Komatsu Hydraulic Excavators PC78UU, PC78US, PC78US Repair Service Manuals
Catalog:
Model:
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
