Komatsu Mini Excavator PC78UU-8 service & repair manual

Description Komatsu Mini Excavator PC78UU-8 service & repair manual

Komatsu Mini Excavator PC78UU-8 pdf workshop service repair manual

Serial number 15001 and up

Technical documentation, specifications, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

SERVICE MANUAL CONTENT:
Index and foreword
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic components
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out work
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
List of Abbreviation
Conversion table

Specification
Specification and technical data
Specification dimension drawings
Working range diagram
Weight table
Table of fuel, coolant and lubricants

Structure and function
Engine and cooling system
PTO
Cooling system
Power train system
Power train
Swing circle
Swing machinery
Undercarriage and frame
Track frame
Idler cushion
Hydraulic system
Hydraulic components layout drawing
Valve control
Hydraulic tank and filter
Hydraulic pump
Control valve
CLSS
Functions and operation by valve
PPC valve
Swing motor
Travel motor
Center swivel joint
Solenoid valve
Accumulator
Multi-control valve
Electrical system
Electrical control system
Monitor system
KOMTRAX system
Sensors

Standard value table
Standard value table for engine
Standard value table for chassis

Testing and adjusting
Tools for testing, adjusting, and troubleshooting
Engine and cooling system
Testing engine speed
Testing exhaust gas temperature
Testing exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Handling fuel system parts
Releasing remaining pressure from fuel system
Testing fuel pressure
Testing fuel return rate and leakage
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Cylinder cut-out test mode
No-injection cranking
Checking and adjusting fan belt
Checking and adjusting air conditioner compressor belt tension
Swing circle and undercarriage
Testing swing circle bearing clearance
Checking and adjusting track tension
Hydraulic system
Testing and adjusting oil pressure in work equipment and travel circuits
Testing and adjusting swing and blade circuit oil pressure (for the machine with blade)
Testing control circuit source pressure
Testing and adjusting oil pressure in pump PC control circuit
Testing LS differential pressure and adjusting LS valve
Testing solenoid valve output pressure
Testing PPC valve output pressure
Adjusting play of work equipment and swing PPC vavles
Isolating the parts causing hydraulic drift of work equipment
Testing and adjusting travel deviation
Releasing remaining pressure from hydraulic circuit
Testing oil leakage amount
Bleeding air from each part
Guard
Adjusting mirrors
Testing and adjusting hood catch
Angle adjustment of rear view camera
Electrical system
Replacement procedure of potentiometer
Special functions of machine monitor
Handling voltage circuit of engine controller
Preparatory work for troubleshooting of electrical system
Procedure for testing diodes
Pm Clinic service
Pm Clinic service

Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and procedures for troubleshooting
Failure codes table
Phenomena and troubleshooting numbers
Information in troubleshooting table
Troubleshooting method for disconnecting wiring harness of pressure sensor system
Connector list and layout
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Fuse locations table
Troubleshooting by failure code
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of oil cooler assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of engine and hydraulic pump assembly
Removal and installation of engine hood assembly
Removal and installation of fuel tank assembly
Power train
Removal and installation of travel motor and final drive assembly
Disassembly and assembly of travel motor and final drive assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Disassembly and assembly of track roller assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of recoil spring assembly
Separation and connection of track shoe assembly
Removal and installation of sprocket
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Hydraulic system
Removal and installation of conter swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of hydraulic pump assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of work equipment assembly
Removal and installation of st boom assembly
Removal and installation of nd boom assembly
Removal and installation of offset bracket assembly
Removal and installation of blade assembly
Cab and its attachments
Removal and installation of operator's cab assembly
Removal and installation of operator cab glass (adhered window glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner compressor assembly
Removal and installation of machine monitor assembly
Removal and installation of work equipment control lever assembly
Electrical system
Removal and installation of engine controller assembly
Removal and installation of pump controller assemby
Removal and installation of air conditioner controller assembly
Removal and installation of KOMTRAX terminal assembly

Maintenance standard
Engine and cooling system
Engine mount
PTO
Cooling system
Power train system
Swing circle
Swing machinery
Undercarriage and frame
Track frame
Idler cushion
Idler
Carrier roller
Track roller
Sprocket
Track shoe
Hydraulic system
Hydraulic tank and filter
Hydraulic pump
Control valve
PPC valve
Swing motor
Travel motor
Center swivel joint
Solenoid valve
Accumulator
Work equipment
Work equipment
Dimensions of components
Work equipment cylinder

Appendix
Air conditioner
Caution about refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Air conditioner controller
Compressor
Condenser
Receiver drier
Sensor
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Detail of air conditioner unit
Part and connector locations
Testing air leakage (duct)
Testing with self-diagnosis function
Testing vent (mode) changeover
Testing Recirc/Fresh air changeover
Testing inner sensor
Testing outer sensor
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart
Information in troubleshooting table
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Troubleshooting for compressor and refrigerant system (Air is not cooled)
Troubleshooting for blower motor system (No air comes out orair flow is abnormal)
Troubleshooting for temperature control
Troubleshooting for vent (mode) changeover
Troubleshooting for Recirc/Fresh air changeover
Troubleshooting for temperature sensor system
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting air conditioner piping
Handling of compressor oil

Diagrams and drawings
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams
Hydraulic circuit diagram
Actuator attachment hydraulic circuit diagram
Electrical diagrams and drawings
Symbols used in electric circuit diagrams
Air conditioner electrical circuit diagram

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