233] TROUBLE IN TVC-EPC SOLENOID SYSTEM….1672
C-3 [E203], C-4 [E213] TROUBLE IN SWING HOLDING BRAKE SOLENOID SYSTEM….1674
C-5 [E206], C-6 [E216] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENOID SYSTEM….1676
C-7 [E403] TROUBLE IN BOOM ANGLE SENSOR CORRECTION….1678
C-8 [E406] TROUBLE IN ARM ANGLE SENSOR CORRECTION….1678
C-9 [E411] TROUBLE IN OFFSET BOOM ANGLE SENSOR CORRECTION (ONLY PC78UU-6)….1678
C-10 [E441] TROUBLE IN INTERFERENCE PREVENTION (FRONT) CORRECTION….1680
C-11 [E442] TROUBLE IN INTERFERENCE PREVENTION (SIDE) CORRECTION (ONLY PC78UU-6)….1680
C-12 [E443] TROUBLE IN DEPTH INDICATION CORRECTION (ONLY PC78UU-6)….1681
C-13 [E258] SHORT CIRCUIT IN 5V SYSTEM OF SENSOR POWER SUPPLY (ONLY PC78UU-6)….1682
C-14 [E224] TROUBLE IN PUMP PRESSURE SENSOR IS DISPLAYED….1685
C-15 [E401], C-16 [E402] TROUBLE IN BOOM ANGLE SENSOR SYSTEM (ONLY PC78UU-6)….1686
C-17 [E404], C-18 [E405] TROUBLE IN ARM ANGLE SENSOR SYSTEM (ONLY PC78UU-6)….1687
C-19 [E407], C-20 [E408] TROUBLE IN OFFSET ANGLE SENSOR SYSTEM (ONLY PC78UU-6)….1688
C-21 [E421] DISCONNECTION IN BOOM RAISE EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6)….1689
C-22 [E422] DISCONNECTION IN BOOM RAISE EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6)….1690
C-23 [E423] SHORT CIRCUIT OR GROUNDING FAULT IN ARM-IN EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6)….1691
C-24 [E424] DISCONNECTION IN ARM-IN EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6)….1692
C-25 [E425] SHORT CIRCUIT OR GROUNDING FAULT IN OFFSET LEFT EPC SYSTEM IS DISPLAYED(ONLY PC78UU-6)….1693
C-26 [E426] DISCONNECTION IN OFFSET LEFT EPC SYSTEM IS DISPLAYED (ONLY PC78UU-6)….1694
C-27 [E431] SHORT CIRCUIT OR GROUNDING FAULT IN PPC BASIC PRESSURE LOCK SOLENOID SYSTEM IS DISPLAYED (ONLY PC78UU-6)….1695
C-28 BOOM DOES NOT STOP AUTOMATICALLY AT NORMAL POSITION BUT INTERFERES WHEN IT IS RAISED(ONLY PC78UU-6)….1698
C-29 ARM DOES NOT STOP AUTOMATICALLY AT NORMAL POSITION BUT INTERFERES WHEN IT IS MOVED IN (ONLY PC78UU-6)….1699
C-30 OFFSET DOES NOT STOP AUTOMATICALLY AT NORMAL POSITION BUT INTERFERES WHEN IT IS MOVED TO LEFT (ONLY PC78UU-6)….1700
C-31 WORK EQUIPMENT STOPS OR NEAR (ONLY PC78UU-6)….1701
C-32 BUZZER SOUNDS FOR 7 SECONDS WHILE EMERGENCY WORK EQUIPMENT OPERATION SWITCH IS NOT TURNED ON (ONLY PC78UU-6)….1702
C-33 BOOM RAISE END CUSHION DOES NOT WORK AT ALL OR NORMALLY (ONLY PC78UU-6)….1704
C-34 ARM-IN END CUSHION DOES NOT WORK AT ALL OR NORMALLY (ONLY PC78UU-6)….1705
C-35 OFFSET ENF CUSHION DOES NOT WORK AT ALL OR NORMALLY (ONLY PC78UU-6)….1706
C-36 WORK EQUIPMENT STOPS AFTER OR BEFORE SET HEIGHT (ONLY PC78UU-6)….1707
C-37 WHEN DEPTH DISPLAY IS RESET,0.0M IS NOT INDICATED AT GL (ONLY PC78UU-6)….1708
C-38 WORK EQUIPMENT STILL MOVES AFTER WORK EQUIPMENT LOCK LEVER IS SET TO LOCK….1709
C-39 MACHINE DOES NOT SWING….1713
C-40 TRAVEL SPEED DOES NOT RISE….1715
C-41 GEAR SPEED DOES NOT CHANG AUTOMATICALLY….1716
C-42 TROUBLE IN CONTROLLER POWER SUPLY SYSTEM (LED OF CONTROLLER IS TURNED OFF)….1716
TROUBLESHOOTING FOR CONTROLLER (INPUT SIGNAL SYSTEM)(F MODE)….1717
F-1 BIT PATTERN 1023-(4) SWING PRESSURE SWITCH DOES NOT LIGHT UP….1718
F-2 BIT PATTERN 1023-(3) TRAVEL PRESSURE SWITCH DOES NOT LIGHT UP….1720
F-3 BIT PATTERN 1023-(6) BOOM RAISE PRESSURE SWITCH DOES NOT LIGHT UP….1722
F-4 BIT PATTERN 1023-(5) ARM IN PRESSURE SWITCH DOES NOT LIGHT UP….1724
F-5 BIT PATTERN 1026-(1) DECELERATION SWITCH OF LEFT KNOB DOES NOT LIGHT UP….1726
F-6 BIT PATTERN 1026-(4) 2ND TRAVEL SPEED SELECTION SWITCH (PEDAL) DOES NOT LIGHT UP (US WITH BLADE SPECIFICATION AND UU)….1728
F-7 BIT PATTERN 1021-(3) COMPRESSOR SIGNAL DOES NOT LIGHT UP….1729
F-8 BIT PATTERN 1026-(3) EMERGENCY WORK EQUIPMENT OPERATION SWITCH DOES NOT LIGHT UP (ONLY PC78UU-6)….1731
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)….1732
TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES….1734
H-1 SPEED OR POWER OF 2 OR MORE SYSTEMS OF WORK EQUIPMENT (BOOM,ARM,BUCKET),TRAVEL,SWING,AND BLADE IS LOW….1736
a) SPEED POWER OF WORK EQUIPMENT (INCLUDING BLADE),TRAVEL,AND SWING SYSTEMS IS LOW….1736
b) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE) ANF TRAVEL IS LOW….1737
c) SPEED OR POWER OF SWING AND BLADE IS LOW….1737
d) SPEED OR POWER OF TRAVEL AND BLADE IS LOW….1738
e) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE) IS LOW….1738
f) SPEED OR POWER OF TRAVEL AND SWING IS LOW….1739
g) SPEED OR POWER OF ALL WORK EQUIPMENT AND SWING IS LOW….1739
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS….1740
H-3 2 OR MORE SYSTEMS OF WORK EQUIPMENT (BOOM,ARM,BUCKET),TRAVEL,SWING,AND BLADE DO NOT MOVE….1742
a) ALL WORK EQUIPMENT (INCLUDING BLADE),TRAVEL,AND SWING SYSTEMS DO NOT MOVE….1742
b) ALL WORK EQUIPMENT (EXCLUDING BLADE) AND TRAVEL SYSTEMS DO NOT MOVE….1743
c) SWING AND BLADE SYSTEMS DO NOT MOVE….1743
d) TRAVEL AND BLADE SYSTEMS DO NOT MOVE….1744
e) ALL WORK EQUIPMENT (EXCLUDING BLADE) DOES NOT MOVE….1744
H-4 ABNORMAL SOUND COMES OUT (FROM AROUND PUMP)….1745
H-5 FINE CONTROLLABILITY OR RESPONSE IS LOW….1746
H-6 HYDRAULIC DRIFT IS LARGE (ALL WORK EQUIPMENT AND BLADE)….1747
H-7 BOOM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)….1748
a) BOOM RAISE SPEED OR POWER IS LOW….1748
b) BOOM LOWER SPEED OR POWER IS LOW….1749
H-8 ARM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)….1750
a) ARM IN SPEED OR POWER IS LOW….1750
b) ARM OUT SPEED OR POWER IS LOW….1752
H-9 BUCKET SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)….1753
a) BUCKET CURL SPEED OR POWER IS LOW….1753
b) BUCKET DUMP SPEED OR POWER IS LOW….1754
H-10 OFFSET SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)(ONLY PC78UU-6)….1755
a) OFFSET LEFT SPEED OR POWER IS LOW….1755
b) OFFSET RIGHT SPEED OR POWER IS LOW….1756
H-11 BOOM DOES NOT MOVE….1757
a) BOOM DOES NOT RISE….1757
b) BOOM DOES NOT LOWER….1758
H-12 ARM DOES NOT MOVE….1759
a) ARM DOES NOT MOVE IN….1759
b) ARM DOES NOT MOVE OUT….1760
H-13 BUCKET DOES NOT MOVE….1761
a) BUCKET DOES NOT CURL….1761
b) BUCKET DOES NOT DUMP….1762
H-14 OFFSET BOOM DOES NOT MOVE (ONLY PC78UU-6)….1763
a) OFFSET BOOM LEFT DOES NOT MOVE….1763
b) OFFSET BOOM RIGHT DOES NOT MOVE….1764
H-15 HYDRAULIC DRIFT OF BOOM IS LARGE….1765
H-16 HYDRAULIC DRIFT OF ARM IS LARGE….1765
H-17 HYDRAULIC DRIFT OF BUCKET IS LARGE….1766
H-18 HYDRAULIC DRIFT OF OFFSET IS LARGE (ONLY PC78UU-6)….1766
a) HYDRAULIC DRIFT OF OFFSET TO LEFT IS LARGE….1766
b) HYDRAULIC DRIFT OF OFFSET TO RIGHT IS LARGE….1766
H-19 TIME LAG IS LARGE (WHEN ENGINE SPEED IS LOW)….1767
H-20 PART LOADED MORE MOVES SLOWER IN COMPOUND OPERATION OF WORK EQUIPMENT….1767
H-21 BOOM RAISE SPEED IS LOW IN COMPOUND OPERATION OF SWING AND BOOM RAISE….1768
H-22 TRAVEL SPEED LOWERS EXTREMELY IN COMPOUND OPERATION OF TRAVEL AND BOOM RAISE….1768
H-23 SPEED IS LOW IN COMPOUND OPERATION OF WORK EQUIPMENT RELIEF AND SWING,WORK EQUIPMENT RELIEF AND OTHER WORK EQUIPMENT….1768
H-24 WORK EQUIPMENT DOES NOT MOVE OR ITS SPEED IS LOW IN COMPOUND OPERATION OF TRAVEL AND WORK EQUIPMENT….1769
H-25 TRAVEL DEVIATION IS LARGE….1770
a) TRAVEL DEVIATION IS LARGE DURING ORDINARY TRAVEL….1770
b) TRAVEL DEVIATION IS LARGE WHEN MACHINE STARTS(BUT NORMAL DURING ORDINARY TRAVEL)….1771
H-26 TRAVEL DEVIATION IS LARGE IN COMPOUND OPERATION OF TRAVEL AND SWING,TRAVEL AND WORK EQUIPMENT….1772
H-27 TRAVEL SPEED OR POWER IS LOW (WORK EQUIPMENT,SWING,AND BLADE OPERATIONS ARE NORMAL)….1773
H-28 MACHINE CANNOT BE STEERED SHARPLY OR STEERING FORCE IS INSUFFICIENT….1775
H-29 TRAVEL SPEED DOES NOT CHANGE AT ALL OR DOES NOT CHANGE QUICKLY….1776
H-30 MACHINE DOES NOT TRAVEL….1777
H-30 SUPPLEMENT….1778
H-31 OVERRUN OF TRAVEL IS LARGE….1779
H-32 TRAVEL HYDRAULIC DRIFT IS LARGE….1779
H-33 FINE CONTROLLABILITY OR RESPONSE IS LOW….1780
H-34 SWING SPEED OR POWER IS LOW (WORK EQUIPMENT,TRAVEL,AND BLADE OPERATIONS ARE NORMAL)….1781
H-35 MACHINE DOES NOT SWING (WORK EQUIPMENT,TRAVEL,AND BLADE OPERATIONS ARE NORMAL)….1784
a) SWING SPEED OR POWER IS LOW IN BOTH DIRECTIONS….1784
b) SWING SPEED OR POWER IS LOW IN EITHER DIRECTION….1785
H-36 SWING ACCELERATION IS LOW….1786
a) SWING ACCELERATION IS LOW IN BOTH DIRECTIONS….1786
b) SWING ACCELERATION IS LOW IN EITHER DIRECTION ….1786
H-37 OVERRUN OF SWING IS LARGE….1787
a) OVERRUN OF SWING IS LARGE IN BOTH DIRECTIONS….1787
b) OVERRUN OF SWING IS LARGE IN EITHER DIRECTION….1787
H-38 LARGE SHOCK IS MODE WHEN MACHINE STOPS SWINGING….1788
H-39 LARGE ABNORMAL SOUND IS MODE WHEN MACHINE STOPS SWINGING….1788
H-40 SWING HYDRAULIC DRIFT IS LARGE….1789
H-41 FINE CONTROLLABILITY OR RESPONSE OF SWING IS LOW….1790
H-42 BLADE SPEED OR POWER IS LOW (WORK EQUIPMENT,TRAVEL,AND SWING OPERATIONS ARE NORMAL)….1791
H-43 BLADE DOES NOT MOVE (WORK EQUIPMENT,TRAVEL,AND SWING OPERATIONS ARE NORMAL)….1792
a) BLADE DOES NOT RISE….1792
b) BLADE DOES NOT LOWER….1793
H-44 HYDRAULIC DRIFT OF BLADE IS LARGE….1794
H-45 FINE CONTROLLABILITY OR RESPONSE OF BLADE IS LOW….1795
H-46 MONITOR PANEL DISPLAYS ERROR CODE AND BOOM RAISE,ARM IN,AND OFFSET LEFT OPERATIONS STOP JUST BEFORE INTERFERENCE(ONLY PC78UU-6)….1796
H-47 MACHINE DOES NOT STOP BOOM RAISE,ARM IN,AND OFFSET LEFT OPERATIONS AUTOMATICALLY BUT INTERFERES (ONLY PC78UU-6)….1796
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM(M MODE)….1797
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE….1798
ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM….1800
M-1 [E101](ERROR HISTORY DATA ARE ABNORMAL) IS DISPLAYED….1806
M-2 [E108](ENGINE COOLANT TEMPERATURE IS 105℃) IS DISPLAYED….1808
M-3 [E112](WIPER FORWARD OUTPUT IS SHORTED) IS DISPLAYED….1808
M-4 [E113](WIPER REVERSE OUTPUT IS SHORTED) IS DISPLAYED….1808
M-5 [E114](CONTACT WITH WASHER OUTPUT OF 24 V) IS DISPLAYED….1808
M-6 [E115](WIPER DOES NOT START WIPING IN 10 SECONDS) IS DISPLAYED….1808
M-7 [E116](WIPER IS NOT RETRACTED IN 10 SECONDS) IS DISPLAYED….1808
M-8 WHEN STARTING SWITCH IS TURNED TO ON POSITION,MONITOR PANEL SEGMENTS DO NOT LIGHT UP FOR 3 SECONDS….1809
a) MONITOR PANEL SEGMENTS DO NOT LIGHT UP AT ALL….1809
b) SOME MONITOR PANEL SEGMENTS DO NOT LIGHT UP….1809
M-9 WHEN STARTING SWITCH IS SET TO ON POSITION,ALL MONITOR PANEL SEGMENTS LIGHT UP BUT DO NOT GO OFF….1811
M-10 WHILE PREHEATING IS NOT EXECUTED,"PREHEATER MONITOR" LIGHTS UP….1811
M-11 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH….1812
a) ALTERNATOR SYSTEM….1812
b) ENGINE OIL SYSTEM….1814
M-12 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED),CAUTION ITEMS AND EMERGENCY STOP ITEMS (EXCLUDING BATTERY AND ENGINE OIL) FLASH….1816
a) ALTERNATOR SYSTEM….1816
b) ENGINE OIL PRESSURE SENSOR SYSTEM….1818
M-13 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED,CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH (WHEN THERE IS NOT ABNORMALITY IN INSPECTION ITEMS AND ENGINE BEFOR TROUBLESHOOTING,HOWEVER)….1820
a) "ENGINE OIL" FLASHES….1820
b) "CHARGE LEVEL" FLASHES….1820
c) "COOLANT TEMPERATURE" FLASHES….1821
d) "FUEL LEVEL" FLASHES….1823
M-14 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED),BUZZER DOES NOT SOUND FOR 1 SECOND WHILE CAUTION ITEM IS FLASHING,BUZZER DOES NOT SOUND….1825
M-15 MONITOR PLANE LAMP FOR NIGHTTIME IS NOT TURNED ON (LC DISPLAY IS NORMAL)….1827
M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE….1829
M-17 COOLANT TEMPERATURE GAUGE IS NOT DISPLAYED (GAUGE DOES NOT RISE TO 1ST LINE DURING OPERATION)….1831
M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL….1833
M-19 FUEL LEVEL GAUGE IS NOT DISPLAYED….1835
M-20 WHILE ENGINE IS RUNNING,SERVICE METER DOES NOT ADVANCE….1837
M-21 TROUBLE IN FUEL LEVEL SENSOR….1838
M-22 TROUBLE IN COOLANT TEMPERATURE SENSOR….1840
M-23 WIPER DOES NOT OPERATE OR OPERATES WHILE WIPER SWITCH IS TURNED OFF….1841
a) WIPER DOES NOT OPERATE….1841
b) WIPER OPERATES WHILE WIPER SWITCH IS TURNNED OFF….1841
M-24 WASHER MOTOR DOES NOT OPERATE OR OPERATES WHILE WASHER SWITCH IS TURNED OFF….1846
a) WASHER MOTOR DOES NOT OPERATE….1846
b) WASHER OPERATES WHILE WIPER SWITCH IS TURNED OFF….1846
M-25 DEPTH SET 0 MODE AND HEIGHT MODE CANNOT BE SELECTED AND SET (ONLY PC78UU-6)….1849
30 DISASSEMBLY AND ASSEMBLY….1850
METHOD OF USING MANUAL….1851
PRECAUTIONS WHEN CARRYING OUT OPERATION….1852
SPECIAL TOOL LIST….1856
COUNTERWEIGHT….1864
REMOVAL AND INSTALLATION….1864
INJECTION PUMP….1866
REMOVAL….1866
INSTALLATION….1867
CYLINDER HEAD….1872
REMOVAL….1872
INSTALLATION….1874
MAIN PUMP….1880
REMOVAL….1880
INSTALLATION….1881
CONTROLL PUMP….1882
REMOVAL AND INSTALLATION….1882
ENGINE AND MAIN PUMP….1883
REMOVAL….1883
INSTALLATION….1885
ENGINE HOOD ASSEMBLY….1886
REMOVAL….1886
INSTALLATION….1886
HYDRAULIC OIL COOLER….1887
REMOVAL AND INSTALLATION….1887
RADIATOR….1889
REMOVAL AND INSTALLATION….1889
SWING MOTOR AND SWING MACHINERY….1891
REMOVAL AND INSTALLATION….1891
SWING MACHINERY….1892
DISASSEMBLY….1892
ASSEMBLY….1894
SWING MOTOR….1902
REMOVAL AND INSTALLATION….1902
CENTER SWIVEL JOINT….1903
REMOVAL AND INSTALLATION….1903
CONTROL VALVE….1905
REMOVAL AND INSTALLATION….1905
WORK EQUIPMENT PPC VALVE….1907
ASSEMBLY….1907
TRAVEL PPC VALVE….1909
ASSEMBLY….1909
HYDRAULIC TANK….1910
REMOVAL AND INSTALLATION….1910
FUEL TANK….1913
REMOVAL….1913
INSTALLATION….1914
CONTROLLER….1917
REMOVAL AND INSTALLATION….1917
MONITOR PANEL….1918
REMOVAL AND INSTALLATION….1918
AIR CONDITIONER UNIT….1919
REMOVAL….1919
INSTALLATION….1920
OPERATOR'S CAB….1921
REMOVAL….1921
INSTALLATION….1922
FLOOR FRAME….1923
REMOVAL….1923
INSTALLATION….1924
OPERATOR'S CAB GLASS (STUCK GLASS)….1925
REMOVAL….1926
INSTALLATION….1927
FRONT WINDOW….1935
REMOVAL AND INSTALLATION….1935
REVOLVING FRAME….1936
REMOVAL….1936
INSTALLATION….1938
SWING CIRCLE….1939
REMOVAL AND INSATLLATION….1939
WORK EQUIPMENT….1940
REMOVAL….1940
INSTALLATION….1942
FIRST BOOM….1946
REMOVAL….1946
INSTALLATION….1948
SECOND BOOM….1949
REMOVAL AND INSTALLATION….1949
OFFSET BRACKET….1950
REMOVAL….1950
INSTALLATION….1951
STEEL SHOE, RUBBER PAD SHOE, ROAD LINER….1952
EXPANSION AND INSTALLATION….1952
RUBBER SHOE….1953
REMOVAL AND INSTALLATION….1953
FINAL DRIVE AND TRAVEL MOTOR….1953
REMOVAL….1953
INSTALLATION….1954
TRAVEL MOTOR….1955
DISASSEMBLY AND ASSEMBLY….1955
IDLER….2006
ASSEMBLY….2006
RECOIL SPRING….2008
DISASSEMBLY….2008
ASSEMBLY….2009
TRACK ROLLER….2010
DISASSEMBLY….2010
ASSEMBLY….2011
HYDRAULIC CYLINDER….2013
DISASSEMBLY….2013
ASSEMBLY….2014
50 OTHER SPECIFICATIONS….2017
PC78US-6(FOR NORWAY & EU)….2018
CONTENTS….2019
GENERAL….2020
SPECIFICATION DIMENSIONS DRAWING….2020
WORKING RANGE DRAWING….2021
SPECIFICATIONS….2022
WEIGHT TABLE….2028
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD….2030
ARRANGEMENT OF HYDRAULIC COMPONENTS….2030
SOLENOID VALVE….2032
ACCUMULATOR FOR PPC….2036
DIMENSIONS OF EACH PART OF WORK EQUIPMENT….2037
BOOM HYDRAULIC ANTI-BURST VALVE….2039
ELECTRIC CONTROL SYSTEM….2045
GENERAL SYSTEM DIAGRAM….2046
OVERLOAD ALARM FUNCTION….2052
OVERLOAD ALARM PRESSURE SENSOR….2053
METER DISPLAY UNIT….2054
TROUBLESHOOTING….2055
CONNECTOR TYPES AND MOUNTING LOCATIONS….2055
CONNECTOR ARRANGEMENT DIAGRAM….2057
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL MECHANISM….2070
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL….2072
TROUBLESHOOTING FOR CONTROLLER PUMP CONTROL SYSTEM(C MODE)….2080
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (PUMP CONTROL SYSTEM)….2081
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE….2082
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC EQUIPMENT….2086
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM….2090
C-1 [E232], C-2 [E233] TROUBLE IN TVC-EPC SOLENOID SYSTEM….2093
C-3 [E203], C-4 [E213] TROUBLE IN SWING HOLDING BRAKE SOLENOID SYSTEM….2095
C-5 [E206], C-6 [216] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENOID SYSTEM….2097
C-7 [E251] TROUBLE IN BOOM BOTTOM PRESSURE SENSOR (OVERLOAD SENSOR) SYSTEM….2099
C-8 [E258] SHORT CIRCUIT IN 5 V SYSTEM OF SENSOR POWER SUPPLY ….2101
C-9 WORK EQUIPMENT STILL MOVES AFTER WORK EQUIPMENT LOCK LEVER IS SET TO LOCK….2104
C-10 MACHINE DOES NOT SWING….2107
C-11 TRAVEL SPEED DOES NOT RISE….2109
C-12 GEAR SPEED DOES NOT CHANGE AUTOMATICALLY….2110
C-13 TROUBLE IN CONTROLLER POWER SUPPLY (LED OF CONTROLLER IS TURNED OFF)….2110
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M MODE)….2111
ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM….2112
M-11 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED,BASIC CHECK ITEMS FLASH….2118
a) ALTERNATOR SYSTEM….2118
b) ENGINE OIL PRESSURE SYSTEM….2120
M-12 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED), CAUTION ITEMS AND EMERGENCY STOP ITEMS (EXCLUDING BATTERY AND ENGINE OIL) FLASH….2122
a) ALTERNATOR SYSTEM….2122
b) ENGINE OIL PRESSURE SENSOR SYSTEM….2124
90 OTHERS….2126
HYDRAULIC CIRCUIT DIAGRAM….2127
PC78US-6 SERIAL NO.:4001-6500 (BLADE-LESS SPECIFICATION)….2127
PC78US-6 SERIAL NO.:6501 AND UP (BLADE-LESS SPECIFICATION)….2129
PC78US-6 (ADDITIONAL ATTACHMENT CIRCUIT)….2128
PC78US-6 SERIAL NO.:4001-6500 (BLADE SPECIFICATION)….2130
PC78US-6 SERIAL NO.:6501 AND UP (BLADE SPECIFICATION)….2131
PC78US-6 SERIAL NO.:4809-6500 (NORWAY & EU SPECIFICATION)….2132
PC78US-6 SERIAL NO.:6501 AND UP (NORWAY & EU SPECIFICATION)….2133
PC78UU-6….2134
ELECTRICAL CIRCUIT DIAGRAM….2135
PC78US-6 SERIAL NO.:4001-5500 (1/2)….2135
PC78US-6 SERIAL NO.:4001-5500 (2/2)….2136
PC78US-6 SERIAL NO.:5501-6500 (1/2)….2137
PC78US-6 SERIAL NO.:5501-6500 (2/2)….2138
PC78US-6 SERIAL NO.:6501 AND UP (1/2)….2139
PC78US-6 SERIAL NO.:6501 AND UP (2/2)….2140
PC78US-6 SERIAL NO.:4809-5500(NORWAY & EU SPECIFICATION) (1/2)….2141
PC78US-6 SERIAL NO.:4809-5500(NORWAY & EU SPECIFICATION) (2/2)….2142
PC78US-6 SERIAL NO.:5501-6500(NORWAY & EU SPECIFICATION) (1/2)….2143
PC78US-6 SERIAL NO.:5501-6500(NORWAY & EU SPECIFICATION) (2/2)….2144
PC78US-6 SERIAL NO.:6501 AND UP(NORWAY & EU SPECIFICATION) (1/2)….2145
PC78US-6 SERIAL NO.:6501 AND UP(NORWAY & EU SPECIFICATION) (2/2)….2146
PC78UU-6 SERIAL NO.:22832-23500(1/2)….2147
PC78UU-6 SERIAL NO.:22832-23500(2/2)….2148
PC78UU-6 SERIAL NO.:23501 AND UP (1/2)….2149
PC78UU-6 SERIAL NO.:23501 AND UP (2/2)….2150
SEN04543-10 – Hydraulic Excavator PC78US-8 Shop Manual….2151
COVER….2151
00 Index and foreword….0
100 Index….2153
Composition of shop manual….2154
Table of contents….2156
200 Foreword and general information….2165
Safety notice….2166
How to read the shop manual….2171
Explanation of terms for maintenance standard….2173
Handling of electric equipment and hydraulic component….2175
Handling of connectors newly used for engines….2184
How to read electric wire code….2187
Precautions when carrying out operation….2190
Method of disassembling and connecting push-pull type coupler….2193
Standard tightening torque table….2196
Conversion table….2200
01 Specification….0
100 Specification and technical data….2207
Specification dimension drawing….2208
Working range diagram….2209
Specifications….2210
Weight table….2214
Table of fuel, coolant and lubricants….2216
10 Structure, function and maintenance standard….0
100 Engine and cooling system….2219
Engine mount….2220
PTO….2221
Cooling system….2222
200 Power train….2225
Power train….2227
Swing circle….2228
Swing machinery….2230
300 Undercarriage and frame….2233
Track frame….2234
Idler cushion….2235
Idler….2236
Track roller….2237
Carrier roller….2238
Sprocket….2239
Track shoe….2240
401 Hydraulic system, Part 1….2247
Hydraulic component layout drawing….2248
Valve control….2250
Hydraulic tank and filter….2252
Hydraulic pump….2254
402 Hydraulic system, Part 2….2273
Control valve….2274
CLSS….2286
Functions and operation by valve….2290
403 Hydraulic system, Part 3….2323
PPC valve….2325
Swing motor….2341
Travel motor….2352
Center swivel joint….2360
Solenoid valve….2362
PPC accumulator….2365
Anti-drop valve….2367
Multi-control valve….2372
500 Work equipment….2375
Work equipment….2376
Dimensions of components….2378
Work equipment cylinder….2384
600 Cab and its attachments….2387
Air conditioner….2388
700 Electrical system….2401
Electronic control system….2402
Monitor system….2434
KOMTRAX system….2448
Sensor….2450
20 Standard value table….0
100 Standard service value table….2457
Standard value table for engine related parts….2458
Standard value table for chassis….2459
30 Testing and adjusting….0
101 Testing and adjusting, Part 1….2469
Tools for testing, adjusting, and troubleshooting….2471
Testing engine speed….2476
Testing exhaust temperature….2477
Checking exhaust gas color….2478
Adjusting valve clearance….2479
Testing compression pressure….2481
Testing blow-by pressure….2483
Testing engine oil pressure….2484
Handling fuel system parts….2485
Releasing residual pressure from fuel system….2485
Testing fuel pressure….2486
Testing fuel return rate and fuel leakage….2487
Bleeding air from fuel circuit….2489
Checking fuel circuit for leakage….2491
Testing and adjusting alternator belt tension….2492
Checking and adjusting air conditioner compressor belt tension….2494
Testing swing circle bearing clearance….2495
Checking and adjusting track shoe tension….2496
Testing and adjusting oil pressure in work equipment and travel circuits….2498
Testing and adjusting swing and blade circuit oil pressure (Blade specification)….2500
Testing control circuit basic pressure….2503
Testing and adjusting oil pressure in pump PC control circuit….2504
Testing PC-EPC solenoid output pressure….2507
Testing LS differential pressure and adjusting LS valve….2508
Testing solenoid valve output pressure….2510
Testing PPC valve output pressure….2512
Adjusting play of work equipment and swing PPC valves….2514
Checking parts which cause hydraulic drift of work equipment….2515
Testing and adjusting travel deviation….2517
Releasing residual pressure from hydraulic circuit….2519
Testing oil leakage….2520
Bleeding air from each part….2523
Adjusting mirrors….2525
Testing and adjusting hood catch….2526
102 Testing and adjusting, Part 2….2529
Special functions of machine monitor….2530
103 Testing and adjusting, Part 3….2581
Handling voltage circuit of engine controller….2582
Preparation work for troubleshooting of electrical system….2583
Procedure for testing diodes….2588
Pm Clinic service….2589
40 Troubleshooting….0
100 Failure code table and fuse locations….2595
Failure code table….2596
Fuse locations….2598
200 General information on troubleshooting….2603
Points to remember when troubleshooting….2604
Sequence of events in troubleshooting….2605
Checks before troubleshooting….2606
Classification and troubleshooting steps….2607
Information in troubleshooting table….2608
Phenomena looking like troubles and troubleshooting Nos….2610
Connection table for connector pin numbers….2613
T- branch box and T- branch adapter table….2649
301 Troubleshooting by failure code, Part 1….2653
Failure code [989L00] Engine controller lock caution 1….2655
Failure code [989M00] Engine controller lock caution 2….2656
Failure code [989N00] Engine controller lock caution 3….2657
Failure code [AB00KE] Charge voltage low….2658
Failure code [B@BAZG] Eng oil press. low….2660
Failure code [B@BCNS] Eng coolant overheat….2661
Failure code [B@HANS] Hydr oil overheat….2661
Failure code [CA111] ECM critical internal failure….2662
Failure code [CA115] Eng. Ne and Bkup speed sensor error….2665
Failure code [CA122] Charge air press sensor high error….2666
Failure code [CA123] Charge air press sensor low error….2668
Failure code [CA131] Throttle sensor high error….2670
Failure code [CA132] Throttle sensor low error….2672
Failure code [CA144] Coolant temp. sensor high error….2674
Failure code [CA145] Coolant temp. sensor low error….2676
Failure code [CA153] Charge air temp. sensor high error….2678
Failure code [CA154] Charge air temp. sensor low error….2680
Failure code [CA187] Sensor sup. 2 volt. low error….2681
Failure code [CA221] Ambient air press. sensor high error….2682
Failure code [CA222] Ambient air press. sensor low error….2684
Failure code [CA227] Sensor sup. 2 volt. high error….2685
Failure code [CA234] Eng. overspeed….2686
Failure code [CA238] Ne speed sensor sup. volt. error….2688
Failure code [CA271] IMV/PCV1 short error….2690
Failure code [CA272] IMV/PCV1 open error….2691
Failure code [CA322] Injector #1 (L #1) system open/short error….2692
Failure code [CA324] Injector #3 (L #3) system open/short error….2694
Failure code [CA331] Injector #2 (L #2) system open/short error….2696
Failure code [CA332] Injector #4 (L #4) system open/short error….2698
302 Troubleshooting by failure code, Part 2….2701
Failure code [CA351] Inj. drive circuit error….2703
Failure code [CA352] Sensor sup. 1 volt. low error….2706
Failure code [CA386] Sensor sup. 1 volt. high error….2708
Failure code [CA435] Abnormality in engine oil pressure switch….2710
Failure code [CA441] Battery voltage low error….2711
Failure code [CA442] Battery voltage high error….2712
Failure code [CA449] Rail press. very high error….2713
Failure code [CA451] Rail press. sensor high error….2714
Failure code [CA452] Rail press. sensor low error….2716
Failure code [CA488] Chg air temp high torque derate….2717
Failure code [CA553] Rail press. high error….2718
Failure code [CA559] Rail press. low error….2719
Failure code [CA689] Eng. Ne speed sensor error….2722
Failure code [CA731] Eng. Bkup speed sensor phase error….2724
Failure code [CA757] All persistent data lost error….2725
Failure code [CA778] Eng. Bkup speed sensor error….2726
Failure code [CA1633] KOMNET datalink timeout error….2728
Failure code [CA2185] Throttle sens. sup. volt. high error….2730
Failure code [CA2186] Throttle sens. sup. volt. low error….2732
Failure code [CA2249] Rail press. very low error….2732
Failure code [CA2311] Abnormality in IMV solenoid….2733
Failure code [D110KB] Battery relay drive short….2734
Failure code [D19JKZ] Personal code relay abnormality….2736
Failure code [D862KA] GPS antenna discon….2738
Failure code [DA22KK] Pump solenoid power low error….2740
Failure code [DA25KP] 5V sensor 1 power abnormality….2742
Failure code [DA26KP] 5V sensor 2 power abnormality….2744
Failure code [DA29KQ] Model selection abnormality….2746
303 Troubleshooting by failure code, Part 3….2749
Failure code [DA2RMC] CAN discon (Pump controller detected)….2750
Failure code [DAFGMC] GPS module error….2752
Failure code [DAFRMC] CAN discon (Monitor detected)….2754
Failure code [DGH2KB] Hydr oil sensor short….2756
Failure code [DHPAMA] Pump press sensor abnormality….2758
Failure code [DHS5KX] Travel PPC press sensor abnormality….2760
Failure code [DHSAMA] Swing right PPC press sensor abnormality….2762
Failure code [DHSBMA] Swing left PPC press sensor abnormality….2764
Failure code [DHX1MA] Overload sensor abnormality (Analog)….2766
Failure code [DV20KB] Travel alarm S/C….2767
Failure code [DW43KA] Travel speed sol discon….2768
Failure code [DW43KB] Travel speed sol short….2769
Failure code [DW45KA] Swing brake sol discon….2770
Failure code [DW45KB] Swing brake sol short….2772
Failure code [DWJ0KA] Merge-divider sol discon….2774
Failure code [DWJ0KB] Merge-divider sol short….2775
304 Troubleshooting by failure code, Part 4….2777
Failure code [DXA8KA] PC-EPC sol discon….2778
Failure code [DXA8KB] PC-EPC sol short….2780
Failure code [DXE4KA] Service current EPC discon….2782
Failure code [DXE4KB] Service current EPC short….2783
Failure code [DY20KA] Wiper working abnormality….2784
Failure code [DY20MA] Wiper parking abnormality….2786
Failure code [DY2CKA] Washer drive discon….2788
Failure code [DY2CKB] Washer drive short….2790
Failure code [DY2DKB] Wiper drive (for) short….2792
Failure code [DY2EKB] Wiper drive (rev) short….2794
400 Troubleshooting of electrical system (E-mode)….2797
Before carrying out troubleshooting of electrical system….2799
Information in troubleshooting table….2802
E-1 When starting switch is turned ON, machine monitor displays nothing….2804
E-2 Engine does not start (Engine does not turn)….2806
E-3 Preheater does not operate….2810
E-4 Automatic warm-up system does not operate (in cold season)….2812
E-5 All work equipment, swing, and travel mechanism do not move or cannot be locked….2814
E-6 Precaution lights up while engine is running….2816
E-7 Emergency stop item lights up while engine is running….2819
E-8 Engine coolant temperature gauge does not indicate normally….2820
E-9 Hydraulic oil temperature gauge does not indicate normally….2822
E-10 Fuel level gauge does not indicate normally….2825
E-11 Contents of display by machine monitor are different from applicable machine….2827
E-12 Machine monitor does not display some items….2827
E-13 Function switch does not work….2827
E-14 Auto-decelerator does not operate normally….2828
E-15 Working mode does not change….2829
E-16 Travel speed does not change….2830
E-17 Alarm buzzer cannot be stopped….2831
E-18 Windshield wiper and window washer do not operate….2832
E-19 Swing holding brake does not operate normally….2836
E-20 Travel alarm does not sound or does not stop sounding….2838
E-21 Air conditioner does not operate normally (including air conditioner abnormality record)….2839
E-22 While starting switch is in OFF position, service meter is not displayed….2852
E-23 Machine monitor cannot be set in service mode….2853
E-24 Monitoring function does not display lever control signal normally….2854
E-25 KOMTRAX system does not operate normally….2870
500 Troubleshooting of hydraulic and mechanical system (H-mode)….2873
Information contained in troubleshooting table….2875
System chart for hydraulic and mechanical systems….2876
H-1 Speed or power of all work equipment, swing, and travel are low….2878
H-2 Engine speed sharply drops or engine stalls….2879
H-3 No work equipment, travel and swing move….2880
H-4 Abnormal noise is heard from around hydraulic pump….2880
H-5 Fine control performance or response of work equipment and travel is low….2881
H-6 Speed or power of boom is low….2882
H-7 Speed or power of arm is low….2883
H-8 Speed or power of bucket is low….2884
H-9 Speed or power of blade is low….2885
H-10 Work equipment does not move in its single operation….2886
H-11 Hydraulic drift of work equipment is large….2887
H-12 Time lag of work equipment is large….2889
H-13 Work equipment loaded more is slower during compound operation….2889
H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE….2889
H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel….2890
H-16 Machine deviates during travel….2891
H-17 Travel speed is low….2892
H-18 Machine cannot be steered easily or steering power is low….2893
H-19 Travel speed does not change or it is kept low or high….2894
H-20 Track does not move (only either side)….2894
H-21 Machine does not swing….2895
H-22 Swing acceleration, swing speed and swing power are low….2896
H-23 Excessive overrun when stopping swing….2898
H-24 When upper structure stops swinging, it makes large shock….2899
H-25 When upper structure stops swinging, it makes large sound….2899
H-26 Hydraulic drift of swing is large….2900
H-27 Flow rate in attachment circuit cannot be adjusted….2901
600 Troubleshooting of engine (S-mode)….2903
Method of using troubleshooting chart….2904
S-1 Starting performance is poor….2908
S-2 Engine does not start….2909
S-3 Engine does not pick up smoothly….2912
S-4 Engine stops during operations….2913
S-5 Engine does not rotate smoothly….2914
S-6 Engine lacks output (or lacks power)….2915
S-7 Exhaust smoke is black (incomplete combustion)….2916
S-8 Oil consumption is excessive (or exhaust smoke is blue)….2917
S-9 Oil becomes contaminated quickly….2918
S-10 Fuel consumption is excessive….2919
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)….2920
S-12 Oil pressure drops….2921
S-13 Oil level rises (Entry of coolant or fuel)….2922
S-14 Coolant temperature becomes too high (overheating)….2923
S-15 Abnormal noise is made….2924
S-16 Vibration is excessive….2925
50 Disassembly and assembly….0
100 General information on disassembly and assembly….2927
How to read this manual….2928
Coating materials list….2930
Special tool list….2933
Sketches of special tools….2937
200 Engine and cooling system….2943
Removal and installation of fuel supply pump assembly….2944
Removal and installation of fuel injector assembly….2948
Removal and installation of engine front seal….2952
Removal and installation of engine rear seal….2953
Removal and installation of cylinder head assembly….2955
Removal and installation of radiator assembly….2966
Removal and installation of aftercooler assembly….2969
Removal and installation of hydraulic oil cooler assembly….2971
Removal and installation of engine and hydraulic pump assembly….2974
Removal and installation of fuel tank assembly….2984
Removal and installation of fuel tank assembly….2985
300 Power train….2989
Removal and installation of travel motor and final drive assembly….2991
Disassembly and assembly oftravel motor and final driveassembly….2993
Removal and installation of swing motor and swing machinery assembly….3031
Disassembly and assembly of swing machinery….3033
Removal and installation of swing circle assembly….3040
400 Undercarriage and frame….3043
Disassembly and assembly of track roller assembly….3044
Disassembly and assembly of idler assembly….3047
Disassembly and assembly of recoil spring assembly….3050
Spreading and installation of track shoe assembly….3052
Removal and installation of sprocket….3054
Removal and installation of revolving frame assembly….3055
Removal and installation of counterweight assembly….3057
500 Hydraulic system….3061
Removal and installation of center swivel joint assembly….3062
Disassembly and assembly of center swivel joint assembly….3064
Removal and installation of hydraulic tank assembly….3066
Removal and installation of hydraulic pump assembly….3069
Removal and installation of control valve assembly….3073
Disassembly and assembly of control valve assembly….3081
Disassembly and assembly of work equipment PPC valve assembly….3084
Disassembly and assembly of travel PPC valve assembly….3086
Disassembly and assembly of hydraulic cylinder assembly….3088
600 Work equipment….3095
Removal and installation of work equipment assembly….3096
Removal and installation of blade assembly….3099
700 Cab and its attachments….3103
Removal and installation of operator cab assembly….3104
Removal and installation of operator's cab glass (Stuck glass)….3109
Removal and installation of front window assembly….3119
Removal and installation of floor frame assembly….3120
800 Electrical system….3127
Removal and installation of air conditioner unit assembly….3128
Removal and Installation of air conditioner condenser assembly….3129
Removal and installation of air conditioner unit assembly….3130
Removal and installation of machine monitor assembly….3134
Removal and installation of pump controller assembly….3135
Removal and installation of engine controller assembly….3136
Removal and installation of KOMTRAX terminal assembly….3138
90 Diagrams and drawings….0
100 Hydraulic diagrams and drawings….3141
Hydraulic circuit diagram….3143
Actuator attachment hydraulic circuit diagram….3146
200 Electrical diagrams and drawings….3149
Electrical circuit diagram….3151
Air conditioner unit electrical circuit diagram….3163
Connector list and stereogram….3164
TEN00004-00 – Hydraulic Excavator GALEO PC78US-6 Operation & Maintenance Manual….3167
COVER….3167
FOREWORD….3168
FOREWORD….3169
SAFETY INFORMATION….3172
INTRODUCTION….3174
DIRECTIONS OF MACHINE….3174
PRODUCT INFORMATION….3175
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….3175
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….3175
EPA NAMEPLATE….3176
SERVICE METER LOCATION….3176
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….3177
CONTENTS….3178
SAFETY….3182
SAFETY INFORMATION….3183
SAFETY LABELS….3185
LOCATION OF SAFETY LABELS….3186
SAFETY LABELS….3187
SAFETY INFORMATION….3193
SAFETY RULES….3193
IF ABNORMALITIES ARE FOUND….3193
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….3193
FIRE EXTINGUISHER AND FIRST AID KIT….3193
SAFETY EQUIPMENT….3193
KEEP MACHINE CLEAN….3194
KEEP OPERATOR'S COMPARTMENT CLEAN….3194
LEAVING OPERATOR'S SEAT WITH LOCK….3194
HANDRAILS AND STEPS….3195
MOUNTING AND DISMOUNTING….3195
NO PERSONS ON ATTACHMENTS….3195
DO NOT GET CAUGHT IN ARTICULATED PORTION….3195
BURN PREVENTION….3196
FIRE PREVENTION AND EXPLOSION PREVENTION….3196
ACTION IF FIRE OCCURS….3197
WINDSHIELD WASHER FLUID….3197
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….3197
ATTACHMENT INSTALLATION….3198
ATTACHMENT COMBINATIONS….3198
CAB WINDOW GLASSES….3198
UNAUTHORIZED MODIFICATIONS….3198
SAFETY AT JOBSITE….3198
WORKING ON LOOSE GROUND….3199
DISTANCE TO HIGH VOLTAGE CABLES….3199
ENSURE GOOD VISIBILITY….3199
VENTILATION FOR ENCLOSED AREA….3200
SIGNALMAN'S SIGNAL AND SIGNS….3200
EMERGENCY EXIT FROM OPERATOR'S CAB….3200
ASBESTOS DUST HAZARD PREVENTION….3200
SAFETY MACHINE OPERATION….3201
STARTING ENGINE….3201
CHECKS BEFORE STARTING ENGINE….3201
SAFETY RULES FOR STARTING ENGINE….3201
STARTING ENGINE IN COLD WEATHER….3202
OPERATION….3203
CHECKS BEFORE OPERATION….3203
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….3203
SAFETY RULES FOR TRAVELING….3204
TRAVELING ON SLOPES….3205
OPERATIONS ON SLOPES….3206
PROHIBITED OPERATIONS….3206
OPERATIONS ON SNOW….3207
PARKING MACHINE….3208
TRANSPORTATION….3209
LOADING AND UNLOADING….3209
SHIPPING THE MACHINE….3209
BATTERY….3210
BATTERY HAZARD PREVENTION….3210
STARTING ENGINE WITH BOOSTER CABLES….3211
TOWING….3212
SAFETY RULES FOR TOWING….3212
LIFTING OBJECTS WITH BUCKET….3213
SAFETY RULES FOR LIFTING OBJECTS….3213
SAFETY MAINTENANCE INFORMATION….3214
WARNING TAG….3214
KEEP WORK PLACE CLEAN AND TIDY….3214
APPOINT LEADER WHEN WORKING WITH OTHERS….3214
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….3215
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….3215
PROPER TOOLS….3216
PERSONNEL….3216
ATTACHMENTS….3216
WORK UNDER THE MACHINE….3217
NOISE….3217
WHEN USING HAMMER….3217
WELDING WORKS….3217
REMOVING BATTERY TERMINALS….3217
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….3218
DO NOT DISASSEMBLE RECOIL SPRINGS….3218
SAFETY RULES FOR HIGH-PRESSURE OIL….3218
SAFETY HANDLING HIGH-PRESSURE HOSES….3219
WASTE MATERIALS….3219
AIR CONDITIONER MAINTENANCE….3219
COMPRESSED AIR….3219
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….3219
OPERATION….3220
MACHINE VIEW ILLUSTRATIONS….3221
OVERALL MACHINE VIEW….3221
CONTROLS AND GAUGES….3222
DETAILED CONTROLS AND GAUGES….3223
MONITORING SYSTEM….3223
SWITCHES….3234
CONTROL LEVERS AND PEDALS….3239
SUN ROOF….3242
WINDSHIELD….3243
SLIDING DOOR….3249
EMERGENCY ESCAPE HAMMER….3249
CAP WITH LOCK….3250
ENGINE HOOD….3251
MUD COVER….3252
BATTERY INSPECTION COVER….3253
FUSE….3254
FUSIBLE LINK….3255
AUXILIARY ELECTRIC POWER….3255
CONTROLLERS….3255
HEATER AND DEFROSTER CONTROLS….3256
AIR CONDITIONER CONTROLS….3261
RADIO….3267
OPERATION MANUAL STORAGE….3272
TOOL, GREASE PUMP STORAGE PLACE….3272
ASHTRAY….3272
FIRE EXTINGUISHER….3272
MACHINE OPERATIONS AND CONTROLS….3273
BEFORE STARTING ENGINE….3273
STARTING ENGINE….3290
AFTER STARTING ENGINE….3295
STOPPING THE ENGINE….3298
MACHINE OPERATION….3299
STEERING THE MACHINE….3303
SWINGING….3305
WORK EQUIPMENT CONTROLS AND OPERATIONS….3306
WORKING MODE….3308
PROHIBITED OPERATIONS….3309
GENERAL OPERATION INFORMATION….3311
TRAVELING ON SLOPES….3313
ESCAPE FROM MUD….3315
RECOMMENDED APPLICATIONS….3316
BUCKET REPLACEMENT AND INVERSION….3318
PARKING MACHINE….3320
MACHINE INSPECTION AFTER DAILY WORK….3322
LOCKING….3322
ROAD LINERS AND RUBBER SHOES….3323
TRANSPORTATION….3328
TRANSPORTATION PROCEDURE….3328
LOADING AND UNLOADING WITH TRAILER….3328
LIFTING MACHINE….3333
COLD WEATHER OPERATION….3335
COLD WEATHER OPERATION INFORMATION….3335
AFTER DAILY WORK COMPLETION….3337
AFTER COLD WEATHER SEASON….3337
LONG TERM STORAGE….3338
BEFORE STORAGE….3338
DURING STORAGE….3338
AFTER STORAGE….3339
TROUBLES AND ACTIONS….3340
RUNNING OUT OF FUEL….3340
PHENOMENA THAT ARE NOT FAILURES….3340
TOWING THE MACHINE….3341
LIGHTWEIGHT TOWING HOLE….3341
SEVERE JOB CONDITION….3341
DISCHARGED BATTERY….3342
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY….3346
OTHER TROUBLE….3347
MAINTENANCE….3352
MAINTENANCE INFORMATION….3353
OUTLINE OF SERVICE….3355
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….3355
ELECTRIC SYSTEM MAINTENANCE….3358
WEAR PARTS….3359
WEAR PARTS LIST….3359
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….3360
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….3361
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN….3362
TIGHTENING TORQUE SPECIFICATIONS….3363
TIGHTENING TORQUE LIST….3363
SAFETY CRITICAL PARTS….3364
SAFETY CRITICAL PARTS LIST….3364
MAINTENANCE SCHEDULE….3365
MAINTENANCE SCHEDULE CHART….3365
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….3366
MAINTENANCE PROCEDURE….3367
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….3367
Replace fuel filter cartridge….3367
Change oil in engine oil pan, replace engine oil filter cartridge….3367
WHEN REQUIRED….3368
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….3368
CLEAN INSIDE OF COOLING SYSTEM….3374
REPLACE WATER SEPARATOR ELEMENT….3377
CHECK AND TIGHTEN TRACK SHOE BOLTS….3378
CHECK AND ADJUST TRACK TENSION….3379
CHECK ROAD LINERS OR RUBBER SHOES….3381
CHECK AND ADJUST RUBBER SHOE TENSION….3383
REPLACE ROAD LINERS….3384
REPLACE RUBBER SHOES….3385
CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES….3387
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)….3388
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….3391
ADJUST BUCKET CLEARANCE….3392
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….3393
CHECK AND ADJUST AIR CONDITIONER….3394
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER….3395
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT….3396
WASH WASHABLE FLOOR….3397
BLEEDING AIR FROM HYDRAULIC SYSTEM….3399
CHECK BEFORE STARTING….3402
EVERY 50 HOURS MAINTENANCE….3403
DRAIN WATER FROM FUEL TANK….3403
EVERY 100 HOURS MAINTENANCE….3404
LUBRICATING….3404
EVERY 250 HOURS MAINTENANCE….3405
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….3405
CHECK LEVEL OF BATTERY ELECTROLYTE….3406
CHECK AND ADJUST COOLING FAN BELT TENSION….3408
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….3410
EVERY 500 HOURS MAINTENANCE….3411
LUBRICATING….3411
REPLACE FUEL FILTER CARTRIDGE….3413
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….3414
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS….3415
CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS….3417
LUBRICATE SWING CIRCLE….3419
CHECK SWING PINION GREASE LEVEL, ADD GREASE….3419
EVERY 1000 HOURS MAINTENANCE….3420
REPLACE HYDRAULIC OIL FILTER ELEMENT….3420
CHANGE OIL IN SWING MACHINERY CASE….3422
CHANGE OIL IN FINAL DRIVE CASE….3423
EVERY 2000 HOURS MAINTENANCE….3424
CHECK PTO GEAR CASE, ADD OIL….3424
CLEAN, CHECK TURBOCHARGER….3424
CHECK ALTERNATOR, STARTING MOTOR….3424
CHECK ENGINE VALVE CLEARANCE, ADJUST….3424
EVERY 4000 HOURS MAINTENANCE….3425
CHECK WATER PUMP….3425
EVERY 5000 HOURS MAINTENANCE….3426
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….3426
SPECIFICATIONS….0
SPECIFICATIONS….3429
ATTACHMENTS AND OPTIONS….3432
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….3433
SAFETY FIRST….3433
ATTACHMENT INSTALLATION….3434
BUCKET WITH HOOK….3435
HOOK CONDITION….3435
PROHIBITED OPERATIONS….3435
MACHINE READY FOR ATTACHMENT….3436
LOCATIONS….3436
HYDRAULIC CIRCUIT….3438
ATTACHMENT OPERATIONS….3439
LONG TERM STORAGE….3441
SPECIFICATIONS….3441
METHOD FOR REMOVING AND INSTALLING EXTRA….3442
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE….3444
CONTROL PATTERN CHANGE PROCEDURE….3444
MACHINE CONTROL PATTERNS….3445
ATTACHMENT GUIDE….3446
OTHER ATTACHMENTS….3446
ATTACHMENT COMBINATIONS….3447
RECOMMENDED ATTACHMENT OPERATIONS….3448
HYDRAULIC BREAKER….3448
INDEX….3454
TEN00072-01 – Hydraulic Excavator GALEO PC78US-6 Operation & Maintenance Manual….3458
COVER….3458
FOREWORD….3459
FOREWORD….3460
SAFETY INFORMATION….3463
INTRODUCTION….3465
DIRECTIONS OF MACHINE….3465
PRODUCT INFORMATION….3466
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….3466
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….3466
EPA NAMEPLATE….3467
SERVICE METER LOCATION….3467
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….3468
CONTENTS….3469
SAFETY….3473
SAFETY INFORMATION….3474
SAFETY LABELS….3476
LOCATION OF SAFETY LABELS….3477
SAFETY LABELS….3478
SAFETY INFORMATION….3484
SAFETY RULES….3484
IF PROBLEMS ARE FOUND….3484
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….3484
FIRE EXTINGUISHER AND FIRST AID KIT….3484
SAFETY EQUIPMENT….3484
KEEP MACHINE CLEAN….3485
KEEP OPERATOR'S COMPARTMENT CLEAN….3485
LEAVING OPERATOR'S SEAT WITH LOCK….3485
HANDRAILS AND STEPS….3486
MOUNTING AND DISMOUNTING….3486
NO PERSONS ON ATTACHMENTS….3486
DO NOT GET CAUGHT IN ARTICULATED PORTION….3486
BURN PREVENTION….3487
FIRE PREVENTION AND EXPLOSION PREVENTION….3487
ACTION IF FIRE OCCURS….3488
WINDSHIELD WASHER FLUID….3488
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….3488
ATTACHMENT INSTALLATION….3489
ATTACHMENT COMBINATIONS….3489
CAB WINDOW GLASSES….3489
UNAUTHORIZED MODIFICATIONS….3489
SAFETY AT JOBSITE….3489
WORKING ON LOOSE GROUND….3490
DISTANCE TO HIGH VOLTAGE CABLES….3490
ENSURE GOOD VISIBILITY….3490
VENTILATION FOR ENCLOSED AREA….3491
SIGNALMAN'S SIGNAL AND SIGNS….3491
EMERGENCY EXIT FROM OPERATOR'S CAB….3491
ASBESTOS DUST HAZARD PREVENTION….3491
SAFETY MACHINE OPERATION….3492
STARTING ENGINE….3492
CHECKS BEFORE STARTING ENGINE….3492
SAFETY RULES FOR STARTING ENGINE….3492
STARTING ENGINE IN COLD WEATHER….3493
OPERATION….3494
CHECKS BEFORE OPERATION….3494
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….3494
SAFETY RULES FOR TRAVELING….3495
TRAVELING ON SLOPES….3496
OPERATIONS ON SLOPES ….3497
PROHIBITED OPERATIONS….3497
OPERATIONS ON SNOW….3498
PARKING MACHINE….3499
TRANSPORTATION….3500
LOADING AND UNLOADING….3500
SHIPPING THE MACHINE….3500
BATTERY….3501
BATTERY HAZARD PREVENTION….3501
STARTING ENGINE WITH BOOSTER CABLES….3502
TOWING….3503
SAFETY RULES FOR TOWING….3503
LIFTING OBJECTS WITH BUCKET….3504
SAFETY RULES FOR LIFTING OBJECTS….3504
SAFETY MAINTENANCE INFORMATION….3505
WARNING TAG….3505
KEEP WORK PLACE CLEAN AND TIDY….3506
APPOINT LEADER WHEN WORKING WITH OTHERS….3506
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….3506
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….3507
PROPER TOOLS….3507
PERSONNEL….3507
ATTACHMENTS….3508
WORK UNDER THE MACHINE….3508
NOISE….3508
WHEN USING HAMMER….3508
WELDING WORKS….3508
REMOVING BATTERY TERMINALS….3509
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….3509
DO NOT DISASSEMBLE RECOIL SPRINGS….3509
SAFETY RULES FOR HIGH-PRESSURE OIL….3509
SAFETY HANDLING HIGH-PRESSURE HOSES….3510
WASTE MATERIALS….3510
AIR CONDITIONER MAINTENANCE….3510
COMPRESSED AIR….3510
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….3510
OPERATION….3511
MACHINE VIEW ILLUSTRATIONS….3512
OVERALL MACHINE VIEW….3512
CONTROLS AND GAUGES….3513
DETAILED CONTROLS AND GAUGES….3514
MONITORING SYSTEM….3514
SWITCHES….3525
CONTROL LEVERS AND PEDALS….3530
SUN ROOF….3533
WINDSHIELD….3534
SLIDING DOOR….3540
EMERGENCY ESCAPE HAMMER….3540
CAP WITH LOCK….3541
ENGINE HOOD….3542
MUD COVER….3543
BATTERY INSPECTION COVER….3544
FUSE….3545
FUSIBLE LINK….3546
AUXILIARY ELECTRIC POWER….3546
CONTROLLERS….3546
HEATER AND DEFROSTER CONTROLS….3547
AIR CONDITIONER CONTROLS….3552
RADIO….3558
OPERATION MANUAL STORAGE….3563
TOOL, GREASE PUMP STORAGE PLACE….3563
ASHTRAY….3563
FIRE EXTINGUISHER….3563
MACHINE OPERATIONS AND CONTROLS….3564
BEFORE STARTING ENGINE….3564
STARTING ENGINE….3581
AFTER STARTING ENGINE….3586
STOPPING THE ENGINE….3589
MACHINE OPERATION….3590
STEERING THE MACHINE….3594
SWINGING….3596
WORK EQUIPMENT CONTROLS AND OPERATIONS….3597
WORKING MODE….3599
PROHIBITED OPERATIONS….3599
GENERAL OPERATION INFORMATION….3602
TRAVELING ON SLOPES….3604
ESCAPE FROM MUD….3606
RECOMMENDED APPLICATIONS….3607
BUCKET REPLACEMENT AND INVERSION….3609
PARKING MACHINE….3611
MACHINE INSPECTION AFTER DAILY WORK….3613
LOCKING….3613
ROAD LINERS AND RUBBER SHOES….3614
TRANSPORTATION….3619
TRANSPORTATION PROCEDURE….3619
LOADING AND UNLOADING WITH TRAILER….3619
LIFTING MACHINE….3624
COLD WEATHER OPERATION….3626
COLD WEATHER OPERATION INFORMATION….3626
AFTER DAILY WORK COMPLETION….3628
AFTER COLD WEATHER SEASON….3628
LONG TERM STORAGE….3629
BEFORE STORAGE….3629
DURING STORAGE….3629
AFTER STORAGE….3630
TROUBLES AND ACTIONS….3631
RUNNING OUT OF FUEL….3631
PHENOMENA THAT ARE NOT FAILURES….3631
TOWING THE MACHINE….3632
LIGHTWEIGHT TOWING HOLE….3633
SEVERE JOB CONDITION….3633
DISCHARGED BATTERY….3634
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY….3638
OTHER TROUBLE….3639
MAINTENANCE….3645
MAINTENANCE INFORMATION….3646
OUTLINE OF SERVICE….3648
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….3648
ELECTRIC SYSTEM MAINTENANCE….3651
WEAR PARTS….3652
WEAR PARTS LIST….3652
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….3653
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….3654
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….3655
TIGHTENING TORQUE SPECIFICATIONS….3656
TIGHTENING TORQUE LIST….3656
SAFETY CRITICAL PARTS….3657
SAFETY CRITICAL PARTS LIST….3657
MAINTENANCE SCHEDULE….3658
MAINTENANCE SCHEDULE CHART….3658
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….3659
MAINTENANCE PROCEDURE….3660
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….3660
WHEN REQUIRED….3661
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….3661
CLEAN INSIDE OF COOLING SYSTEM….3667
REPLACE WATER SEPARATOR ELEMENT….3670
CHECK AND TIGHTEN TRACK SHOE BOLTS….3671
CHECK AND ADJUST TRACK TENSION….3672
CHECK ROAD LINERS OR RUBBER SHOES….3674
CHECK AND ADJUST RUBBER SHOE TENSION….3676
REPLACE ROAD LINERS….3677
REPLACE RUBBER SHOES….3678
CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES….3680
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)….3681
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….3684
ADJUST BUCKET CLEARANCE….3685
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….3686
CHECK AND MAINTENANCE AIR CONDITIONER….3687
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER….3688
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT….3689
WASH WASHABLE FLOOR….3690
BLEEDING AIR FROM HYDRAULIC SYSTEM….3692
CHECK BEFORE STARTING….3695
EVERY 50 HOURS MAINTENANCE….3696
DRAIN WATER FROM FUEL TANK….3696
EVERY 100 HOURS MAINTENANCE….3697
LUBRICATING….3697
EVERY 250 HOURS MAINTENANCE….3698
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….3698
CHECK LEVEL OF BATTERY ELECTROLYTE….3699
CHECK AND ADJUST COOLING FAN BELT TENSION….3701
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….3703
EVERY 500 HOURS MAINTENANCE….3704
LUBRICATING….3704
REPLACE FUEL FILTER CARTRIDGE….3706
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….3707
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS….3708
CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS….3710
LUBRICATE SWING CIRCLE….3712
CHECK SWING PINION GREASE LEVEL, ADD GREASE….3712
EVERY 1000 HOURS MAINTENANCE….3713
REPLACE HYDRAULIC OIL FILTER ELEMENT….3713
CHANGE OIL IN SWING MACHINERY CASE….3715
CHANGE OIL IN FINAL DRIVE CASE….3716
EVERY 2000 HOURS MAINTENANCE….3717
CHECK PTO GEAR CASE, ADD OIL….3717
CLEAN, CHECK TURBOCHARGER….3717
CHECK ALTERNATOR, STARTING MOTOR….3717
CHECK ENGINE VALVE CLEARANCE, ADJUST….3717
EVERY 4000 HOURS MAINTENANCE….3718
CHECK WATER PUMP….3718
EVERY 5000 HOURS MAINTENANCE….3719
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….3719
SPECIFICATIONS….3721
SPECIFICATIONS….3722
ATTACHMENTS, OPTIONS….3725
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….3726
SAFETY FIRST….3726
ATTACHMENT INSTALLATION….3727
BUCKET WITH HOOK….3728
HOOK CONDITION….3728
PROHIBITED OPERATIONS….3728
MACHINE READY FOR ATTACHMENT….3729
LOCATIONS….3729
HYDRAULIC CIRCUIT….3731
ATTACHMENT OPERATIONS….3732
LONG TERM STORAGE….3734
SPECIFICATIONS….3734
METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT….3735
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)….3737
CONTROL PATTERN CHANGE PROCEDURE….3737
MACHINE CONTROL PATTERNS….3738
ATTACHMENT GUIDE….3739
OTHER ATTACHMENTS….3739
ATTACHMENT COMBINATIONS….3740
RECOMMENDED ATTACHMENT OPERATIONS….3741
HYDRAULIC BREAKER….3741
CRUSHER….3746
INDEX….3749
TEN00200-00 – Hydraulic Excavator GALEO PC78US-6 Operation & Maintenance Manual….3753
COVER….3753
FOREWORD….3754
FOREWORD….3755
SAFETY INFORMATION….3758
INTRODUCTION….3760
DIRECTIONS OF MACHINE….3760
PRODUCT INFORMATION….3761
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….3761
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….3761
EPA NAMEPLATE….3762
SERVICE METER LOCATION….3762
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….3763
CONTENTS….3764
SAFETY….3767
SAFETY INFORMATION….3768
SAFETY LABELS….3770
LOCATION OF SAFETY LABELS….3771
SAFETY LABELS….3772
SAFETY INFORMATION….3778
SAFETY RULES….3778
IF PROBLEMS ARE FOUND….3778
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….3778
FIRE EXTINGUISHER AND FIRST AID KIT….3778
SAFETY EQUIPMENT….3778
KEEP MACHINE CLEAN….3779
KEEP OPERATOR'S COMPARTMENT CLEAN….3779
LEAVING OPERATOR'S SEAT WITH LOCK….3779
HANDRAILS AND STEPS….3780
MOUNTING AND DISMOUNTING….3780
NO PERSONS ON ATTACHMENTS….3780
DO NOT GET CAUGHT IN ARTICULATED PORTION….3780
BURN PREVENTION….3781
FIRE PREVENTION AND EXPLOSION PREVENTION….3781
ACTION IF FIRE OCCURS….3782
WINDSHIELD WASHER FLUID….3782
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….3782
ATTACHMENT INSTALLATION….3783
ATTACHMENT COMBINATIONS….3783
CAB WINDOW GLASSES….3783
UNAUTHORIZED MODIFICATIONS….3783
SAFETY AT JOBSITE….3783
WORKING ON LOOSE GROUND….3784
DISTANCE TO HIGH VOLTAGE CABLES….3784
ENSURE GOOD VISIBILITY….3784
VENTILATION FOR ENCLOSED AREA….3785
SIGNALMAN'S SIGNAL AND SIGNS….3785
EMERGENCY EXIT FROM OPERATOR'S CAB….3785
ASBESTOS DUST HAZARD PREVENTION….3785
SAFETY MACHINE OPERATION….3786
STARTING ENGINE….3786
CHECKS BEFORE STARTING ENGINE….3786
SAFETY RULES FOR STARTING ENGINE….3786
STARTING ENGINE IN COLD WEATHER….3787
OPERATION….3788
CHECKS BEFORE OPERATION….3788
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….3788
SAFETY RULES FOR TRAVELING….3789
TRAVELING ON SLOPES….3790
OPERATIONS ON SLOPES….3791
PROHIBITED OPERATIONS….3791
OPERATIONS ON SNOW….3792
PARKING MACHINE….3793
TRANSPORTATION….3794
LOADING AND UNLOADING….3794
SHIPPING THE MACHINE….3794
BATTERY….3795
BATTERY HAZARD PREVENTION….3795
STARTING ENGINE WITH BOOSTER CABLES….3796
TOWING….3797
SAFETY RULES FOR TOWING….3797
LIFTING OBJECTS WITH BUCKET….3798
SAFETY RULES FOR LIFTING OBJECTS….3798
SAFETY MAINTENANCE INFORMATION….3799
WARNING TAG….3799
KEEP WORK PLACE CLEAN AND TIDY….3800
APPOINT LEADER WHEN WORKING WITH OTHERS….3800
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….3800
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….3801
PROPER TOOLS….3801
PERSONNEL….3801
ATTACHMENTS….3802
WORK UNDER THE MACHINE….3802
NOISE….3802
WHEN USING HAMMER….3802
WELDING WORKS….3802
REMOVING BATTERY TERMINALS….3803
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….3803
DO NOT DISASSEMBLE RECOIL SPRINGS….3803
SAFETY RULES FOR HIGH-PRESSURE OIL….3803
SAFETY HANDLING HIGH-PRESSURE HOSES….3804
WASTE MATERIALS….3804
AIR CONDITIONER MAINTENANCE….3804
COMPRESSED AIR….3805
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….3805
OPERATION….3806
MACHINE VIEW ILLUSTRATIONS….3807
OVERALL MACHINE VIEW….3807
CONTROLS AND GAUGES….3808
DETAILED CONTROLS AND GAUGES….3809
MONITORING SYSTEM….3809
SWITCHES….3820
CONTROL LEVERS AND PEDALS….3825
SUN ROOF….3828
WINDSHIELD….3829
SLIDING DOOR….3835
EMERGENCY ESCAPE HAMMER….3835
CAP WITH LOCK….3836
ENGINE HOOD….3837
MUD COVER….3838
BATTERY INSPECTION COVER….3839
FUSE….3840
FUSIBLE LINK….3841
AUXILIARY ELECTRIC POWER….3841
CONTROLLERS….3841
HEATER AND DEFROSTER CONTROLS….3842
AIR CONDITIONER CONTROLS….3847
RADIO….3853
OPERATION MANUAL STORAGE….3859
TOOL, GREASE PUMP STORAGE PLACE….3859
ASHTRAY….3859
FIRE EXTINGUISHER….3859
MACHINE OPERATIONS AND CONTROLS….3860
BEFORE STARTING ENGINE….3860
STARTING ENGINE….3877
AFTER STARTING ENGINE….3882
STOPPING THE ENGINE….3885
MACHINE OPERATION….3886
STEERING THE MACHINE….3890
SWINGING….3892
WORK EQUIPMENT CONTROLS AND OPERATIONS….3893
WORKING MODE….3895
PROHIBITED OPERATIONS….3895
GENERAL OPERATION INFORMATION….3898
TRAVELING ON SLOPES….3900
ESCAPE FROM MUD….3902
RECOMMENDED APPLICATIONS….3903
BUCKET REPLACEMENT AND INVERSION….3905
PARKING MACHINE….3908
MACHINE INSPECTION AFTER DAILY WORK….3910
LOCKING….3910
ROAD LINERS AND RUBBER SHOES….3911
TRANSPORTATION….3916
TRANSPORTATION PROCEDURE….3916
LOADING AND UNLOADING WITH TRAILER….3916
LIFTING MACHINE….3922
COLD WEATHER OPERATION….3924
COLD WEATHER OPERATION INFORMATION….3924
AFTER DAILY WORK COMPLETION….3926
AFTER COLD WEATHER SEASON….3926
LONG TERM STORAGE….3927
BEFORE STORAGE….3927
DURING STORAGE….3927
AFTER STORAGE….3928
TROUBLES AND ACTIONS….3929
RUNNING OUT OF FUEL….3929
PHENOMENA THAT ARE NOT FAILURES….3929
TOWING THE MACHINE….3930
LIGHTWEIGHT TOWING HOLE….3930
SEVERE JOB CONDITION….3931
DISCHARGED BATTERY….3931
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY….3935
OTHER TROUBLE….3936
MAINTENANCE….3941
MAINTENANCE INFORMATION….3942
OUTLINE OF SERVICE….3944
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….3944
ELECTRIC SYSTEM MAINTENANCE….3947
WEAR PARTS….3948
WEAR PARTS LIST….3948
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….3949
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….3950
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….3951
TIGHTENING TORQUE SPECIFICATIONS….3952
TIGHTENING TORQUE LIST….3952
SAFETY CRITICAL PARTS….3953
SAFETY CRITICAL PARTS LIST….3953
MAINTENANCE SCHEDULE….3954
MAINTENANCE SCHEDULE CHART….3954
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….3955
MAINTENANCE PROCEDURE….3956
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….3956
WHEN REQUIRED….3957
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….3957
CLEAN INSIDE OF COOLING SYSTEM….3963
REPLACE WATER SEPARATOR ELEMENT….3966
CHECK AND TIGHTEN TRACK SHOE BOLTS….3967
CHECK AND ADJUST TRACK TENSION….3968
CHECK ROAD LINERS OR RUBBER SHOES….3970
CHECK AND ADJUST RUBBER SHOE TENSION….3972
REPLACE ROAD LINERS….3973
REPLACE RUBBER SHOES….3974
CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES….3976
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)….3977
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….3980
ADJUST BUCKET CLEARANCE….3981
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….3982
CHECK AND MAINTENANCE AIR CONDITIONER….3983
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER….3984
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT….3985
WASH WASHABLE FLOOR….3986
BLEEDING AIR FROM HYDRAULIC SYSTEM….3988
CHECK BEFORE STARTING….3991
EVERY 50 HOURS MAINTENANCE….3992
DRAIN WATER FROM FUEL TANK….3992
EVERY 100 HOURS MAINTENANCE….3993
LUBRICATING….3993
CHECK SWING MACHINERY CASE OIL, ADD OIL….3994
EVERY 250 HOURS MAINTENANCE….3995
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….3995
CHECK LEVEL OF BATTERY ELECTROLYTE….3996
CHECK AND ADJUST COOLING FAN BELT TENSION….3998
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….4000
EVERY 500 HOURS MAINTENANCE….4001
LUBRICATING….4001
REPLACE FUEL FILTER CARTRIDGE….4003
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….4004
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS….4005
CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS….4007
LUBRICATE SWING CIRCLE….4009
CHECK SWING PINION GREASE LEVEL, ADD GREASE….4009
EVERY 1000 HOURS MAINTENANCE….4010
REPLACE HYDRAULIC OIL FILTER ELEMENT….4010
CHANGE OIL IN SWING MACHINERY CASE….4012
GREASE SWING MACHINERY BEARING….4012
CHANGE OIL IN FINAL DRIVE CASE….4013
EVERY 2000 HOURS MAINTENANCE….4014
CHECK PTO GEAR CASE, ADD OIL….4014
CLEAN, CHECK TURBOCHARGER….4014
CHECK ALTERNATOR, STARTING MOTOR….4014
CHECK ENGINE VALVE CLEARANCE, ADJUST….4014
EVERY 4000 HOURS MAINTENANCE….4015
CHECK WATER PUMP….4015
EVERY 5000 HOURS MAINTENANCE….4016
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….4016
SPECIFICATIONS….4018
SPECIFICATIONS….4019
ATTACHMENTS, OPTIONS….4021
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….4022
SAFETY FIRST….4022
ATTACHMENT INSTALLATION….4023
BUCKET WITH HOOK….4024
HOOK CONDITION….4024
PROHIBITED OPERATIONS….4024
MACHINE READY FOR ATTACHMENT….4025
LOCATIONS….4025
HYDRAULIC CIRCUIT….4027
ATTACHMENT OPERATIONS….4028
LONG TERM STORAGE….4030
SPECIFICATIONS….4030
METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT….4031
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)….4033
CONTROL PATTERN CHANGE PROCEDURE….4033
MACHINE CONTROL PATTERNS….4034
ATTACHMENT GUIDE….4035
OTHER ATTACHMENTS….4035
ATTACHMENT COMBINATIONS….4036
RECOMMENDED ATTACHMENT OPERATIONS….4037
HYDRAULIC BREAKER….4037
CRUSHER….4042
INDEX….4045
TEN00307-05 – Hydraulic Excavator PC78US-8 Operation & Maintenance Manual….4049
COVER….4049
FOREWORD….4050
BEFORE READING THIS MANUAL….4051
SAFETY INFORMATION….4052
INTRODUCTION….4053
USE OF MACHINE….4053
DIRECTIONS OF MACHINE….4053
VISIBILITY FROM OPERATOR'S SEAT….4053
PRODUCT INFORMATION….4054
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….4054
EPA REGULATIONS, ENGINE NUMBER PLATE….4054
SERVICE METER LOCATION….4055
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….4055
CONTENTS….4056
SAFETY….4060
SAFETY….4061
SAFETY LABELS….4064
LOCATION OF SAFETY LABELS….4065
SAFETY LABELS….4066
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….4073
PRECAUTIONS BEFORE STARTING OPERATION….4073
PREPARATIONS FOR SAFE OPERATION….4073
FIRE PREVENTION….4075
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….4076
DO NOT GET CAUGHT IN WORK EQUIPMENT….4078
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….4079
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS….4079
UNAUTHORIZED MODIFICATION….4080
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….4080
PRECAUTIONS RELATED TO CAB GLASS….4080
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….4080
PRECAUTIONS FOR OPERATION….4081
PRECAUTIONS FOR JOBSITE….4081
STARTING ENGINE….4083
OPERATION….4085
TRANSPORTATION….4093
TOWING….4094
LIFTING OBJECTS WITH BUCKET….4095
PRECAUTIONS FOR MAINTENANCE….4096
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….4096
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….4100
OPERATION….4106
MACHINE VIEW ILLUSTRATIONS….4107
OVERALL MACHINE VIEW….4107
CONTROLS AND GAUGES….4108
DETAILED CONTROLS AND GAUGES….4110
MONITORING SYSTEM….4110
SWITCHES….4169
CONTROL LEVERS AND PEDALS….4173
SUN ROOF….4177
WINDSHIELD….4178
SLIDING DOOR….4184
EMERGENCY ESCAPE HAMMER….4185
COVER WITH LOCK….4186
ENGINE HOOD….4187
MUD COVER….4189
BATTERY INSPECTION COVER….4190
AIR CONDITIONER CONTROLS….4191
RADIO….4204
FUSE….4209
FUSIBLE LINK….4210
AUXILIARY ELECTRIC POWER….4211
CONTROLLERS….4212
OPERATION MANUAL STORAGE….4213
CUP HOLDER….4213
TOOL BOX….4213
GREASE PUMP HOLDER….4213
ASHTRAY….4214
FIRE EXTINGUISHER….4214
MACHINE OPERATIONS AND CONTROLS….4215
BEFORE STARTING ENGINE….4215
STARTING ENGINE….4234
AFTER STARTING ENGINE….4239
STOPPING THE ENGINE….4248
MACHINE OPERATION….4249
STEERING THE MACHINE….4253
SWINGING….4255
WORK EQUIPMENT CONTROLS AND OPERATIONS….4256
WORKING MODE….4258
PROHIBITED OPERATIONS….4260
GENERAL OPERATION INFORMATION….4263
TRAVELING ON SLOPES….4265
ESCAPE FROM MUD….4267
RECOMMENDED APPLICATIONS….4268
BUCKET REPLACEMENT AND INVERSION….4270
PARKING MACHINE….4273
MACHINE INSPECTION AFTER DAILY WORK….4275
LOCKING….4275
ROAD LINERS AND RUBBER SHOES….4276
TRANSPORTATION….4281
TRANSPORTATION PROCEDURE….4281
LOADING AND UNLOADING WITH TRAILER….4282
LIFTING MACHINE….4288
COLD WEATHER OPERATION….4290
COLD WEATHER OPERATION INFORMATION….4290
AFTER DAILY WORK COMPLETION….4292
AFTER COLD WEATHER SEASON….4292
LONG TERM STORAGE….4293
BEFORE STORAGE….4293
DURING STORAGE….4293
AFTER STORAGE….4293
STARTING MACHINE AFTER LONG-TERM STORAGE….4294
TROUBLES AND ACTIONS….4295
RUNNING OUT OF FUEL….4295
PHENOMENA THAT ARE NOT FAILURES….4296
TOWING THE MACHINE….4297
SEVERE JOB CONDITION….4297
DISCHARGED BATTERY….4298
OTHER TROUBLE….4303
MAINTENANCE….4308
MAINTENANCE INFORMATION….4309
OUTLINE OF SERVICE….4311
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….4311
ELECTRIC SYSTEM MAINTENANCE….4314
WEAR PARTS….4315
WEAR PARTS LIST….4315
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….4317
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….4317
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….4318
TIGHTENING TORQUE SPECIFICATIONS….4319
TIGHTENING TORQUE LIST….4319
SAFETY CRITICAL PARTS….4320
SAFETY CRITICAL PARTS LIST….4320
MAINTENANCE SCHEDULE….4322
MAINTENANCE SCHEDULE CHART….4322
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….4324
MAINTENANCE PROCEDURE….4325
WHEN REQUIRED….4325
CHECK BEFORE STARTING….4362
EVERY 100 HOURS MAINTENANCE….4363
EVERY 250 HOURS MAINTENANCE….4365
EVERY 500 HOURS MAINTENANCE….4372
EVERY 1000 HOURS MAINTENANCE….4384
EVERY 2000 HOURS MAINTENANCE….4395
EVERY 4000 HOURS MAINTENANCE….4399
EVERY 5000 HOURS MAINTENANCE….4400
SPECIFICATIONS….4404
SPECIFICATIONS….4405
ATTACHMENTS, OPTIONS ….4408
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….4409
SAFETY FIRST….4409
ATTACHMENT INSTALLATION….4410
BUCKET WITH HOOK….4411
HOOK CONDITION….4411
PROHIBITED OPERATIONS….4411
MACHINE READY FOR ATTACHMENT….4412
LOCATIONS….4412
HYDRAULIC CIRCUIT….4415
ATTACHMENT REMOVAL AND INSTALLATION….4416
ATTACHMENT OPERATIONS….4420
LONG TERM STORAGE….4424
SPECIFICATIONS….4424
METHOD FOR INSTALLING EXTRA COUNTERWEIGHT….4425
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)….4427
CONTROL PATTERN CHANGE PROCEDURE….4427
MACHINE CONTROL PATTERNS….4428
ATTACHMENT GUIDE….4429
OTHER ATTACHMENTS….4430
ATTACHMENT COMBINATIONS….4431
TRACK SHOES SELECTION….4432
RECOMMENDED ATTACHMENT OPERATIONS….4433
HYDRAULIC BREAKER….4433
CRUSHER….4438
HANDLING MACHINES EQUIPPED WITH KOMTRAX….4441
BASIC PRECAUTIONS….4441
INDEX….4442
TEN00466-01 – Hydraulic Excavator PC78US-8 Operation & Maintenance Manual….4446
COVER….4446
FOREWORD….4447
BEFORE READING THIS MANUAL….4448
SAFETY INFORMATION….4449
INTRODUCTION….4450
USE OF MACHINE….4450
DIRECTIONS OF MACHINE….4450
VISIBILITY FROM OPERATOR'S SEAT….4450
PROTECTIVE STRUCTURE….4450
PRODUCT INFORMATION….4451
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….4451
EPA REGULATIONS, ENGINE NUMBER PLATE….4451
SERVICE METER LOCATION….4452
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….4452
CONTENTS….4453
SAFETY….4457
SAFETY….4458
SAFETY LABELS….4461
LOCATION OF SAFETY LABELS….4462
SAFETY LABELS….4463
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….4470
PRECAUTIONS BEFORE STARTING OPERATION….4470
PREPARATIONS FOR SAFE OPERATION….4470
FIRE PREVENTION….4472
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….4473
DO NOT GET CAUGHT IN WORK EQUIPMENT….4475
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….4476
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS….4477
UNAUTHORIZED MODIFICATION….4477
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….4477
PRECAUTIONS RELATED TO CAB GLASS….4477
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….4478
PRECAUTIONS FOR OPERATION….4479
PRECAUTIONS FOR JOBSITE….4479
STARTING ENGINE….4481
OPERATION….4483
TRANSPORTATION….4491
TOWING….4492
LIFTING OBJECTS WITH BUCKET….4493
PRECAUTIONS FOR MAINTENANCE….4494
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….4494
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….4498
OPERATION….4505
MACHINE VIEW ILLUSTRATIONS….4506
OVERALL MACHINE VIEW….4506
CONTROLS AND GAUGES….4507
DETAILED CONTROLS AND GAUGES….4509
MONITORING SYSTEM….4509
SWITCHES….4568
CONTROL LEVERS AND PEDALS….4572
SUN ROOF….4576
WINDSHIELD….4577
SLIDING DOOR….4583
EMERGENCY ESCAPE HAMMER….4584
COVER WITH LOCK….4585
ENGINE HOOD….4586
MUD COVER….4588
BATTERY INSPECTION COVER….4589
AIR CONDITIONER CONTROLS….4590
RADIO….4603
FUSE….4608
FUSIBLE LINK….4609
AUXILIARY ELECTRIC POWER….4610
CONTROLLERS….4611
OPERATION MANUAL STORAGE….4612
CUP HOLDER….4612
TOOL BOX….4612
GREASE PUMP HOLDER….4612
ASHTRAY….4613
FIRE EXTINGUISHER….4613
MACHINE OPERATIONS AND CONTROLS….4614
BEFORE STARTING ENGINE….4614
STARTING ENGINE….4633
AFTER STARTING ENGINE….4638
STOPPING THE ENGINE….4647
MACHINE OPERATION….4648
STEERING THE MACHINE….4652
SWINGING….4654
WORK EQUIPMENT CONTROLS AND OPERATIONS….4655
WORKING MODE….4657
PROHIBITED OPERATIONS….4659
GENERAL OPERATION INFORMATION….4662
TRAVELING ON SLOPES….4664
ESCAPE FROM MUD….4666
RECOMMENDED APPLICATIONS….4667
BUCKET REPLACEMENT AND INVERSION….4669
PARKING MACHINE….4672
MACHINE INSPECTION AFTER DAILY WORK….4674
LOCKING….4674
ROAD LINERS AND RUBBER SHOES….4675
TRANSPORTATION….4680
TRANSPORTATION PROCEDURE….4680
LOADING AND UNLOADING WITH TRAILER….4681
LIFTING MACHINE….4687
COLD WEATHER OPERATION….4689
COLD WEATHER OPERATION INFORMATION….4689
AFTER DAILY WORK COMPLETION….4691
AFTER COLD WEATHER SEASON….4691
LONG TERM STORAGE….4692
BEFORE STORAGE….4692
DURING STORAGE….4692
AFTER STORAGE….4693
STARTING MACHINE AFTER LONG-TERM STORAGE….4693
TROUBLES AND ACTIONS….4694
RUNNING OUT OF FUEL….4694
PHENOMENA THAT ARE NOT FAILURES….4695
TOWING THE MACHINE….4696
SEVERE JOB CONDITION….4696
DISCHARGED BATTERY….4697
OTHER TROUBLE….4702
MAINTENANCE….4707
MAINTENANCE INFORMATION….4708
OUTLINE OF SERVICE….4710
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….4710
ELECTRIC SYSTEM MAINTENANCE….4713
WEAR PARTS….4714
WEAR PARTS LIST….4714
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….4716
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….4716
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….4717
TIGHTENING TORQUE SPECIFICATIONS….4718
TIGHTENING TORQUE LIST….4718
SAFETY CRITICAL PARTS….4719
SAFETY CRITICAL PARTS LIST….4719
MAINTENANCE SCHEDULE….4721
MAINTENANCE SCHEDULE CHART….4721
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….4723
MAINTENANCE PROCEDURE….4724
WHEN REQUIRED….4724
CHECK BEFORE STARTING….4760
EVERY 100 HOURS MAINTENANCE….4761
EVERY 250 HOURS MAINTENANCE….4763
EVERY 500 HOURS MAINTENANCE….4770
EVERY 1000 HOURS MAINTENANCE….4782
EVERY 2000 HOURS MAINTENANCE….4793
EVERY 4000 HOURS MAINTENANCE….4797
EVERY 5000 HOURS MAINTENANCE….4798
SPECIFICATIONS….4801
SPECIFICATIONS….4802
ATTACHMENTS, OPTIONS ….4805
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….4806
SAFETY FIRST….4806
ATTACHMENT INSTALLATION….4807
BUCKET WITH HOOK….4808
HOOK CONDITION….4808
PROHIBITED OPERATIONS….4808
MACHINE READY FOR ATTACHMENT….4809
LOCATIONS….4809
HYDRAULIC CIRCUIT….4812
ATTACHMENT REMOVAL AND INSTALLATION….4813
ATTACHMENT OPERATIONS….4817
LONG TERM STORAGE….4821
SPECIFICATIONS….4821
METHOD FOR INSTALLING EXTRA COUNTERWEIGHT….4822
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)….4824
CONTROL PATTERN CHANGE PROCEDURE….4824
MACHINE CONTROL PATTERNS….4825
ATTACHMENT GUIDE….4826
OTHER ATTACHMENTS….4827
ATTACHMENT COMBINATIONS….4828
TRACK SHOES SELECTION….4829
RECOMMENDED ATTACHMENT OPERATIONS….4830
HYDRAULIC BREAKER….4830
CRUSHER….4835
HANDLING MACHINES EQUIPPED WITH KOMTRAX….4838
BASIC PRECAUTIONS….4838
INDEX….4839

Komatsu Hydraulic Excavators PC78UU, PC78US, PC78US Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC78MR, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavators PC78MR workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEBM030601 – Hydraulic Excavator PC78MR-6 Shop Manual.pdf
SEBM030604 – Hydraulic Excavator PC78MR-6 Shop Manual.pdf
TEN00032-00 – Hydraulic Excavator GALEO PC78MR-6 Operation & Maintenance Manual.pdf
TEN00074-00 – Hydraulic Excavator GALEO PC78MR-6 Operation & Maintenance Manual.pdf
TEN00202-00 – Hydraulic Excavator GALEO PC78MR-6 Operation & Maintenance Manual.pdf
TEN00288-00 – Hydraulic Excavator PC78MR-6 Operation & Maintenance Manual.pdf

Total Pages: 2,361 pages
File Format: PDF
Language: English

SEBM030601 – Hydraulic Excavator PC78MR-6 Shop Manual….2
SEBM030604 – Hydraulic Excavator PC78MR-6 Shop Manual….594
COVER….594
CONTENTS….595
SAFETY….599
SAFETY NOTICE….599
FOREWARD….601
GENERAL….601
HOW TO READ THE SHOP MANUAL….602
HOISTING INSTRUCTIONS….603
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER….604
COATING MATERIALS….606
STANDARD TIGHTENING TORQUE….608
ELECTRIC WIRE CODE….611
CONVERSION TABLE….612
UNITS….618
01 GENERAL….620
SPECIFICATION DIMENSIONS DRAWING….621
WORKING RANGE DRAWING….623
SPECIFICATIONS….624
WEIGHT TABLE….627
LIST OF LUBRICANTS AND COOLANT….629
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD….631
PTO ….632
COOLING SYSTEM….633
POWER TRAIN SYSTEM….634
SWING CIRCLE….635
SWING MACHINERY….636
TRACK FRAME AND IDLER CUSHION….638
IDLER….640
TRACK ROLLER….641
CARRIER ROLLER….643
SPROCKET….644
TRACK SHOE….645
ARRANGEMENT OF HYDRAULIC COMPONENTS….650
HYDRAULIC TANK AND OIL FILTER….651
CENTER SWIVEL JOINT….652
TRAVEL MOTOR….653
WORK EQUIPMENT CYLINDER….661
SOLENOID VALVE….665
SOLENOID VALVE (FOR EU SPEC.)….673
ACCUMULATOR FOR PPC….677
MULTI-CONTROL VALVE….678
ACCUMULATOR FOR BRAKER….679
HYDRAULIC PUMP….680
CONTROL VALVE….694
CLSS….706
SWING MOTOR….738
WORK EQUIPMENT AND SWING PPC VALVE….746
TRAVEL PPC VALVE….752
BOOM SWING PPC VALVE, BLADE PPC VALVE….756
BOOM HYDRAULIC ANTI-BURST VALVE (FOR EU SPEC)….760
WORK EQUIPMENT….766
DIMENSIONS OF EACH PART OF WORK EQUIPMENT….768
AIR CONDITIONER PIPING (OPTIONAL)….772
ELECTRIC CONTROL SYSTEM….773
SYSTEM COMPONENTS….793
MONITOR SYSTEM….802
SENSORS….807
20 TESTING AND ADJUSTING….810
STANDARD VALUE TABLE FOR ENGINE….811
STANARD VALUE TABLE FOR CHASSIS….812
STANDARD VALUE TABLE FOR ELECTRIC PARTS….820
TESTING AND ADJUSTING….826
LIST OF DEVICES FOR TESTING, ADJUSTING, AND TROUBLESHOOTING….827
MEASURING ENGINE SPEED….828
MEASURING EXHAUST GAS COLOR….829
ADJUSTING VALVE CLEARANCE….830
MEASURING COMPRESSION PRESSURE….831
MEASURING BLOW-BY PRESSURE….832
TESTING AND ADJUSTING FUEL INJECTION TIMING….833
MEASURING ENGINE OIL PRESSURE….837
ADJUSTING ENGINE STOP SOLENOID….838
ADJUSTING FUEL CONTROL LINKAGE….840
ADJUSTING ENGINE SPEED SENSOR….842
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS….843
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE….846
ADJUSTING PC VALVE….848
TESTING TVC-EPC SOLENOID OUTPUT PRESSURE….848
MEASURING CONTROL CIRCUIT PRESSURE….849
MEASURING PPC VALVE OUTPUT PRESSURE….850
TESTING SOLENOID VALVE OUTPUT PRESSURE….851
ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE….853
TESTING TRAVEL DEVIATION….854
TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT….856
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTORS….857
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT….858
TESTING CLEARANCE OF SWING CIRCLE BEARING….859
TESTING AND ADJUSTING TRACK SHOE TENSION….860
BLEEDING AIR FROM HYDRAULIC CIRCUIT….861
REPLACEMENT PROCEDURE OF POTENTIOMETERS….863
PROCEDURE FOR TESTING DIODE….864
TROUBLESHOOTING….866
POINTS TO REMEMBER WHEN TROUBLESHOOTING….867
SEQUENCE OF EVENTS IN TROUBLESHOOTING….868
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE….869
CHECKS BEFORE TROUBLESHOOTING….877
TYPE AND LOCATION OF CONNECTORS….879
CONNECTOR ARRANGEMENT DIAGRAM….881
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….884
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL MECHANISM….907
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL….908
TVC VALVE CURRENT ADJUSTMENT TABLE….919
METHOD OF USING JUDGEMENT TABLE….920
HOW TO READ FLOW OF TROUBLESHOOTING….922
CONTENTS AND PROCEDURE OF TROUBLESHOOTING….924
TROUBLESHOOTING OF ENGINE (S MODE)….925
METHOD OF USING TROUBLESHOOTING CHART….926
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)….930
S-2 ENGINE DOES NOT START….932
1) ENGINE DOES NOT TURN….932
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)….933
3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)….934
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)….935
S-4 ENGINE STOPS DURING OPERATIONS….936
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)….937
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)….938
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)….939
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)….940
S-9 OIL BECOMES CONTAMINATED QUICKLY….941
S-10 FUEL CONSUMPTION IS EXCESSIVE….942
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN….943
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)….944
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)….945
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)….946
S-15 ABNORMAL NOISE IS MADE….947
S-16 VIBRATION IS EXCESSIVE….948
TROUBLESHOOTING OF COMMUNICATION SYSTEM (N MODE)….949
N-1 DEFECTIVE COMMUNICATION….950
TROUBLESHOOTING FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)….951
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (GOVERNOR CONTROL SYSTEM)….952
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE….954
JUDGEMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE….956
E-1 CONTROLLER POWER SUPPLY IS DEFECTIVE (LED OF CONTROLLER IS TURNED OFF)….958
E-2 [E323] (SHORT CIRCUIT IN ACCELERATOR RELAY SYSTEM) IS DISPLAYED….959
E-3 [E325] (SHORT CIRCUIT IN DECELERATOR RELAY SYSTEM) IS DISPLAYED….960
E-4 [E328] (STALL OF MOTOR) IS DISPLAYED….961
E-5 [E227] (TROUBLE IN ENGINE SPEED SENSOR) IS DISPLAYED….963
E-6 ONE TOUCH SLOW DOWN MECHANISM DOES NOT WORK….964
E-7 ENGINE DOES NOT START….965
a) [E304] SHORT CIRCUIT IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED….965
b) [E314] DISCONNECTION IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED….965
c) ENGINE STOP SOLENOID SYSTEM….966
d) STARTING SYSTEM….968
E-8 ENGINE DOES NOT STOP….972
TROUBLESHOOTING FOR CONTROLLER PUMP CONTROL SYSTEM (C MODE)….973
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (PUMP CONTROL SYSTEM)….974
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE….976
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC EQUIPMENT….980
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM (FOR STD. SPEC)….982
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM (FOR EU SPEC)….984
C-1 [E232], C-2 [E233] TROUBLE IN TVC-EPC SOLENOID SYSTEM….986
C-3 [E203], C-4 [E213] TROUBLE IN SWING HOLDING BRAKE SOLENOID SYSTEM….987
C-5 [E206], C-6 [E216] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENOID SYSTEM….988
C-7 [E411] TROUBLE IN BOOM SWING ANGLE SENSOR CORRECTION….989
C-8 [E251] TROUBLE IN BOOM BOTTOM PRESSURE SENSOR (OVERLOAD SENSOR) SYSTEM (FOR EU SPEC)….990
C-9 [E258] SHORT CIRCUIT IN 5V SYSTEM OF SENSOR POWER SUPPLY (FOR EU SPEC)….990
C-9 [E258] SHORT CIRCUIT IN 5V SYSTEM OF SENSOR POWER SUPPLY (FOR STD SPEC)….991
C-10 [E412], C-11 [E413] TROUBLE IN BOOM SWING ANGLE SENSOR SYSTEM….992
C-12 [E451] SHORT CIRCUIT IN BOOM SWING LEFT STOP EPC SOLENOID SYSTEM IS DISPLAYED….993
C-13 [E452] DISCONNECTION IN BOOM SWING LEFT STOP EPC SOLENOID SYSTEM IS DISPLAYED….994
C-14 [E453] SHORT CIRCUIT IN BOOM SWING RIGHT STOP EPC SOLENOID SYSTEM IS DISPLAYED….995
C-15 [E454] DISCONNECTION IN BOOM SWING RIGHT STOP EPC SOLENOID SYSTEM IS DISPLAYED….996
C-16 BOOM SWING LEFTT END CUSHION DOES NOT WORK AT ALL OR NORMALLY….997
C-17 BOOM SWING RIGHT END CUSHION DOES NOT WORK AT ALL OR NORMALLY….999
C-18 WORK EQUIPMENT STILL MOVES AFTER WORK EQUIPMENT LOCK LEVER IS SET TO LOCK….1001
C-19 MACHINE DOES NOT SWING….1002
C-20 TRAVEL SPEED DOES NOT RISE….1003
C-21 TROUBLE IN CONTROLLER POWER SUPPLY (LED OF CONTROLLER IS TURNED OFF)….1003
TROUBLESHOOTING FOR CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)….1004
F-1 BIT PATTERN 1023-(4) SWING PRESSURE SWITCH DOES NOT LIGHT UP….1005
F-2 BIT PATTERN 1023-(3) TRAVEL PRESSURE SWITCH DOES NOT LIGHT UP….1006
F-3 BIT PATTERN 1023-(6) BOOM RAISE PRESSURE SWITCH DOES NOT LIGHT UP….1007
F-4 BIT PATTERN 1023-(5) ARM IN PRESSURE SWITCH DOES NOT LIGHT UP….1008
F-5 BIT PATTERN 1026-(1) DECELERATION SWITCH OF LEFT KNOB DOES NOT LIGHT UP….1009
F-6 BIT PATTERN 1026-(4) 2ND TRAVEL SPEED SELECTION SWITCH (PEDAL) DOES NOT LIGHT UP….1010
F-7 BIT PATTERN 1021-(3) COMPRESSOR SIGNAL DOES NOT LIGHT UP….1011
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)….1012
TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES….1015
H-1 SPEED OR POWER OF 2 OR MORE SYSTEMS OF WORK EQUIPMENT (BOOM, ARM, BUCKET) TRAVEL, SWING, AND BLADE IS LOW….1017
a) SPEED OR POWER OF WORK EQUIPMENT (INCLUDING BLADE), TRAVEL, AND SWING SYSTEMS IS LOW….1017
b) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE) AND TRAVEL IS LOW….1018
c) SPEED OR POWER OF SWING AND BLADE IS LOW….1018
d) SPEED OR POWER OF TRAVEL AND BLADE IS LOW….1019
e) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE) IS LOW….1019
f) SPEED OR POWER OF TRAVEL AND SWING IS LOW….1019
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS….1020
H-3 2 OR MORE SYSTEMS OF WORK EQUIPMENT (BOOM, ARM, BUCKET), TRAVEL, SWING, AND BLADE DO NOT MOVE….1022
a) ALL WORK EQUIPMENT (INCLUDING BLADE), TRAVEL, AND SWING SYSTEMS DO NOT MOVE….1022
b) ALL WORK EQUIPMENT (EXCLUDING BLADE) AND TRAVEL SYSTEMS DO NOT MOVE….1023
c) SWING AND BLADE SYSTEMS DO NOT MOVE….1023
d) TRAVEL AND BLADE SYSTEMS DO NOT MOVE….1024
e) ALL WORK EQUIPMENT (EXCLUDING BLADE) DOES NOT MOVE….1024
H-4 ABNORMAL SOUND COMES OUT (FROM AROUND PUMP)….1025
H-5 FINE CONTROLLABILITY OR RESPONSE IS LOW….1026
H-6 HYDRAULIC DRIFT IS LARGE (ALL WORK EQUIPMENT AND BLADE)….1027
H-7 BOOM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)….1028
a) BOOM RAISE SPEED OR POWER IS LOW….1028
b) BOOM LOWER SPEED OR POWER IS LOW….1029
H-8 ARM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)….1030
a) ARM IN SPEED OR POWER IS LOW….1030
b) ARM OUT SPEED OR POWER IS LOW….1031
H-9 BUCKET SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)….1032
a) BUCKET CURL SPEED OR POWER IS LOW….1032
b) BUCKET DUMP SPEED OR POWER IS LOW….1033
H-10 BOOM SWING SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)….1034
a) SWING LEFT SPEED OR POWER IS LOW….1034
b) SWING RIGHT SPEED OR POWER IS LOW….1035
H-11 BOOM DOES NOT MOVE….1036
a) BOOM DOES NOT RISE….1036
b) BOOM DOES NOT LOWER….1037
H-12 ARM DOES NOT MOVE….1038
a) ARM DOES NOT MOVE IN….1038
b) ARM DOES NOT MOVE OUT….1039
H-13 BUCKET DOES NOT MOVE….1040
a) BUCKET DOES NOT CURL….1040
b) BUCKET DOES NOT DUMP….1041
H-14 BOOM SWING DOES NOT MOVE….1042
a) BOOM SWING LEFT DOES NOT MOVE….1042
b) BOOM SWING RIGHT DOES NOT MOVE….1043
H-15 HYDRAULIC DRIFT OF BOOM IS LARGE….1044
H-16 HYDRAULIC DRIFT OF ARM IS LARGE….1044
H-17 HYDRAULIC DRIFT OF BUCKET IS LARGE….1045
H-18 HYDRAULIC DRIFT OF SWING IS LARGE….1045
a) HYDRAULIC DRIFT OF SWING TO LEFT IS LARGE….1045
b) HYDRAULIC DRIFT OF SWING TO RIGHT IS LARGE….1045
H-19 TIME LAG IS LARGE (WHEN ENGINE SPEED IS LOW)….1046
H-20 PART LOADED MORE MOVES SLOWER IN COMPOUND OPERATION OF WORK EQUIPMENT….1046
H-21 BOOM RAISE SPEED IS LOW IN COMPOUND OPERATION OF SWING AND BOOM RAISE….1047
H-22 TRAVEL SPEED LOWERS EXTREMELY IN COMPOUND OPERATION OF TRAVEL AND BOOM RAISE….1047
H-23 SPEED IS LOW IN COMPOUND OPERATION OF WORK EQUIPMENT RELIEF AND SWING, WORK EQUIPMENT RELIEF AND OTHER WORK EQUIPMENT….1047
H-24 TRAVEL DEVIATION IS LARGE….1048
a) TRAVEL DEVIATION IS LARGE DURING ORDINARY TRAVEL….1048
b) TRAVEL DEVIATION IS LARGE WHEN MACHINE STARTS (BUT NORMAL DURING ORDINARY TRAVEL)….1049
H-25 TRAVEL DEVIATION IS LARGE IN COMPOUND OERATION OF TRAVEL AND SWING, TRAVEL AND WORK EQUIPMENT….1050
H-26 TRAVEL SPEED OR POWER IS LOW (WORK EQUIPMENT, SWING, AND BLADE OPERATIONS ARE NORMAL)….1051
H-27 MACHINE CANNOT BE STEERED SHARPLY OR STEERING FORCE IS INSUFFICIENT….1053
H-28 TRAVEL SPEED DOES NOT CHANGE AT ALL OR DOES NOT CHANGE QUICKLY….1054
H-29 MACHINE DOES NOT TRAVEL….1055
H-29 SUPPLEMENT….1056
H-30 OVERRUN OF TRAVEL IS LARGE….1057
H-31 TRAVEL HYDRAULIC DRIFT IS LARGE….1057
H-32 FINE CONTROLLABILITY OR RESPONSE IS LOW….1058
H-33 SWING SPEED OR POWER IS LOW (WORK EQUIPMENT, TRAVEL, AND BLADE OPERATIONS ARE NORMAL)….1059
H-34 MACHINE DOES NOT SWING (WORK EQUIPMENT, TRAVEL, AND BLADE OPERATIONS ARE NORMAL)….1061
a) SWING SPEED OR POWER IS LOW IN BOTH DIRECTIONS….1061
b) SWING SPEED OR POWER IS LOW IN EITHER DIRECTION….1062
H-35 SWING ACCELERATION IS LOW….1063
a) SWING ACCELERATION IS LOW IN BOTH DIRECTIONS….1063
b) SWING ACCELERATION IS LOW IN EITHER DIRECTION….1063
H-36 OVERRUN OF SWING IS LARGE….1064
a) OVERRUN OF SWING IS LARGE IN BOTH DIRECTIONS….1064
b) OVERRUN OF SWING IS LARGE IN EITHER DIRECTION….1064
H-37 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING….1065
H-38 LARGE ABNORMAL SOUND IS MADE WHEN MACHINE STOPS SWINGING….1065
H-39 SWING HYDRAULIC DRIFT IS LARGE….1066
H-40 FINE CONTROLLABILITY OR RESPONSE OF SWING IS LOW….1067
H-41 BLADE SPEED OR POWER IS LOW (WORK EQUIPMENT, TRAVEL, AND SWING OPERATIONS ARE NORMAL)….1068
H-42 BLADE DOES NOT MOVE (WORK EQUIPMENT, TRAVEL, AND SWING OPERATIONS ARE NORMAL)….1069
a) BLADE DOES NOT RISE….1069
b) BLADE DOES NOT LOWER….1070
H-43 HYDRAULIC DRIFT OF BLADE IS LARGE….1071
H-44 FINE CONTROLLABILITY OR RESPONSE OF BLADE IS LOW….1072
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M MODE)….1074
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE….1075
ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM….1077
M-1 [E101] (ERROR HISTORY DATA ARE ABNORMAL) IS DISPLAYED….1079
M-2 [E108] (ENGINE COOLANT TEMPERATURE IS 105 DEGREES C) IS DISPLAYED….1080
M-3 [E112] (WIPER FORWARD OUTPUT IS SHORTED) IS DISPLAYED….1080
M-4 [E113] (WIPER REVERSE OUTPUT IS SHORTED) IS DISPLAYED….1080
M-5 [E114] (CONTACT WITH WASHER OUTPUT OF 24V) IS DISPLAYED….1080
M-6 [E115] (WIPER DOES NOT START WIPING IN 10 SECONDS) IS DISPLAYED….1080
M-7 [E116] (WIPER IS NOT RETRACTED IN 10 SECONDS) IS DISPLAYED….1080
M-8 MONITOR PANEL SEGMENTS DO NOT LIGHT UP AT ALL FOR 3 SECONDS AFTER STARTING SWITCH IS TURNED ON….1081
a) MONITOR PANEL SEGMENTS DO NOT LIGHT UP AT ALL….1081
b) SOME MONITOR PANEL SEGMENTS DO NOT LIGHT UP….1081
M-9 WHEN STARTING SWITCH IS SET TO ON POSITION, ALL MONITOR PANEL SEGMENTS LIGHT UP BUT DO NOT GO OFF….1083
M-10 WHILE PREHEATING IS NOT EXECUTED, "PREHEATER MONITOR" LIGHTS UP….1083
M-11 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH….1084
a) ALTERNATOR SYSTEM….1084
b) ENGINE OIL SYSTEM….1085
M-12 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED), CAUTION ITEMS (EXCLUDING BATTERY AND ENGINE OIL) FLASH….1086
a) ALTERNATOR SYSTEM….1086
b) ENGINE OIL PRESSURE SENSOR SYSTEM….1087
M-13 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH (WHEN THERE IS NOT ABNORMALITY IN INSPECTION ITEMS AND ENGINE BEFORE TROUBLESHOOTING, HOWEVER)….1088
a) "ENGINE OIL" FLASHES….1088
b) "CHARGE LEVEL" FLASHES….1088
c) "COOLANT TEMPERATURE" FLASHES….1089
d) "FUEL LEVEL" FLASHES….1090
M-14 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND WHILE CAUTION ITEM IS FLASHING, BUZZER DOES NOT SOUND….1091
M-15 MONITOR PLANE LAMP FOR NIGHTTIME IS NOT TURNED ON (LC DISPLAY IS NORMAL)….1092
M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE….1093
M-17 COOLANT TEMPERATURE GAUGE IS NOT DISPLAYED (GAUGE DOES NOT RISE TO 1ST LINE DURING OPERATION)….1093
M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL….1094
M-19 FUEL LEVEL GAUGE IS NOT DISPLAYED….1094
M-20 WHILE ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE….1095
M-21 TROUBLE IN FUEL LEVEL SENSOR….1096
M-22 TROUBLE IN COOLANT TEMPERATURE SENSOR….1097
M-23 WIPER DOES NOT OPERATE OR OPERATES WHILE WIPER SWITCH IS TURNED OFF….1098
a) WIPER DOES NOT OPERATE….1098
b) WIPER OPERATES WHILE WIPER SWITCH IS TURNED OFF….1098
M-24 WASHER MOTOR DOES NOT OPERATE OR OPERATES WHILE WASHER SWITCH IS TURNED OFF….1101
a) WASHER MOTOR DOES NOT OPERATE….1101
b) WASHER OPERATES WHILE WIPER SWITCH IS TURNED OFF….1101
30 DISASSEMBLY AND ASSEMBLY….1104
METHOD OF USING MANUAL….1105
PRECAUTIONS WHEN CARRYING OUT OPERATION….1106
SPECIAL TOOL LIST….1110
COUNTERWEIGHT ….1116
REMOVAL AND INSTALLATION….1116
INJECTION PUMP ….1117
REMOVAL….1117
INSTALLATION….1118
CYLINDER HEAD….1119
REMOVAL….1119
INSTALLATION….1122
MAIN PUMP….1123
REMOVAL….1123
INSTALLATION….1124
CONTROL PUMP….1124
REMOVAL AND INSTALLATION….1124
ENGINE AND MAIN PUMP….1125
REMOVAL….1125
INSTALLATION….1127
HYDRAULIC OIL COOLER….1128
REMOVAL AND INSTALLATION….1128
RADIATOR ….1128
REMOVAL….1128
INSTALLATION….1129
SWING MOTOR AND SWING MACHINERY….1130
REMOVAL AND INSTALLATION….1130
SWING MACHINERY….1131
DISASSEMBLY….1131
ASSEMBLY….1133
SWING MOTOR ….1137
REMOVAL AND INSTALLATION….1137
CENTER SWIVEL JOINT….1137
REMOVAL….1137
INSTALLATION….1138
DISASSEMBLY AND ASSEMBLY….1139
CONTROL VALVE….1140
REMOVAL AND INSTALLATION….1140
ASSEMBLY….1141
WORK EQUIPMENT PPC VALVE….1142
ASSEMBLY….1142
TRAVEL PPC VALVE ….1143
ASSEMBLY….1143
HYDRAULIC TANK ….1145
REMOVAL AND INSTALLATION….1145
FUEL TANK….1146
REMOVAL….1146
INSTALLATION….1147
CONTROLLER….1149
REMOVAL AND INSTALLATION….1149
MONITOR PANEL….1150
REMOVAL AND INSTALLATION….1150
AIR CONDITIONER UNIT….1150
REMOVAL….1150
INSTALLATION….1151
OPERATOR'S CAB….1152
REMOVAL AND INSTALLATION….1152
FLOOR FRAME ….1153
REMOVAL….1153
INSTALLATION….1154
REVOLVING FRAME….1155
REMOVAL AND INSTALLATION….1155
SWING CIRCLE….1156
REMOVAL AND INSTALLATION….1156
WORK EQUIPMENT ….1157
REMOVAL….1157
INSTALLATION….1158
SWING BRACKET….1159
REMOVAL….1159
INSTALLATION….1160
STEEL SHOE, RUBBER PAD SHOE, ROAD LINER….1161
EXPANSION AND INSTALLATION….1161
RUBBER SHOE ….1162
REMOVAL AND INSTALLATION….1162
FINAL DRIVE ….1162
REMOVAL….1162
INSTALLATION….1163
IDLER ….1163
ASSEMBLY….1163
RECOIL SPRING….1165
DISASSEMBLY….1165
ASSEMBLY….1166
TRACK ROLLER….1167
DISASSEMBLY….1167
ASSEMBLY….1168
HYDRAULIC CYLINDER….1170
DISASSEMBLY….1170
ASSEMBLY….1172
90 OTHERS….1174
HYDRAULIC CIRCUIT DIAGRAM (FOR STD SPEC)….1175
HYDRAULIC CIRCUIT DIAGRAM (FOR EU SPEC)….1176
ELECTRICAL CIRCUIT DIAGRAM (FOR STD SPEC) (1/2)….1177
ELECTRICAL CIRCUIT DIAGRAM (FOR STD SPEC) (2/2)….1178
ELECTRICAL CIRCUIT DIAGRAM (FOR EU SPEC) (1/2)….1179
ELECTRICAL CIRCUIT DIAGRAM (FOR EU SPEC) (2/2)….1180
ELECTRICAL CIRCUIT DIAGRAM (FOR NORWAY SPEC.) (1/2)….1181
ELECTRICAL CIRCUIT DIAGRAM (FOR NORWAY SPEC.) (2/2)….1182
TEN00032-00 – Hydraulic Excavator GALEO PC78MR-6 Operation & Maintenance Manual….1183
COVER….1183
FOREWORD….1184
FOREWORD….1185
SAFETY INFORMATION….1188
INTRODUCTION….1190
DIRECTIONS OF MACHINE….1190
PRODUCT INFORMATION….1191
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….1191
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….1191
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION….1192
SERVICE METER LOCATION….1192
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….1193
CONTENTS….1194
SAFETY….1198
SAFETY INFORMATION….1199
SAFETY LABELS….1201
LOCATION OF SAFETY LABELS….1202
SAFETY LABELS….1203
SAFETY INFORMATION….1210
SAFETY RULES….1210
IF ABNORMALITIES ARE FOUND….1210
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….1210
FIRE EXTINGUISHER AND FIRST AID KIT….1210
SAFETY EQUIPMENT….1210
KEEP MACHINE CLEAN….1211
KEEP OPERATOR'S COMPARTMENT CLEAN….1211
LEAVING OPERATOR'S SEAT WITH LOCK….1211
HANDRAILS AND STEPS….1212
MOUNTING AND DISMOUNTING….1212
NO PERSONS ON ATTACHMENTS….1212
DO NOT GET CAUGHT IN ARTICULATED PORTION….1212
BURN PREVENTION….1213
FIRE PREVENTION AND EXPLOSION PREVENTION….1213
ACTION IF FIRE OCCURS….1214
WINDSHIELD WASHER FLUID….1214
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….1214
ATTACHMENT INSTALLATION….1215
ATTACHMENT COMBINATIONS….1215
CAB WINDOW GLASSES….1215
UNAUTHORIZED MODIFICATIONS….1215
SAFETY AT JOBSITE….1215
WORKING ON LOOSE GROUND….1216
DISTANCE TO HIGH VOLTAGE CABLES….1216
ENSURE GOOD VISIBILITY….1216
VENTILATION FOR ENCLOSED AREA….1217
SIGNALMAN'S SIGNAL AND SIGNS….1217
EMERGENCY EXIT FROM OPERATOR'S CAB….1217
ASBESTOS DUST HAZARD PREVENTION….1217
SAFETY MACHINE OPERATION….1218
STARTING ENGINE….1218
CHECKS BEFORE STARTING ENGINE….1218
SAFETY RULES FOR STARTING ENGINE….1219
STARTING ENGINE IN COLD WEATHER….1219
OPERATION….1220
CHECKS BEFORE OPERATION….1220
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….1220
SAFETY RULES FOR TRAVELING….1221
TRAVELING ON SLOPES….1222
OPERATIONS ON SLOPES….1223
PROHIBITED OPERATIONS….1223
OPERATIONS ON SNOW….1224
PARKING MACHINE….1225
TRANSPORTATION….1226
LOADING AND UNLOADING….1226
SHIPPING THE MACHINE….1226
BATTERY….1227
BATTERY HAZARD PREVENTION….1227
STARTING ENGINE WITH BOOSTER CABLES….1228
TOWING….1229
SAFETY RULES FOR TOWING….1229
LIFTING OBJECTS WITH BUCKET….1230
SAFETY RULES FOR LIFTING OBJECTS….1230
SAFETY MAINTENANCE INFORMATION….1231
WARNING TAG….1231
KEEP WORK PLACE CLEAN AND TIDY….1231
APPOINT LEADER WHEN WORKING WITH OTHERS….1231
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….1231
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….1232
PROPER TOOLS….1233
ACCUMULATOR….1233
PERSONNEL….1233
ATTACHMENTS….1233
WORK UNDER THE MACHINE….1234
NOISE….1234
WHEN USING HAMMER….1234
WELDING WORKS….1234
REMOVING BATTERY TERMINALS….1234
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….1235
DO NOT DISASSEMBLE RECOIL SPRINGS….1235
SAFETY RULES FOR HIGH-PRESSURE OIL….1235
SAFETY HANDLING HIGH-PRESSURE HOSES….1235
WASTE MATERIALS….1236
AIR CONDITIONER MAINTENANCE….1236
COMPRESSED AIR….1236
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….1236
OPERATION….1238
MACHINE VIEW ILLUSTRATIONS….1239
OVERALL MACHINE VIEW….1239
CONTROLS AND GAUGES….1240
DETAILED CONTROLS AND GAUGES….1241
MONITORING SYSTEM….1241
SWITCHES….1252
CONTROL LEVERS AND PEDALS….1257
SUN ROOF….1263
WINDSHIELD….1264
SLIDING DOOR….1269
EMERGENCY ESCAPE HAMMER….1269
CAP WITH LOCK….1271
ENGINE HOOD….1272
MUD COVER….1273
BATTERY INSPECTION COVER….1274
FUSE….1275
FUSIBLE LINK….1276
AUXILIARY ELECTRIC POWER….1276
CONTROLLERS….1276
AIR CONDITIONER CONTROLS….1277
HEATER AND DEFROSTER CONTROLS….1283
RADIO….1288
OPERATION MANUAL STORAGE….1293
TOOL BOX….1293
GREASE PUMP HOLDER….1293
ASHTRAY….1293
FIRE EXTINGUISHER….1294
MACHINE OPERATIONS AND CONTROLS….1295
BEFORE STARTING ENGINE….1295
STARTING ENGINE….1311
AFTER STARTING ENGINE….1316
STOPPING THE ENGINE….1319
CHECK AFTER SHUT OFF ENGINE….1319
MACHINE OPERATION….1320
STEERING THE MACHINE….1324
SWINGING….1326
WORK EQUIPMENT CONTROLS AND OPERATIONS….1327
WORKING MODE….1329
PROHIBITED OPERATIONS….1330
GENERAL OPERATION INFORMATION….1332
TRAVELING ON SLOPES….1334
ESCAPE FROM MUD….1336
RECOMMENDED APPLICATIONS….1337
MACHINE READY FOR ATTACHMENT….1339
BUCKET REPLACEMENT AND INVERSION….1345
PARKING MACHINE….1347
MACHINE INSPECTION AFTER DAILY WORK….1348
LOCKING….1348
ROAD LINERS AND RUBBER SHOES….1349
TRANSPORTATION….1354
TRANSPORTATION PROCEDURE….1354
LOADING AND UNLOADING WITH TRAILER….1354
LIFTING MACHINE….1360
COLD WEATHER OPERATION….1362
COLD WEATHER OPERATION INFORMATION….1362
AFTER DAILY WORK COMPLETION….1364
AFTER COLD WEATHER SEASON….1364
LONG TERM STORAGE….1365
BEFORE STORAGE….1365
DURING STORAGE….1365
AFTER STORAGE….1365
TROUBLES AND ACTIONS….1366
RUNNING OUT OF FUEL….1366
PHENOMENA THAT ARE NOT FAILURES….1366
TOWING THE MACHINE….1367
SEVERE JOB CONDITION….1367
DISCHARGED BATTERY….1368
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY….1373
OTHER TROUBLE….1374
MAINTENANCE….1380
MAINTENANCE INFORMATION….1381
OUTLINE OF SERVICE….1383
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1383
ELECTRIC SYSTEM MAINTENANCE….1386
WEAR PARTS….1387
WEAR PARTS LIST….1387
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….1388
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1389
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN….1390
TIGHTENING TORQUE SPECIFICATIONS….1391
TIGHTENING TORQUE LIST….1391
SAFETY CRITICAL PARTS….1392
SAFETY CRITICAL PARTS LIST….1392
MAINTENANCE SCHEDULE….1393
MAINTENANCE SCHEDULE CHART….1393
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….1394
MAINTENANCE PROCEDURE….1395
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….1395
REPLACE FUEL FILTER CARTRIDGE….1440
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….1441
WHEN REQUIRED….1396
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….1396
CLEAN INSIDE OF COOLING SYSTEM….1400
REPLACE WATER SEPARATOR ELEMENT….1403
CLEAN FUEL TANK….1404
CHECK AND TIGHTEN TRACK SHOE BOLTS….1405
CHECK AND ADJUST TRACK TENSION….1406
CHECK ROAD LINERS OR RUBBER SHOES….1408
CHECK AND ADJUST RUBBER SHOE TENSION….1410
REPLACE ROAD LINERS….1411
REPLACE RUBBER SHOES….1412
CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES….1414
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)….1415
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….1418
ADJUST BUCKET CLEARANCE….1419
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….1420
CHECK AND ADJUST AIR CONDITIONER….1421
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER….1422
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT….1423
WASH WASHABLE FLOOR….1424
BLEEDING AIR FROM HYDRAULIC SYSTEM….1426
CHECK BEFORE STARTING….1429
EVERY 50 HOURS MAINTENANCE….1430
DRAIN WATER FROM FUEL TANK….1430
EVERY 100 HOURS MAINTENANCE….1431
LUBRICATING….1431
EVERY 250 HOURS MAINTENANCE….1432
LUBRICATING….1432
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….1434
CHECK LEVEL OF BATTERY ELECTROLYTE….1435
CHECK AND ADJUST COOLING FAN BELT TENSION….1437
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….1439
EVERY 500 HOURS MAINTENANCE….1440
REPLACE FUEL FILTER CARTRIDGE….1440
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….1441
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS….1442
CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS….1444
LUBRICATE SWING CIRCLE….1446
CHECK SWING PINION GREASE LEVEL, ADD GREASE….1446
EVERY 1000 HOURS MAINTENANCE….1447
REPLACE HYDRAULIC OIL FILTER ELEMENT….1447
CHANGE OIL IN SWING MACHINERY CASE….1449
CHANGE OIL IN FINAL DRIVE CASE….1450
EVERY 2000 HOURS MAINTENANCE….1451
CHECK PTO GEAR CASE, ADD OIL….1451
CLEAN, CHECK TURBOCHARGER….1451
CHECK ALTERNATOR, STARTING MOTOR….1451
CHECK ENGINE VALVE CLEARANCE, ADJUST….1451
EVERY 4000 HOURS MAINTENANCE….1452
CHECK WATER PUMP….1452
EVERY 5000 HOURS MAINTENANCE….1453
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….1453
SPECIFICATIONS….1456
SPECIFICATIONS….1457
ATTACHMENTS, OPTIONS….1460
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….1461
SAFETY FIRST….1461
ATTACHMENT INSTALLATION….1462
BUCKET WITH HOOK….1463
HOOK CONDITION….1463
PROHIBITED OPERATIONS….1463
METHOD FOR REMOVING AND INSTALLING EXTRA….1464
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE….1466
CONTROL PATTERN CHANGE PROCEDURE….1466
MACHINE CONTROL PATTERNS….1467
ATTACHMENT GUIDE….1468
OTHER ATTACHMENTS….1468
ATTACHMENT COMBINATIONS….1469
SELECTION OF TRACK SHOES….1470
RECOMMENDED ATTACHMENT OPERATIONS….1471
HYDRAULIC BREAKER….1471
INDEX….1476
TEN00074-00 – Hydraulic Excavator GALEO PC78MR-6 Operation & Maintenance Manual….1480
COVER….1480
FOREWORD….1481
FOREWORD….1482
SAFETY INFORMATION….1485
INTRODUCTION….1487
DIRECTIONS OF MACHINE….1487
PRODUCT INFORMATION….1488
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….1488
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….1488
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION….1489
SERVICE METER LOCATION….1489
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….1490
CONTENTS….1491
SAFETY….1495
SAFETY INFORMATION….1496
SAFETY LABELS….1498
LOCATION OF SAFETY LABELS….1499
SAFETY LABELS….1500
SAFETY INFORMATION….1507
SAFETY RULES….1507
IF PROBLEMS ARE FOUND….1507
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….1507
FIRE EXTINGUISHER AND FIRST AID KIT….1507
SAFETY EQUIPMENT….1507
KEEP MACHINE CLEAN….1508
KEEP OPERATOR'S COMPARTMENT CLEAN….1508
LEAVING OPERATOR'S SEAT WITH LOCK….1508
HANDRAILS AND STEPS….1509
MOUNTING AND DISMOUNTING….1509
NO PERSONS ON ATTACHMENTS….1509
DO NOT GET CAUGHT IN ARTICULATED PORTION….1509
BURN PREVENTION….1510
FIRE PREVENTION AND EXPLOSION PREVENTION….1510
ACTION IF FIRE OCCURS….1511
WINDSHIELD WASHER FLUID….1511
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….1511
ATTACHMENT INSTALLATION….1512
ATTACHMENT COMBINATIONS….1512
CAB WINDOW GLASSES….1512
UNAUTHORIZED MODIFICATIONS….1512
SAFETY AT JOBSITE….1512
WORKING ON LOOSE GROUND….1513
DISTANCE TO HIGH VOLTAGE CABLES….1513
ENSURE GOOD VISIBILITY….1513
VENTILATION FOR ENCLOSED AREA….1514
SIGNALMAN'S SIGNAL AND SIGNS….1514
EMERGENCY EXIT FROM OPERATOR'S CAB….1514
ASBESTOS DUST HAZARD PREVENTION….1514
SAFETY MACHINE OPERATION….1515
STARTING ENGINE….1515
CHECKS BEFORE STARTING ENGINE….1515
SAFETY RULES FOR STARTING ENGINE….1516
STARTING ENGINE IN COLD WEATHER….1516
OPERATION….1517
CHECKS BEFORE OPERATION….1517
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….1517
SAFETY RULES FOR TRAVELING….1518
TRAVELING ON SLOPES….1519
OPERATIONS ON SLOPES….1520
PROHIBITED OPERATIONS….1520
OPERATIONS ON SNOW….1521
PARKING MACHINE….1522
TRANSPORTATION….1523
LOADING AND UNLOADING….1523
SHIPPING THE MACHINE….1523
BATTERY….1524
BATTERY HAZARD PREVENTION….1524
STARTING ENGINE WITH BOOSTER CABLES….1525
TOWING….1526
SAFETY RULES FOR TOWING….1526
LIFTING OBJECTS WITH BUCKET….1527
SAFETY RULES FOR LIFTING OBJECTS….1527
SAFETY MAINTENANCE INFORMATION….1528
WARNING TAG….1528
KEEP WORK PLACE CLEAN AND TIDY….1528
APPOINT LEADER WHEN WORKING WITH OTHERS….1528
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….1528
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….1529
PROPER TOOLS….1530
ACCUMULATOR….1530
PERSONNEL….1530
ATTACHMENTS….1530
WORK UNDER THE MACHINE….1531
NOISE….1531
WHEN USING HAMMER….1531
WELDING WORKS….1531
REMOVING BATTERY TERMINALS….1531
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….1532
DO NOT DISASSEMBLE RECOIL SPRINGS….1532
SAFETY RULES FOR HIGH-PRESSURE OIL….1532
SAFETY HANDLING HIGH-PRESSURE HOSES….1532
WASTE MATERIALS….1533
AIR CONDITIONER MAINTENANCE….1533
COMPRESSED AIR….1533
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….1533
OPERATION….1535
MACHINE VIEW ILLUSTRATIONS….1536
OVERALL MACHINE VIEW….1536
CONTROLS AND GAUGES….1537
DETAILED CONTROLS AND GAUGES….1538
MONITORING SYSTEM….1538
SWITCHES….1548
CONTROL LEVERS AND PEDALS….1553
SUN ROOF….1558
WINDSHIELD….1559
SLIDING DOOR….1564
EMERGENCY ESCAPE HAMMER….1564
CAP WITH LOCK….1566
ENGINE HOOD….1567
MUD COVER….1568
BATTERY INSPECTION COVER….1569
FUSE….1570
FUSIBLE LINK….1571
AUXILIARY ELECTRIC POWER….1571
CONTROLLERS….1571
AIR CONDITIONER CONTROLS….1572
HEATER AND DEFROSTER CONTROLS….1578
RADIO….1583
OPERATION MANUAL STORAGE….1588
TOOL BOX….1588
GREASE PUMP HOLDER….1588
ASHTRAY….1588
FIRE EXTINGUISHER….1589
MACHINE OPERATIONS AND CONTROLS….1590
BEFORE STARTING ENGINE….1590
STARTING ENGINE….1606
AFTER STARTING ENGINE….1611
STOPPING THE ENGINE….1614
CHECK AFTER SHUT OFF ENGINE….1614
MACHINE OPERATION….1615
STEERING THE MACHINE….1619
SWINGING….1621
WORK EQUIPMENT CONTROLS AND OPERATIONS….1622
WORKING MODE….1624
PROHIBITED OPERATIONS….1625
GENERAL OPERATION INFORMATION….1627
TRAVELING ON SLOPES….1629
ESCAPE FROM MUD….1631
RECOMMENDED APPLICATIONS….1632
MACHINE READY FOR ATTACHMENT….1634
BUCKET REPLACEMENT AND INVERSION….1640
PARKING MACHINE….1642
MACHINE INSPECTION AFTER DAILY WORK….1643
LOCKING….1643
ROAD LINERS AND RUBBER SHOES….1644
TRANSPORTATION….1649
TRANSPORTATION PROCEDURE….1649
LOADING AND UNLOADING WITH TRAILER….1649
LIFTING MACHINE….1655
COLD WEATHER OPERATION….1657
COLD WEATHER OPERATION INFORMATION….1657
AFTER DAILY WORK COMPLETION….1659
AFTER COLD WEATHER SEASON….1659
LONG TERM STORAGE….1660
BEFORE STORAGE….1660
DURING STORAGE….1660
AFTER STORAGE….1660
TROUBLES AND ACTIONS….1661
RUNNING OUT OF FUEL….1661
PHENOMENA THAT ARE NOT FAILURES….1661
TOWING THE MACHINE….1662
SEVERE JOB CONDITION….1662
DISCHARGED BATTERY….1663
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY….1668
OTHER TROUBLE….1669
MAINTENANCE….1675
MAINTENANCE INFORMATION….1676
OUTLINE OF SERVICE….1678
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1678
ELECTRIC SYSTEM MAINTENANCE….1681
WEAR PARTS….1682
WEAR PARTS LIST….1682
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….1683
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1684
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….1685
TIGHTENING TORQUE SPECIFICATIONS….1686
TIGHTENING TORQUE LIST….1686
SAFETY CRITICAL PARTS….1687
SAFETY CRITICAL PARTS LIST….1687
MAINTENANCE SCHEDULE….1688
MAINTENANCE SCHEDULE CHART….1688
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….1689
MAINTENANCE PROCEDURE….1690
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….1690
REPLACE FUEL FILTER CARTRIDGE….1735
CHANGE OIL IN ENGINE OIL PAN, REPLACE OIL FILTER CARTRIDGE….1736
WHEN REQUIRED….1691
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….1691
CLEAN INSIDE OF COOLING SYSTEM….1695
REPLACE WATER SEPARATOR ELEMENT….1698
CLEAN FUEL TANK….1699
CHECK AND TIGHTEN TRACK SHOE BOLTS….1700
CHECK AND ADJUST TRACK TENSION….1701
CHECK ROAD LINERS OR RUBBER SHOES….1703
CHECK AND ADJUST RUBBER SHOE TENSION….1705
REPLACE ROAD LINERS….1706
REPLACE RUBBER SHOES….1707
CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES….1709
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)….1710
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….1713
ADJUST BUCKET CLEARANCE….1714
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….1715
CHECK AND ADJUST AIR CONDITIONER….1716
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER….1717
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT….1718
WASH WASHABLE FLOOR….1719
BLEEDING AIR FROM HYDRAULIC SYSTEM….1721
CHECK BEFORE STARTING….1724
EVERY 50 HOURS MAINTENANCE….1725
DRAIN WATER FROM FUEL TANK….1725
EVERY 100 HOURS MAINTENANCE….1726
LUBRICATING….1726
EVERY 250 HOURS MAINTENANCE….1727
LUBRICATING….1727
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….1729
CHECK LEVEL OF BATTERY ELECTROLYTE….1730
CHECK AND ADJUST COOLING FAN BELT TENSION….1732
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….1734
EVERY 500 HOURS MAINTENANCE….1735
REPLACE FUEL FILTER CARTRIDGE….1735
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….1736
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS….1737
CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS….1739
LUBRICATE SWING CIRCLE….1741
CHECK SWING PINION GREASE LEVEL, ADD GREASE….1741
EVERY 1000 HOURS MAINTENANCE….1742
REPLACE HYDRAULIC OIL FILTER ELEMENT….1742
CHANGE OIL IN SWING MACHINERY CASE….1744
CHANGE OIL IN FINAL DRIVE CASE….1745
EVERY 2000 HOURS MAINTENANCE….1746
CHECK PTO GEAR CASE, ADD OIL….1746
CLEAN, CHECK TURBOCHARGER….1746
CHECK ALTERNATOR, STARTING MOTOR….1746
EVERY 4000 HOURS MAINTENANCE….1747
CHECK WATER PUMP….1747
EVERY 5000 HOURS MAINTENANCE….1748
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….1748
SPECIFICATIONS….1751
SPECIFICATIONS….1752
ATTACHMENTS, OPTIONS….1755
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….1756
SAFETY FIRST….1756
ATTACHMENT INSTALLATION….1757
BUCKET WITH HOOK….1758
HOOK CONDITION….1758
PROHIBITED OPERATIONS….1758
METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT….1759
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)….1761
CONTROL PATTERN CHANGE PROCEDURE….1761
MACHINE CONTROL PATTERNS….1762
ATTACHMENT GUIDE….1763
OTHER ATTACHMENTS….1763
ATTACHMENT COMBINATIONS….1764
SELECTION OF TRACK SHOES….1765
RECOMMENDED ATTACHMENT OPERATIONS….1766
HYDRAULIC BREAKER….1766
INDEX….1771
TEN00202-00 – Hydraulic Excavator GALEO PC78MR-6 Operation & Maintenance Manual….1775
COVER….1775
FOREWORD….1776
FOREWORD….1777
SAFETY INFORMATION….1780
INTRODUCTION….1782
DIRECTIONS OF MACHINE….1782
PRODUCT INFORMATION….1783
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….1783
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….1783
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION….1784
SERVICE METER LOCATION….1784
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….1785
CONTENTS….1786
SAFETY….1789
SAFETY INFORMATION….1790
SAFETY LABELS….1792
LOCATION OF SAFETY LABELS….1793
SAFETY LABELS….1794
SAFETY INFORMATION….1801
SAFETY RULES….1801
IF PROBLEMS ARE FOUND….1801
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….1801
FIRE EXTINGUISHER AND FIRST AID KIT….1801
SAFETY EQUIPMENT….1801
KEEP MACHINE CLEAN….1802
KEEP OPERATOR'S COMPARTMENT CLEAN….1802
LEAVING OPERATOR'S SEAT WITH LOCK….1802
HANDRAILS AND STEPS….1803
MOUNTING AND DISMOUNTING….1803
NO PERSONS ON ATTACHMENTS….1803
DO NOT GET CAUGHT IN ARTICULATED PORTION….1803
BURN PREVENTION….1804
FIRE PREVENTION AND EXPLOSION PREVENTION….1804
ACTION IF FIRE OCCURS….1805
WINDSHIELD WASHER FLUID….1805
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….1805
ATTACHMENT INSTALLATION….1806
ATTACHMENT COMBINATIONS….1806
CAB WINDOW GLASSES….1806
UNAUTHORIZED MODIFICATIONS….1806
SAFETY AT JOBSITE….1806
WORKING ON LOOSE GROUND….1807
DISTANCE TO HIGH VOLTAGE CABLES….1807
ENSURE GOOD VISIBILITY….1807
VENTILATION FOR ENCLOSED AREA….1808
SIGNALMAN'S SIGNAL AND SIGNS….1808
EMERGENCY EXIT FROM OPERATOR'S CAB….1808
ASBESTOS DUST HAZARD PREVENTION….1808
SAFETY MACHINE OPERATION….1809
STARTING ENGINE….1809
CHECKS BEFORE STARTING ENGINE….1809
SAFETY RULES FOR STARTING ENGINE….1810
STARTING ENGINE IN COLD WEATHER….1810
OPERATION….1811
CHECKS BEFORE OPERATION….1811
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….1811
SAFETY RULES FOR TRAVELING….1812
TRAVELING ON SLOPES….1813
OPERATIONS ON SLOPES….1814
PROHIBITED OPERATIONS….1814
OPERATIONS ON SNOW….1815
PARKING MACHINE….1816
TRANSPORTATION….1817
LOADING AND UNLOADING….1817
SHIPPING THE MACHINE….1817
BATTERY….1818
BATTERY HAZARD PREVENTION….1818
STARTING ENGINE WITH BOOSTER CABLES….1819
TOWING….1820
SAFETY RULES FOR TOWING….1820
LIFTING OBJECTS WITH BUCKET….1821
SAFETY RULES FOR LIFTING OBJECTS….1821
SAFETY MAINTENANCE INFORMATION….1822
WARNING TAG….1822
KEEP WORK PLACE CLEAN AND TIDY….1822
APPOINT LEADER WHEN WORKING WITH OTHERS….1822
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….1822
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….1823
PROPER TOOLS….1824
ACCUMULATOR….1824
PERSONNEL….1824
ATTACHMENTS….1824
WORK UNDER THE MACHINE….1825
NOISE….1825
WHEN USING HAMMER….1825
WELDING WORKS….1825
REMOVING BATTERY TERMINALS….1825
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….1826
DO NOT DISASSEMBLE RECOIL SPRINGS….1826
SAFETY RULES FOR HIGH-PRESSURE OIL….1826
SAFETY HANDLING HIGH-PRESSURE HOSES….1826
WASTE MATERIALS….1827
AIR CONDITIONER MAINTENANCE….1827
COMPRESSED AIR….1827
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….1827
OPERATION….1828
MACHINE VIEW ILLUSTRATIONS….1829
OVERALL MACHINE VIEW….1829
CONTROLS AND GAUGES….1830
DETAILED CONTROLS AND GAUGES….1831
MONITORING SYSTEM….1831
SWITCHES….1841
CONTROL LEVERS AND PEDALS….1846
SUN ROOF….1851
WINDSHIELD….1852
SLIDING DOOR….1857
EMERGENCY ESCAPE HAMMER….1857
CAP WITH LOCK….1859
ENGINE HOOD….1860
MUD COVER….1861
BATTERY INSPECTION COVER….1862
FUSE….1863
FUSIBLE LINK….1864
AUXILIARY ELECTRIC POWER….1864
CONTROLLERS….1864
AIR CONDITIONER CONTROLS….1865
HEATER AND DEFROSTER CONTROLS….1871
RADIO….1876
OPERATION MANUAL STORAGE….1881
TOOL BOX….1881
GREASE PUMP HOLDER….1881
ASHTRAY….1881
FIRE EXTINGUISHER….1882
MACHINE OPERATIONS AND CONTROLS….1883
BEFORE STARTING ENGINE….1883
STARTING ENGINE….1899
AFTER STARTING ENGINE….1904
STOPPING THE ENGINE….1907
CHECK AFTER SHUT OFF ENGINE….1907
MACHINE OPERATION….1908
STEERING THE MACHINE….1912
SWINGING….1914
WORK EQUIPMENT CONTROLS AND OPERATIONS….1915
WORKING MODE….1917
PROHIBITED OPERATIONS….1918
GENERAL OPERATION INFORMATION….1920
TRAVELING ON SLOPES….1922
ESCAPE FROM MUD….1924
RECOMMENDED APPLICATIONS….1925
MACHINE READY FOR ATTACHMENT….1927
BUCKET REPLACEMENT AND INVERSION….1933
PARKING MACHINE….1936
MACHINE INSPECTION AFTER DAILY WORK….1937
LOCKING….1937
ROAD LINERS AND RUBBER SHOES….1938
TRANSPORTATION….1943
TRANSPORTATION PROCEDURE….1943
LOADING AND UNLOADING WITH TRAILER….1943
LIFTING MACHINE….1949
COLD WEATHER OPERATION….1951
COLD WEATHER OPERATION INFORMATION….1951
AFTER DAILY WORK COMPLETION….1953
AFTER COLD WEATHER SEASON….1953
LONG TERM STORAGE….1954
BEFORE STORAGE….1954
DURING STORAGE….1954
AFTER STORAGE….1954
TROUBLES AND ACTIONS….1955
RUNNING OUT OF FUEL….1955
PHENOMENA THAT ARE NOT FAILURES….1955
TOWING THE MACHINE….1956
SEVERE JOB CONDITION….1956
DISCHARGED BATTERY….1957
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY….1962
OTHER TROUBLE….1963
MAINTENANCE….1968
MAINTENANCE INFORMATION….1969
OUTLINE OF SERVICE….1971
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1971
ELECTRIC SYSTEM MAINTENANCE….1975
WEAR PARTS….1976
WEAR PARTS LIST….1976
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….1977
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1978
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….1979
TIGHTENING TORQUE SPECIFICATIONS….1980
TIGHTENING TORQUE LIST….1980
SAFETY CRITICAL PARTS….1981
SAFETY CRITICAL PARTS LIST….1981
MAINTENANCE SCHEDULE….1982
MAINTENANCE SCHEDULE CHART….1982
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….1983
MAINTENANCE PROCEDURE….1984
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….1984
WHEN REQUIRED….1985
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….1985
CLEAN INSIDE OF COOLING SYSTEM….1989
REPLACE WATER SEPARATOR ELEMENT….1992
CLEAN FUEL TANK….1993
CHECK AND TIGHTEN TRACK SHOE BOLTS….1994
CHECK AND ADJUST TRACK TENSION….1995
CHECK ROAD LINERS OR RUBBER SHOES….1997
CHECK AND ADJUST RUBBER SHOE TENSION….1999
REPLACE ROAD LINERS….2000
REPLACE RUBBER SHOES….2001
CHANGE STEEL SHOES OR ROAD LINER TO RUBBER SHOES….2003
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)….2004
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….2007
ADJUST BUCKET CLEARANCE….2008
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….2009
CHECK AND MAINTENANCE AIR CONDITIONER….2010
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER….2011
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT….2012
WASH WASHABLE FLOOR….2013
BLEEDING AIR FROM HYDRAULIC SYSTEM….2015
CHECK BEFORE STARTING….2018
EVERY 50 HOURS MAINTENANCE….2019
DRAIN WATER FROM FUEL TANK….2019
EVERY 100 HOURS MAINTENANCE….2020
LUBRICATING….2020
CHECK SWING MACHINERY CASE OIL, ADD OIL….2021
EVERY 250 HOURS MAINTENANCE….2022
LUBRICATING….2022
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….2024
CHECK LEVEL OF BATTERY ELECTROLYTE….2025
CHECK AND ADJUST COOLING FAN BELT TENSION….2027
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….2029
EVERY 500 HOURS MAINTENANCE….2030
REPLACE FUEL FILTER CARTRIDGE….2030
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….2031
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS….2032
CLEAN, CHECK RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS….2034
LUBRICATE SWING CIRCLE….2036
CHECK SWING PINION GREASE LEVEL, ADD GREASE….2036
EVERY 1000 HOURS MAINTENANCE….2037
REPLACE HYDRAULIC OIL FILTER ELEMENT….2037
CHANGE OIL IN SWING MACHINERY CASE….2039
GREASE SWING MACHINERY BEARING….2040
CHANGE OIL IN FINAL DRIVE CASE….2041
EVERY 2000 HOURS MAINTENANCE….2042
CHECK PTO GEAR CASE, ADD OIL….2042
CLEAN, CHECK TURBOCHARGER….2042
CHECK ALTERNATOR, STARTING MOTOR….2042
CHECK ENGINE VALVE CLEARANCE, ADJUST….2042
EVERY 4000 HOURS MAINTENANCE….2043
CHECK WATER PUMP….2043
EVERY 5000 HOURS MAINTENANCE….2044
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….2044
SPECIFICATIONS….2046
SPECIFICATIONS….2047
ATTACHMENTS, OPTIONS….2049
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….2050
SAFETY FIRST….2050
ATTACHMENT INSTALLATION….2051
BUCKET WITH HOOK….2052
HOOK CONDITION….2052
PROHIBITED OPERATIONS….2052
METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT….2053
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)….2055
CONTROL PATTERN CHANGE PROCEDURE….2055
MACHINE CONTROL PATTERNS….2056
ATTACHMENT GUIDE….2057
OTHER ATTACHMENTS….2057
ATTACHMENT COMBINATIONS….2058
SELECTION OF TRACK SHOES….2059
RECOMMENDED ATTACHMENT OPERATIONS….2060
HYDRAULIC BREAKER….2060
INDEX….2065
TEN00288-00 – Hydraulic Excavator PC78MR-6 Operation & Maintenance Manual….2069
COVER….2070
FOREWORD….2070
FOREWORD….2071
SAFETY INFORMATION….2072
INTRODUCTION….2074
DIRECTIONS OF MACHINE….2074
PRODUCT INFORMATION….2075
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….2075
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….2075
ADDITIONAL ENGINE SERIAL NO. PLATE….2076
SERVICE METER LOCATION….2076
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….2076
CONTENTS….2077
SAFETY….2080
SAFETY….2081
SAFETY LABELS….2083
LOCATION OF SAFETY LABELS….2084
SAFETY LABELS….2085
GENERAL PRECAUTIONS….2092
SAFETY MACHINE OPERATION….2100
STARTING ENGINE….2100
OPERATION….2102
TRANSPORTATION….2108
BATTERY….2109
TOWING….2111
LIFTING OBJECTS WITH BUCKET….2112
SAFETY MAINTENANCE INFORMATION….2113
OPERATION….2120
MACHINE VIEW ILLUSTRATIONS….2121
OVERALL MACHINE VIEW….2121
CONTROLS AND GAUGES….2122
DETAILED CONTROLS AND GAUGES….2123
MONITORING SYSTEM….2123
SWITCHES….2133
CONTROL LEVERS AND PEDALS….2138
SUN ROOF….2143
WINDSHIELD….2144
SLIDING DOOR….2149
EMERGENCY ESCAPE HAMMER….2149
CAP WITH LOCK….2151
ENGINE HOOD….2152
MUD COVER….2153
BATTERY INSPECTION COVER….2154
FUSE….2155
FUSIBLE LINK….2156
AUXILIARY ELECTRIC POWER….2156
CONTROLLERS….2156
AIR CONDITIONER CONTROLS….2157
HEATER AND DEFROSTER CONTROLS….2163
RADIO….2168
OPERATION MANUAL STORAGE….2173
TOOL BOX….2173
GREASE PUMP HOLDER….2173
ASHTRAY….2173
FIRE EXTINGUISHER….2174
MACHINE OPERATIONS AND CONTROLS….2175
BEFORE STARTING ENGINE….2175
STARTING ENGINE….2191
AFTER STARTING ENGINE….2196
STOPPING THE ENGINE….2199
CHECK AFTER SHUT OFF ENGINE….2199
MACHINE OPERATION….2200
STEERING THE MACHINE….2204
SWINGING….2206
WORK EQUIPMENT CONTROLS AND OPERATIONS….2207
WORKING MODE….2209
PROHIBITED OPERATIONS….2210
GENERAL OPERATION INFORMATION….2212
TRAVELING ON SLOPES….2214
ESCAPE FROM MUD….2216
RECOMMENDED APPLICATIONS….2217
MACHINE READY FOR ATTACHMENT….2219
BUCKET REPLACEMENT AND INVERSION….2225
PARKING MACHINE….2228
MACHINE INSPECTION AFTER DAILY WORK….2229
LOCKING….2229
ROAD LINERS AND RUBBER SHOES….2230
TRANSPORTATION….2235
TRANSPORTATION PROCEDURE….2235
LOADING AND UNLOADING WITH TRAILER….2235
LIFTING MACHINE….2241
COLD WEATHER OPERATION….2243
COLD WEATHER OPERATION INFORMATION….2243
AFTER DAILY WORK COMPLETION….2245
AFTER COLD WEATHER SEASON….2245
LONG TERM STORAGE….2246
BEFORE STORAGE….2246
DURING STORAGE….2246
AFTER STORAGE….2246
TROUBLES AND ACTIONS….2247
RUNNING OUT OF FUEL….2247
PHENOMENA THAT ARE NOT FAILURES….2247
TOWING THE MACHINE….2248
SEVERE JOB CONDITION….2248
DISCHARGED BATTERY….2249
HOW TO LOWER WORK EQUIPMENT WHEN ENGINE STOPS DUE TO ABNORMALITY….2254
OTHER TROUBLE….2255
MAINTENANCE….2260
MAINTENANCE INFORMATION….2261
OUTLINE OF SERVICE….2263
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….2263
ELECTRIC SYSTEM MAINTENANCE….2267
WEAR PARTS….2268
WEAR PARTS LIST….2268
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….2269
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….2270
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….2271
TIGHTENING TORQUE SPECIFICATIONS….2272
TIGHTENING TORQUE LIST….2272
SAFETY CRITICAL PARTS….2273
SAFETY CRITICAL PARTS LIST….2273
MAINTENANCE SCHEDULE….2274
MAINTENANCE SCHEDULE CHART….2274
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….2275
MAINTENANCE PROCEDURE….2276
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….2276
WHEN REQUIRED….2277
CHECK BEFORE STARTING….2310
EVERY 50 HOURS MAINTENANCE….2311
EVERY 100 HOURS MAINTENANCE….2312
EVERY 250 HOURS MAINTENANCE….2314
EVERY 500 HOURS MAINTENANCE….2322
EVERY 1000 HOURS MAINTENANCE….2329
EVERY 2000 HOURS MAINTENANCE….2334
EVERY 4000 HOURS MAINTENANCE….2335
EVERY 5000 HOURS MAINTENANCE….2336
SPECIFICATIONS….2338
SPECIFICATIONS….2339
ATTACHMENTS, OPTIONS….2342
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….2343
SAFETY FIRST….2343
ATTACHMENT INSTALLATION….2344
BUCKET WITH HOOK….2345
HOOK CONDITION….2345
PROHIBITED OPERATIONS….2345
METHOD FOR REMOVING AND INSTALLING EXTRA COUNTERWEIGHT….2346
CHANGING MACHINE CONTROL PATTERN (IF PATTERN CHANGE VALVE EQUIPPED)….2348
CONTROL PATTERN CHANGE PROCEDURE….2348
MACHINE CONTROL PATTERNS….2349
ATTACHMENT GUIDE….2350
OTHER ATTACHMENTS….2350
ATTACHMENT COMBINATIONS….2351
SELECTION OF TRACK SHOES….2352
RECOMMENDED ATTACHMENT OPERATIONS….2353
HYDRAULIC BREAKER….2353
INDEX….2358

Komatsu Hydraulic Excavators PC78MR Repair Service Manuals

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