Professional Documents
Culture Documents
SM Pc78uu-6 Pc78us-6 1025-1-45
SM Pc78uu-6 Pc78us-6 1025-1-45
SM Pc78uu-6 Pc78us-6 1025-1-45
• This shop manual may contain attachments and optional equipment that are not available in your
area. Please consult your local Komatsu distributor for those items you may require. Materials and
specifications are subject to change without notice.
• PC78UU-6, PC78US-6 mounts the 4D95LE-2 and S4D95LE-3-A engine.
For details of the engine, see the 95-2 Series and 95-3 Series Engine Shop Manual.
• For the PC78US-6 for Norway (Serial No. 4809 and up), the parts which different from the standard
model have been put together and added as Section 50. For the common parts, see this manual.
© 2010
All Rights Reserved
Printed in Japan 04-10(02) 00-1
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CONTENTS
No. of page
01 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
90 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 PC78US-6
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The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the Q Page to be newly added Add
table below.
q Page to be replaced Replace
PC78US-6 00-2-1
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number number number number number
10-162 (10) 10-215 (10) 10-268 (10) q 20-117 (18) 20-218-5 (12)
10-163 (10) 10-216 (10) 10-269 (10) q 20-118 (18) 20-218-6 (12)
10-164 (10) 10-217 (10) 10-270 (10) 20-119 (12) 20-218-8 (17)
10-165 (10) 10-218 (10) 10-271 (10) 20-120 (12) 20-218-9 (12)
10-166 (10) 10-219 (10) 10-272 (10) 20-121 (13) 20-218-10 (12)
10-167 (10) 10-220 (10) 10-273 (10) 20-121-1 (13) 20-219 (12)
10-168 (10) 10-221 (10) 10-274 (10) 20-122 (5) 20-219-1 (12)
10-169 (10) 10-222 (10) 20-123 (12) 20-219-3 (12)
10-170 (13) 10-223 (10) 20-1 (1) 20-124 (12) 20-219-4 (12)
10-171 (13) 10-224 (10) 20-2 (7) 20-125 (5) 20-219-5 (12)
10-172 (10) 10-225 (10) 20-2-1 (7) 20-126 (12) 20-219-6 (12)
10-173 (10) 10-226 (10) 20-3 (5) 20-127 (1) 20-219-7 (12)
10-174 (13) 10-227 (10) 20-4 (12) 20-128 (1) 20-219-9 (12)
10-175 (13) 10-228 (10) 20-5 (5) 20-129 (12) 20-219-10 (12)
10-176 (10) 10-229 (10) 20-6 (5) 20-130 (12) 20-219-11 (12)
10-177 (10) 10-230 (10) 20-7 (12) 20-131 (1) 20-220 (1)
10-178 (13) 10-231 (10) 20-8 (12) 20-132 (1) 20-221 (1)
10-179 (13) 10-232 (10) 20-9 (12) 20-133 (12) 20-222 (1)
10-180 (10) 10-233 (10) 20-10 (5) 20-134 (12) 20-223 (12)
10-181 (10) 10-234 (10) 20-11 (7) 20-135 (12) 20-224 (1)
10-183 (10) 10-236 (10) 20-12 (12) 20-136 (12) 20-225 (1)
10-184 (10) 10-237 (10) 20-13 (7) Q 20-136-1 (18) 20-226 (12)
10-185 (10) 10-238 (10) 20-14 (7) Q 20-136-2 (18) 20-227 (1)
10-186 (13) 10-239 (10) 20-15 (7) 20-137 (13) 20-228 (12)
10-187 (13) 10-240 (10) 20-16 (7) 20-138 (12) 20-229 (1)
10-188 (13) 10-241 (10) 20-17 (5) 20-139 (15) 20-230 (1)
10-189 (13) 10-242 (10) 20-18 (12) 20-140 (15) 20-231 (1)
10-190 (13) 10-243 (10) 20-19 (12) 20-141 (15) 20-232 (1)
10-191 (10) 10-244 (10) 20-20 (12) 20-142 (15) 20-233 (1)
10-192 (10) 10-245 (10) 20-21 (12) 20-201 (13) 20-234 (1)
10-193 (10) 10-246 (10) 20-22 (12) 20-202 (12) 20-235 (1)
10-195 (10) 10-247 (10) q 20-101 (18) 20-203 (2) 20-236 (1)
10-196 (10) 10-248 (10) 20-102 (13) 20-204 (12) 20-237 (1)
10-197 (10) 10-249 (10) 20-103 (12) 20-205 (12) 20-238 (1)
10-198 (10) 10-250 (10) 20-104 (12) 20-206 (12) 20-239 (1)
10-199 (10) 10-252 (10) 20-105 (13) 20-207 (12) 20-240 (1)
10-200 (10) 10-253 (10) 20-106 (12) 20-208 (12) 20-241 (12)
10-201 (10) 10-254 (10) 20-106-1 (7) 20-209 (12) 20-242 (12)
10-202 (10) 10-255 (10) 20-106-2 (12) 20-210 (2) 20-244 (12)
10-203 (10) 10-256 (10) 20-107 (7) 20-211 (2) 20-245 (12)
10-204 (10) 10-257 (10) 20-108 (13) 20-212 (1) 20-245-1 (5)
10-205 (10) 10-258 (10) 20-109 (13) 20-214 (12) 20-245-2 (5)
10-206 (10) 10-259 (10) 20-110 (13) 20-215 (7) 20-246 (5)
10-207 (10) 10-260 (10) 20-111 (13) 20-215-1 (7) 20-247 (1)
10-208 (10) 10-261 (10) 20-111-1 (12) 20-215-2 (7) 20-248 (12)
10-209 (10) 10-262 (10) 20-112 (7) 20-216 (7) 20-248-1 (12)
10-210 (10) 10-263 (10) 20-113 (12) 20-217 (12) 20-249 (1)
10-211 (10) 10-264 (10) 20-114 (12) 20-218 (12) 20-250 (7)
10-212 (10) 10-265 (10) 20-115 (12) 20-218-2 (12) 20-251 (12)
10-213 (10) 10-266 (10) 20-115-1 (7) 20-218-3 (7) 20-252 (12)
10-214 (10) 10-267 (10) 20-116 (12) 20-218-4 (7) 20-252-1 (13)
00-2-2 PC78US-6
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number number number number number
20-253 (12) 20-342 (12) 20-368 (12) 20-432 (1) 20-478 (5)
20-253-1 (13) 20-343 (12) 20-369 (12) 20-433 (1) 20-479 (5)
20-253-2 (13) 20-343-1 (12) 20-370 (12) 20-434 (1) 20-480 (5)
20-254 (5) 20-343-2 (12) 20-371 (12) 20-435 (1) 20-481 (5)
20-255 (5) 20-344 (12) 20-372 (12) 20-436 (5) 20-482 (5)
20-255-1 (13) 20-345 (12) 20-373 (12) 20-437 (5) 20-483 (5)
20-255-2 (12) 20-346 (12) 20-374 (12) 20-438 (4) 20-484 (5)
20-255-3 (12) 20-347 (12) 20-375 (12) 20-439 (1) 20-485 (5)
20-255-4 (12) 20-348 (12) 20-376 (12) 20-440 (1) 20-501 (12)
20-255-6 (12) 20-349 (12) 20-376-1 (12) 20-441 (1) 20-502 (1)
20-255-7 (12) 20-349-1 (12) 20-376-2 (12) 20-442 (5) 20-503 (6)
20-256 (12) 20-349-2 (12) 20-377 (12) 20-443 (4) 20-504 (12)
20-259 (12) 20-349-3 (12) 20-378 (12) 20-444 (5) 20-505 (12)
20-260 (12) 20-349-4 (12) 20-379 (12) 20-444-1 (5) 20-506 (12)
20-301 (1) 20-351 (12) 20-380 (12) 20-445 (4) 20-507 (12)
20-302 (12) 20-352 (1) 20-381 (12) 20-446 (1) 20-508 (12)
20-303 (12) 20-354 (12) 20-381-1 (12) 20-447 (1) 20-509 (12)
20-325 (12) 20-355 (12) 20-382 (12) 20-447-1 (5) 20-510 (12)
20-326 (12) 20-355-1 (5) 20-383 (12) 20-447-2 (5) 20-511 (12)
20-328 (16) 20-355-2 (5) 20-384 (12) 20-448 (5) 20-512 (12)
20-329 (12) 20-355-3 (12) 20-385 (12) 20-449 (5) 20-513 (12)
20-329-1 (12) 20-355-4 (12) 20-386 (12) 20-450 (5) 20-514 (12)
20-329-2 (12) 20-356 (12) 20-387 (12) 20-451 (4) 20-515 (12)
20-329-3 (13) 20-357 (12) 20-387-1 (12) 20-452 (5) 20-516 (12)
20-330 (13) 20-357-1 (12) 20-387-2 (12) 20-453 (5) 20-517 (12)
20-331 (13) 20-357-2 (12) 20-387-3 (12) 20-453-1 (5) 20-518 (12)
20-331-1 (13) 20-358 (7) 20-388 (12) 20-453-2 (5) 20-519 (12)
20-331-2 (12) 20-358-1 (5) 20-388-1 (12) 20-454 (5) 20-520 (12)
20-332 (12) 20-358-2 (7) 20-389 (12) 20-455 (5) 20-521 (12)
20-332-1 (12) 20-358-3 (7) 20-389-1 (12) 20-456 (5) 20-522 (12)
20-333 (7) 20-358-4 (7) 20-401 (12) 20-457 (5) 20-523 (12)
20-334 (12) 20-358-5 (7) 20-402 (12) 20-458 (5) 20-524 (12)
20-334-1 (12) 20-358-6 (12) 20-403 (12) 20-459 (5) 20-525 (12)
20-334-2 (12) 20-358-7 (7) 20-404 (12) 20-460 (5) 20-526 (12)
20-334-3 (12) 20-358-8 (12) 20-405 (12) 20-461 (5) 20-527 (12)
20-335 (12) 20-358-9 (12) 20-406 (12) 20-462 (5) 20-528 (12)
20-335-1 (12) 20-359 (12) 20-407 (12) 20-463 (5) 20-529 (12)
20-336 (7) 20-359-1 (12) 20-408 (12) 20-464 (5) 20-530 (12)
20-336-1 (7) 20-360 (12) 20-409 (12) 20-465 (5) 20-531 (12)
20-336-2 (12) 20-360-1 (12) 20-410 (12) 20-466 (5) 20-532 (12)
20-337 (7) 20-361 (12) 20-411 (12) 20-467 (5) 20-533 (12)
20-337-1 (12) 20-361-1 (12) 20-412 (12) 20-468 (5) 20-534 (12)
20-338 (12) 20-362 (5) 20-413 (12) 20-469 (5) 20-535 (12)
20-338-1 (12) 20-363 (5) 20-414 (12) 20-470 (5) 20-536 (12)
20-338-2 (12) 20-364 (5) 20-415 (12) 20-471 (5) 20-537 (12)
20-338-3 (12) 20-365 (5) 20-425 (5) 20-472 (5) 20-538 (12)
20-339 (12) 20-366 (12) 20-426 (5) 20-473 (5) 20-539 (12)
20-339-1 (12) 20-366-1 (12) 20-428 (5) 20-474 (5) 20-540 (12)
20-340 (12) 20-366-2 (12) 20-429 (5) 20-475 (5) 20-541 (12)
20-340-1 (12) 20-366-3 (12) 20-430 (5) 20-476 (5) 20-542 (12)
20-341 (12) 20-367 (12) 20-431 (1) 20-477 (5) 20-543 (12)
PC78US-6 00-2-3
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number number number number number
20-544 (12) 30-38 (11) 30-89 (11) 30-141 (16) 50-19 (13)
20-545 (12) 30-39 (11) 30-90 (11) 30-142 (16) 50-20 (13)
20-546 (12) 30-40 (11) 30-91 (11) 30-143 (16) 50-21 (10)
20-547 (7) 30-41 (11) 30-92 (11) 30-144 (16) 50-22 (10)
20-548 (12) 30-42 (11) 30-93 (11) 30-145 (16) 50-23 (10)
20-549 (12) 30-43 (11) 30-94 (11) 30-146 (16) 50-23-1 (10)
20-550 (12) 30-44 (11) 30-95 (11) 30-147 (16) 50-23-2 (10)
20-551 (12) 30-45 (11) 30-96 (11) 30-148 (16) 50-23-3 (10)
20-552 (12) 30-46 (11) 30-97 (11) 30-149 (16) 50-23-4 (10)
20-553 (12) 30-47 (11) 30-98 (11) 30-150 (16) 50-24 (10)
30-48 (11) 30-99 (11) 30-151 (16) 50-25 (10)
q 30-1 (18) 30-49 (11) 30-100 (11) 30-152 (16) 50-26 (10)
30-2 (11) 30-50 (11) 30-101 (16) 30-153 (16) 50-101 (7)
30-3 (11) 30-51 (11) 30-102 (16) 30-154 (16) 50-102 (12)
30-4 (11) 30-52 (11) 30-103 (16) 30-155 (16) 50-104 (7)
30-5 (11) 30-53 (11) 30-105 (16) 30-156 (16) 50-105 (7)
30-6 (11) 30-54 (11) 30-106 (16) 30-157 (16) 50-106 (4)
30-7 (11) 30-55 (11) 30-107 (16) 30-158 (16) 50-107 (12)
30-8 (11) 30-56 (11) 30-108 (16) 30-159 (16) 50-107-1 (12)
30-9 (11) 30-57 (11) 30-109 (16) 30-160 (16) 50-107-3 (12)
30-10 (11) 30-58 (11) 30-110 (16) 30-161 (16) 50-107-4 (7)
30-11 (11) 30-59 (11) 30-111 (16) 30-162 (16) 50-107-5 (7)
30-12 (11) 30-60 (11) 30-112 (16) 30-163 (16) 50-107-6 (12)
30-13 (11) 30-61 (11) 30-113 (16) 30-164 (16) 50-107-7 (12)
30-14 (11) 30-62 (11) 30-114 (16) 50-107-9 (12)
30-15 (11) 30-63 (11) 30-115 (16) 50-1 (10) 50-107-10 (12)
30-16 (11) 30-64 (11) 30-116 (16) 50-3 (10) 50-107-11 (12)
30-17 (11) 30-65 (11) 30-117 (16) 50-4 (14) 50-108 (12)
30-18 (15) 30-66 (11) 30-118 (16) 50-5 (10) 50-108-1 (12)
30-18-1 (15) 30-67 (11) 30-119 (16) 50-6 (10) 50-109 (4)
30-19 (11) 30-68 (11) 30-120 (16) 50-6-2 (10) 50-110 (4)
30-20 (15) 30-69 (11) 30-121 (16) 50-6-3 (6) 50-111 (12)
30-20-1 (15) 30-70 (11) 30-122 (16) 50-6-4 (13) 50-112 (4)
30-21 (11) 30-71 (11) 30-123 (16) 50-7 (13) 50-113 (12)
30-22 (11) 30-72 (11) 30-124 (16) 50-8 (6) 50-114 (7)
30-23 (11) 30-73 (11) 30-125 (16) 50-9 (6) 50-115 (12)
30-24 (11) 30-74 (11) 30-126 (16) 50-10 (13) 50-116 (4)
30-25 (11) 30-75 (11) 30-127 (16) 50-11 (10) 50-117 (12)
30-26 (11) 30-76 (11) 30-128 (16) 50-12 (14) 50-118 (4)
30-27 (11) 30-77 (11) 30-129 (16) 50-13 (14) 50-120 (12)
30-28 (11) 30-78 (11) 30-130 (16) 50-13-1 (14) 50-121 (12)
30-29 (11) 30-79 (11) 30-131 (16) 50-13-2 (14) 50-121-1 (12)
30-30 (11) 30-80 (11) 30-132 (16) 50-13-3 (14) 50-121-2 (12)
30-31 (11) 30-81 (11) 30-133 (16) 50-13-4 (14) 50-122 (12)
30-32 (11) 30-82 (11) 30-134 (16) 50-13-5 (14) 50-123 (12)
30-33 (11) 30-83 (11) 30-135 (16) 50-14 (6) 50-123-1 (12)
30-34 (11) 30-84 (11) 30-136 (16) 50-15 (3) 50-123-2 (12)
Q 30-34-1 (18) 30-85 (11) 30-137 (16) 50-16 (3) 50-124 (7)
30-35 (11) 30-86 (11) 30-138 (16) 50-17 (13) 50-124-1 (12)
30-36 (11) 30-87 (11) 30-139 (16) 50-17-1 (13) 50-124-2 (12)
30-37 (11) 30-88 (11) 30-140 (16) 50-18 (13) 50-125 (12)
00-2-4 PC78US-6
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Mark Page Mark Page Mark Page Mark Page Mark Page
number number number number number
50-126 (12) 90-23 (10)
50-127 (12) 90-23-2 (10)
50-128 (12) 90-23-4 (10)
50-129 (12) 90-25 (6)
50-130 (12) 90-27 (6)
50-131 (12) 90-29 (6)
50-132 (12) 90-31 (6)
50-132-1 (12)
50-132-2 (12)
50-132-3 (12)
50-132-4 (12)
50-132-5 (12)
50-132-6 (12)
50-132-7 (12)
50-132-8 (12)
50-132-9 (12)
50-132-10 (12)
50-133 (7)
50-134 (7)
50-135 (4)
50-135-1 (12)
50-135-2 (7)
50-135-3 (12)
50-135-4 (12)
50-136 (12)
50-137 (12)
50-137-1 (12)
50-137-2 (12)
50-138 (12)
50-139 (12)
50-140 (12)
50-141 (12)
90-1 (10)
90-3 (10)
90-3-2 (10)
90-5 (6)
90-7 (10)
90-7-2 (10)
90-7-4 (14)
90-7-6 (14)
90-7-8 (10)
90-9 (6)
90-11 (6)
90-13 (10)
90-15 (10)
90-15-2 (10)
90-15-4 (10)
90-17 (10)
90-19 (10)
90-21 (10)
PC78US-6 00-2-5
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
4
10 - 3 tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine)
5
Places where oil, water or
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
6
item. Places where oil or water
Drain m u s t b e d r a i n ed , a n d
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
! Do not hold rubber cap portion (4).
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
! The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
! For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
Sealing surface
mm mm Nm kgm
00-12
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
00-13
FOREWORD STANDARD TIGHTENING TORQUE
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
! Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
! Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Thread size Nominal thread Root diameter
Range Target (mm) size - Threads per (mm) (Reference)
inch, Thread series
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
1 Pri-
mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Green Yellow Blue & Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL —
6
Color — — — Red & Blue Yellow & White Green & Blue —
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
00-16
FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
FOREWORD CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
FOREWORD CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
01 GENERAL
PC78US-6 01-1
GENERAL SPECIFICATION DIMENSIONS DRAWING
12
SPECIFICATION DIMENSIONS DRAWING
PC78US-6
PC78US-6
Item Unit
Steel shoe spec. Road liner spec. Rubber shoe spec.
Standard spec. 6,850 6,880 6,780
Machine weight kg
Blade sped. 7,190 7,220 7,120
Bucket capacity m³ 0.28
*1 KOMATSU 4D95LE-2 Diesel engine
Engine model —
*2 KOMATSU S4D95LE-3-A Diesel engine
Rated engine output kW {HP}/rpm 40.5 {54.0}/1,850
A Overall length mm 5,770
B Overall height mm 2,730 2,750 2,730
C Overall width mm 2,330
D Shoe width mm 450
E Tail swing radius mm 1,240
F Overall length of track mm 2,840 2,900 2,880
Distance between tumbler
G mm 2,235 2,235 2,265
centers
Minimum ground clearance mm 360 400 380
Travel speed (Low/High) km/h 3.0/4.5 3.2/4.8
Continuous swing speed rpm 10.0
01-2 PC78US-6
GENERAL SPECIFICATION DIMENSIONS DRAWING
PC78UU-6
PC78UU-6
Item Unit
Road liner spec. Rubber shoe spec. Steel shoe spec.
Machine weight kg 7,700 7,600 7,670
Bucket capacity m³ 0.28
*1 KOMATSU 4D95LE-2 Diesel engine
Engine model —
*2 KOMATSU S4D95LE-3-A Diesel engine
Rated engine output kW {HP}/rpm 40.5 {54.0}/1,850
A Overall length mm 6,060
B Overall height mm 2,750 2,730 2,730
C Overall width mm 2,330
D Shoe width mm 450
E Tail swing radius mm 1,240
F Overall length of track mm 2,900 2,880 2,840
Distance between tumbler
G mm 2,235 2,265 2,235
centers
Minimum ground clearance mm 400 380 360
Travel speed (Low/High) km/h 3.0/4.5 3.2/4.8 3.0/4.5
Continuous swing speed rpm 10.0
PC78US-6 01-3
GENERAL WORKING RANGE DRAWING
01-4 PC78US-6
GENERAL SPECIFICATIONS
SPECIFICATIONS
PC78US-6
PC78US-6
Machine model
Blade-less specification Blade specification
Serial Number 4001 – 5500
Bucket capacity m3 0.28 0.28
6,850 (6,880) 7,190 (7,220)
Machine weight kg
[6,780] [7,120]
Max. digging depth mm 4,100 4,100
Max. vertical wall depth mm 3,610 3,610
Working range
Figures (steel shoe specification) are common to the all specifications unless otherwise specified.
( ) Figures in ( ): Road liner specification
[ ] Figures in [ ]: Rubber shoe specification
01-6 PC78US-6
GENERAL SPECIFICATIONS
PC78US-6
Blade-less specification Blade specification
5501 and up
0.28 0.28
6,850 (6,880) 7,190 (7,220)
[6,780] [7,120]
4,100 4,100
3,610 3,610
6,380 6,380
6,240 6,240
7,300 7,300
5,180 5,180
– 380
– 245
61.29 {6,250} 61.29 {6,250}
10.0 10.0
20.0 19.0
3.0/4.5 [3.2/4.8] 3.0/4.5 [3.2/4.8]
35 35
30.4 {0.31} 32.4 {0.33}
5,770 5,770
2,330 2,330
2,730 (2,750) 2,730 (2,750)
2,710 (2,750 [2,730] 2,710 (2,750) [2,730]
735 (780) [760] 735 (780) [760]
360 (400) [380] 360 (400) [380]
1,240 1,240
1,750 1,750
2,320 2,320
2,840 (2,900) [2,880] 2,840 (2,900) [2,880]
2,235 [2,265] 2,235 [2,265]
1,870 1,870
1,745 (1,795) [1,775] 1,745 (1,795) [1,775]
– 2,320 × 470
PC78US-6 01-7
GENERAL SPECIFICATIONS
PC78US-6
Machine model
Blade-less specification Blade specification
Serial Number 4001 – 5500
Model 4D95LE-2
Type 4-cycle, water-cooled, in-line vertical type, direct injection
No. of cylinders - bore × stroke mm 4-95 × 115
Total displacement {cc} 3.26 {3,260}
Nm/rpm 226/1,500
Max. torque {kgm/rpm} {23.0/1,500}
Engine
Battery (*1) 12 V, 48 Ah × 2
Type of radiator core CF29-3
Carrier roller 1 on each side
Undercarriage
Set pressures
*2 (Work equipment, swing, travel) MPa 26.5 {270} –
*3 (Work equipment, travel) {kg/cm2} – 26.5 {270}
*3. (Swing, blade) – 21.1 {215}
(Control) 3.1 {32} 3.1 {32}
Hydraulic system
01-8 PC78US-6
(13)
GENERAL SPECIFICATIONS
PC78US-6 PC78US-6
Blade-less specification Blade specification Blade-less specification Blade specification
6501 and up 5501 – 6500
S4D95LE-3-A S4D95LE-3-A
4-cycle, water-cooled, in-line vertical type, 4-cycle, water-cooled, in-line vertical type,
direct injection, with turbocharger direct injection, with turbocharger
4-95 × 115 4-95 × 115
3.26 {3,260} 3.26 {3,260}
40.5/1,850 40.5/1,850
{54.0/1,850} {54.0/1,850}
237/1,500 237/1,500
{24.2/1,500} {24.2/1,500}
2,020 2,020
1,130 1,130
227 {169} 227 {169}
24 V, 3.0 kw 24 V, 3.0 kw
24 V, 25 A 24 V, 25 A
12 V, 48 Ah × 2 12 V, 48 Ah × 2
ALW-4 CF29-3
1 on each side 1 on each side
5 on each side 5 on each side
Assembly-type triple grouser, 39 on each side Assembly-type triple grouser, 39 on each side
Assembly-type road liner, 39 on each side Assembly-type road liner, 39 on each side
Unit-type rubber crawler Unit-type rubber crawler
Variable-capacity piston pump Variable-capacity piston pump Variable-capacity piston pump Variable-capacity piston pump
×1 ×1 ×1 ×1
Gear pump × 1 Gear pump × 2 Gear pump × 1 Gear pump × 2
80× 2+12.7 80× 2+60+12.7 80× 2+12.7 80× 2+60+12.7
PC78US-6 01-9
(13)
GENERAL SPECIFICATIONS
PC78US-6
Machine model
Blade-less specification Blade specification
Serial Number 4001 – 5500
Type Reciprocating piston Reciprocating piston
Boom cylinder
01-10 PC78US-6
GENERAL SPECIFICATIONS
PC78US-6
Blade-less specification Blade specification
5501 and up
Reciprocating piston Reciprocating piston
ø 115 ø 115
ø 65 ø 65
858 858
2,143 2,143
1,285 1,285
Reciprocating piston Reciprocating piston
ø 100 ø 100
ø 60 ø 60
865 865
2,193 2,193
1,328 1,328
Reciprocating piston Reciprocating piston
ø 90 ø 90
ø 55 ø 55
710 710
1,765 1,765
1,055 1,055
– Reciprocating piston
– ø 130
– ø 65
– 130
– 679
– 549
PC78US-6 01-11
GENERAL SPECIFICATIONS
PC78UU-6
PC78UU-6
Machine model
—
Serial Number 22832 – 23500
Bucket capacity m3 0.28
Machine weight kg 7,700 (7,600) [7,670]
Max. digging depth mm 4,200
Max. vertical wall depth mm 3,160
Max. digging reach mm 6,400
Working range
Figures (Road liner specification) are common to the all specifications unless otherwise specified.
( ) Figures in ( ): Rubber shoe specification
[ ] Figures in [ ]: Steel shoe specification
01-12 PC78US-6
GENERAL SPECIFICATIONS
PC78UU-6
—
23501 and up
0.28
7,700 (7,600) [7,670]
4,200
3,160
6,400
6,240
7,360
5,290
1,030/1,065
415
210
61.3 {6,250}
10.0
13.0
3.0/4.5 (3.2/4.8)
35
34.3 {0.35}
6,060
2,330
2,750 (2,730) [2,730]
2,750 (2,730) [2,710]
780 (760) [735]
400 (380) [360]
1,240
1,200
2,320
2,900 (2,880) [2,840]
2,235 (2,265)
1,870
1,795 (1,775) [1,745]
2,320 x 470
PC78US-6 01-13
GENERAL SPECIFICATIONS
PC78UU-6
Machine model
—
Serial Number 22832 – 23500
Model 4D95LE-2
Type 4-cycle, water-cooled, in-line vertical type, direct injection
No. of cylinders - bore × stroke mm 4–95 × 115
Total displacement {cc} 3.260 {3,260}
Nm/rpm 226/1,500
Max. torque {kgm/rpm} {23.0/1,500}
Engine
01-14 PC78US-6
(13)
GENERAL SPECIFICATIONS
PC78UU-6
—
23501 and up
S4D95LE-3-A
4-cycle, water-cooled, in-line vertical type,
direct injection, with turbocharger
4–95 × 115
3.260 {3,260}
40.5/1,850
{54.0/1,850}
237/1,500
{24.2/1,500}
2,020
1,130
227 {169}
24 V, 3.0 kw
24 V, 25 A
12 V, 48 Ah × 2
CF29-3
1 on each side
5 on each side
26.5 {270}
21.1 {215}
3.1 {32}
8-spool type × 1
Hydraulically assisted
Box-shaped, open
Tank return side
Air-cooled (CF40-1)
PC78US-6 01-15
(13)
GENERAL SPECIFICATIONS
PC78UU-6
Machine model
—
Serial Number 22832 – 23500
Type Reciprocating piston
Boom cylinder
Bucket cylinder
01-16 PC78US-6
GENERAL SPECIFICATIONS
PC78UU-6
—
23501 and up
Reciprocating piston
ø 120
ø 70
1,015
2,436.5
1,421.5
Reciprocating piston
ø 110
ø 65
715
955
240
Reciprocating piston
ø 90
ø 55
710
1,765
1,055
Reciprocating piston
ø 110
ø 55
350
1,500
1,150
Reciprocating piston
ø 130
ø 65
130
679
549
PC78US-6 01-17