Komatsu Hydraulic Excavators PC78MR Repair Service Manual + Operation Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC78MR, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC78MR workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 2,361 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
MAIN MENU...0
COVER...1
CONTENTS...2
SAFETY...6
SAFETY NOTICE...6
FOREWARD...8
GENERAL...8
HOW TO READ THE SHOP MANUAL...9
HOISTING INSTRUCTIONS...10
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER...11
COATING MATERIALS...13
STANDARD TIGHTENING TORQUE...15
ELECTRIC WIRE CODE...18
CONVERSION TABLE...19
UNITS...25
01 GENERAL...27
SPECIFICATION DIMENSIONS DRAWING...28
WORKING RANGE DRAWING...30
SPECIFICATIONS...31
WEIGHT TABLE...34
LIST OF LUBRICANTS AND COOLANT...36
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...38
PTO ...39
COOLING SYSTEM...40
POWER TRAIN SYSTEM...41
SWING CIRCLE...42
SWING MACHINERY...43
TRACK FRAME AND IDLER CUSHION...45
IDLER...47
TRACK ROLLER...48
CARRIER ROLLER...50
SPROCKET...51
TRACK SHOE...52
ARRANGEMENT OF HYDRAULIC COMPONENTS...57
HYDRAULIC TANK AND OIL FILTER...58
CENTER SWIVEL JOINT...59
TRAVEL MOTOR...60
WORK EQUIPMENT CYLINDER...68
SOLENOID VALVE...72
SOLENOID VALVE (FOR EU SPEC.)...80
ACCUMULATOR FOR PPC...84
MULTI-CONTROL VALVE...85
ACCUMULATOR FOR BRAKER...86
HYDRAULIC PUMP...87
CONTROL VALVE...101
CLSS...113
SWING MOTOR...145
WORK EQUIPMENT AND SWING PPC VALVE...153
TRAVEL PPC VALVE...159
BOOM SWING PPC VALVE, BLADE PPC VALVE...163
BOOM HYDRAULIC ANTI-BURST VALVE (FOR EU SPEC)...167
WORK EQUIPMENT...173
DIMENSIONS OF EACH PART OF WORK EQUIPMENT...175
AIR CONDITIONER PIPING (OPTIONAL)...179
ELECTRIC CONTROL SYSTEM...180
SYSTEM COMPONENTS...200
MONITOR SYSTEM...209
SENSORS...214
20 TESTING AND ADJUSTING...217
STANDARD VALUE TABLE FOR ENGINE...218
STANARD VALUE TABLE FOR CHASSIS...219
STANDARD VALUE TABLE FOR ELECTRIC PARTS...227
TESTING AND ADJUSTING...233
LIST OF DEVICES FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...234
MEASURING ENGINE SPEED...235
MEASURING EXHAUST GAS COLOR...236
ADJUSTING VALVE CLEARANCE...237
MEASURING COMPRESSION PRESSURE...238
MEASURING BLOW-BY PRESSURE...239
TESTING AND ADJUSTING FUEL INJECTION TIMING...240
MEASURING ENGINE OIL PRESSURE...244
ADJUSTING ENGINE STOP SOLENOID...245
ADJUSTING FUEL CONTROL LINKAGE...247
ADJUSTING ENGINE SPEED SENSOR...249
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...250
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE...253
ADJUSTING PC VALVE...255
TESTING TVC-EPC SOLENOID OUTPUT PRESSURE...255
MEASURING CONTROL CIRCUIT PRESSURE...256
MEASURING PPC VALVE OUTPUT PRESSURE...257
TESTING SOLENOID VALVE OUTPUT PRESSURE...258
ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE...260
TESTING TRAVEL DEVIATION...261
TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT...263
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTORS...264
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT...265
TESTING CLEARANCE OF SWING CIRCLE BEARING...266
TESTING AND ADJUSTING TRACK SHOE TENSION...267
BLEEDING AIR FROM HYDRAULIC CIRCUIT...268
REPLACEMENT PROCEDURE OF POTENTIOMETERS...270
PROCEDURE FOR TESTING DIODE...271
TROUBLESHOOTING...273
POINTS TO REMEMBER WHEN TROUBLESHOOTING...274
SEQUENCE OF EVENTS IN TROUBLESHOOTING...275
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...276
CHECKS BEFORE TROUBLESHOOTING...284
TYPE AND LOCATION OF CONNECTORS...286
CONNECTOR ARRANGEMENT DIAGRAM...288
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...291
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL MECHANISM...314
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL...315
TVC VALVE CURRENT ADJUSTMENT TABLE...326
METHOD OF USING JUDGEMENT TABLE...327
HOW TO READ FLOW OF TROUBLESHOOTING...329
CONTENTS AND PROCEDURE OF TROUBLESHOOTING...331
TROUBLESHOOTING OF ENGINE (S MODE)...332
METHOD OF USING TROUBLESHOOTING CHART...333
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...337
S-2 ENGINE DOES NOT START...339
1) ENGINE DOES NOT TURN...339
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...340
3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...341
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)...342
S-4 ENGINE STOPS DURING OPERATIONS...343
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...344
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...345
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...346
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...347
S-9 OIL BECOMES CONTAMINATED QUICKLY...348
S-10 FUEL CONSUMPTION IS EXCESSIVE...349
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...350
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...351
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...352
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...353
S-15 ABNORMAL NOISE IS MADE...354
S-16 VIBRATION IS EXCESSIVE...355
TROUBLESHOOTING OF COMMUNICATION SYSTEM (N MODE)...356
N-1 DEFECTIVE COMMUNICATION...357
TROUBLESHOOTING FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)...358
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (GOVERNOR CONTROL SYSTEM)...359
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE...361
JUDGEMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE...363
E-1 CONTROLLER POWER SUPPLY IS DEFECTIVE (LED OF CONTROLLER IS TURNED OFF)...365
E-2 [E323] (SHORT CIRCUIT IN ACCELERATOR RELAY SYSTEM) IS DISPLAYED...366
E-3 [E325] (SHORT CIRCUIT IN DECELERATOR RELAY SYSTEM) IS DISPLAYED...367
E-4 [E328] (STALL OF MOTOR) IS DISPLAYED...368
E-5 [E227] (TROUBLE IN ENGINE SPEED SENSOR) IS DISPLAYED...370
E-6 ONE TOUCH SLOW DOWN MECHANISM DOES NOT WORK...371
E-7 ENGINE DOES NOT START...372
a) [E304] SHORT CIRCUIT IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED...372
b) [E314] DISCONNECTION IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED...372
c) ENGINE STOP SOLENOID SYSTEM...373
d) STARTING SYSTEM...375
E-8 ENGINE DOES NOT STOP...379
TROUBLESHOOTING FOR CONTROLLER PUMP CONTROL SYSTEM (C MODE)...380
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (PUMP CONTROL SYSTEM)...381
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE...383
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC EQUIPMENT...387
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM (FOR STD. SPEC)...389
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM (FOR EU SPEC)...391
C-1 [E232], C-2 [E233] TROUBLE IN TVC-EPC SOLENOID SYSTEM...393
C-3 [E203], C-4 [E213] TROUBLE IN SWING HOLDING BRAKE SOLENOID SYSTEM...394
C-5 [E206], C-6 [E216] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENOID SYSTEM...395
C-7 [E411] TROUBLE IN BOOM SWING ANGLE SENSOR CORRECTION...396
C-8 [E251] TROUBLE IN BOOM BOTTOM PRESSURE SENSOR (OVERLOAD SENSOR) SYSTEM (FOR EU SPEC)...397
C-9 [E258] SHORT CIRCUIT IN 5V SYSTEM OF SENSOR POWER SUPPLY (FOR EU SPEC)...397
C-9 [E258] SHORT CIRCUIT IN 5V SYSTEM OF SENSOR POWER SUPPLY (FOR STD SPEC)...398
C-10 [E412], C-11 [E413] TROUBLE IN BOOM SWING ANGLE SENSOR SYSTEM...399
C-12 [E451] SHORT CIRCUIT IN BOOM SWING LEFT STOP EPC SOLENOID SYSTEM IS DISPLAYED...400
C-13 [E452] DISCONNECTION IN BOOM SWING LEFT STOP EPC SOLENOID SYSTEM IS DISPLAYED...401
C-14 [E453] SHORT CIRCUIT IN BOOM SWING RIGHT STOP EPC SOLENOID SYSTEM IS DISPLAYED...402
C-15 [E454] DISCONNECTION IN BOOM SWING RIGHT STOP EPC SOLENOID SYSTEM IS DISPLAYED...403
C-16 BOOM SWING LEFTT END CUSHION DOES NOT WORK AT ALL OR NORMALLY...404
C-17 BOOM SWING RIGHT END CUSHION DOES NOT WORK AT ALL OR NORMALLY...406
C-18 WORK EQUIPMENT STILL MOVES AFTER WORK EQUIPMENT LOCK LEVER IS SET TO LOCK...408
C-19 MACHINE DOES NOT SWING...409
C-20 TRAVEL SPEED DOES NOT RISE...410
C-21 TROUBLE IN CONTROLLER POWER SUPPLY (LED OF CONTROLLER IS TURNED OFF)...410
TROUBLESHOOTING FOR CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)...411
F-1 BIT PATTERN 1023-(4) SWING PRESSURE SWITCH DOES NOT LIGHT UP...412
F-2 BIT PATTERN 1023-(3) TRAVEL PRESSURE SWITCH DOES NOT LIGHT UP...413
F-3 BIT PATTERN 1023-(6) BOOM RAISE PRESSURE SWITCH DOES NOT LIGHT UP...414
F-4 BIT PATTERN 1023-(5) ARM IN PRESSURE SWITCH DOES NOT LIGHT UP...415
F-5 BIT PATTERN 1026-(1) DECELERATION SWITCH OF LEFT KNOB DOES NOT LIGHT UP...416
F-6 BIT PATTERN 1026-(4) 2ND TRAVEL SPEED SELECTION SWITCH (PEDAL) DOES NOT LIGHT UP...417
F-7 BIT PATTERN 1021-(3) COMPRESSOR SIGNAL DOES NOT LIGHT UP...418
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...419
TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES...422
H-1 SPEED OR POWER OF 2 OR MORE SYSTEMS OF WORK EQUIPMENT (BOOM, ARM, BUCKET) TRAVEL, SWING, AND BLADE IS LOW...424
a) SPEED OR POWER OF WORK EQUIPMENT (INCLUDING BLADE), TRAVEL, AND SWING SYSTEMS IS LOW...424
b) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE) AND TRAVEL IS LOW...425
c) SPEED OR POWER OF SWING AND BLADE IS LOW...425
d) SPEED OR POWER OF TRAVEL AND BLADE IS LOW...426
e) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE) IS LOW...426
f) SPEED OR POWER OF TRAVEL AND SWING IS LOW...426
