Komatsu PC78UU-6 Shop Manual
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Komatsu PC78UU-6 Shop Manual

Komatsu PC78UU-6 Shop Manual

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MACHINE MODEL
PC78UU-6
PC78US-6
PC78US-6
• 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)
SERIAL NUMBER
22832 and up
4001 and up
4809 and up (For Norway & EU)
SEBM025118
00-1
(18)

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  • Page 1 4809 and up (For Norway & EU) • 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.
  • Page 2 CONTENTS No. of page GENERAL..........01-1 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD .
  • Page 3 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 Page to be newly added Add table below. Page to be replaced Replace Page to be deleted Discard...
  • Page 4 Revision Revision Revision Revision Revision Mark Page Mark Page Mark Page Mark Page Mark Page number number number number number 10-162 (10) 10-215 (10) 10-268 (10) 20-117 (18) 20-218-5 (12) 10-163 (10) 10-216 (10) 10-269 (10) 20-118 (18) 20-218-6 (12) 10-164 (10) 10-217...
  • Page 5 Revision Revision Revision Revision Revision Mark Page Mark Page Mark Page Mark Page Mark Page number number number number number 20-253 (12) 20-342 (12) 20-368 (12) 20-432 20-478 20-253-1 (13) 20-343 (12) 20-369 (12) 20-433 20-479 20-253-2 (13) 20-343-1 (12) 20-370 (12) 20-434...
  • Page 6 Revision Revision Revision Revision Revision Mark Page Mark Page Mark Page Mark Page Mark Page 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...
  • Page 7 Revision Revision Revision Revision Revision 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 50-130 (12) 90-27 50-131 (12) 90-29 50-132 (12)
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  • Page 10: Important 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.

  • Page 11: Safety Notice

    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 •...
  • Page 12 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.

  • Page 13: How To Read The Shop Manual

    DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be Symbol Item Remarks sent to KOMATSU distributors. Get the most up-to- date information before you start any work. Special safety precautions Safety are necessary when per- forming the work.

  • Page 14: Hoisting Instructions

    FOREWORD HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS HOISTING k Heavy parts (25 kg or more) must be lifted Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have max- with a hoist, etc.
  • Page 15 FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER k Before carrying out the following work, release Type 1 the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.
  • Page 16 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.

  • Page 17: 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 •...
  • Page 18 FOREWORD COATING MATERIALS Category Komatsu code Part No. Q’ty Container Main applications, features • Used as lubricant for sliding portion (to LM-G 09940-00051 60 g prevent from squeaking). Molybdenum • Used to prevent seizure or scuffling of the disulphide thread when press fitting or shrink fitting.

  • Page 19: Standard Tightening Torque

    FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ! In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter Width across...
  • Page 20 FOREWORD STANDARD TIGHTENING TORQUE TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ! In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter Width across flat Tightening torque 59 –...
  • Page 21 FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter Tightening torque 10 ± 2 1.02 ± 0.20 24 ± 4 2.45 ±...
  • Page 22 FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe. CLASSIFICATION BY THICKNESS Copper wire Current...

  • Page 23: Conversion Table

    FOREWORD CONVERSION TABLE CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE •...
  • Page 24 FOREWORD CONVERSION TABLE Millimeters to Inches 1 mm = 0.03937 in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260...
  • Page 25 FOREWORD CONVERSION TABLE Liter to U.S. Gallon 1l = 0.2642 U.S. Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189...
  • Page 26 FOREWORD CONVERSION TABLE kgm to ft. lb 1 kgm = 7.233 ft. lb 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2...
  • Page 27 FOREWORD CONVERSION TABLE kg/cm to lb/in 1kg/cm = 14.2233 lb/in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
  • Page 28 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.
  • Page 29 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/cm kPa {mmH kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}...
  • Page 30 01 GENERAL Specifiaction dimensions drawing ....01- 2 Working range drawing ......... 01- 4 Specifications ..........01- 6 Weight table ........... 01-18 List of lubricants and coolant ......01-22 01-1 PC78US-6...
  • Page 31 Standard spec. 6,850 6,880 6,780 Machine weight Blade sped. 7,190 7,220 7,120 Bucket capacity m³ 0.28 KOMATSU 4D95LE-2 Diesel engine Engine model — KOMATSU S4D95LE-3-A Diesel engine Rated engine output kW {HP}/rpm 40.5 {54.0}/1,850 Overall length 5,770 Overall height 2,730 2,750...
  • Page 32 Road liner spec. Rubber shoe spec. Steel shoe spec. Machine weight 7,700 7,600 7,670 Bucket capacity m³ 0.28 KOMATSU 4D95LE-2 Diesel engine Engine model — KOMATSU S4D95LE-3-A Diesel engine Rated engine output kW {HP}/rpm 40.5 {54.0}/1,850 Overall length 6,060 Overall height...
  • Page 33 GENERAL WORKING RANGE DRAWING WORKING RANGE DRAWING Working range (mm) PC78US-6 PC78UU-6 Max. digging reach 6,380 6,400 Max. digging depth 4,100 4,200 Max. digging height 7,300 7,360 Max. vertical wall depth 3,610 3,160 Max. dumping height 5,180 5,290 Min. swing radius of work...

  • Page 34: Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS PC78US-6 PC78US-6 Machine model Blade-less specification Blade specification Serial Number 4001 – 5500 Bucket capacity 0.28 0.28 6,850 (6,880) 7,190 (7,220) Machine weight [6,780] [7,120] Max. digging depth 4,100 4,100 Max. vertical wall depth 3,610 3,610 Max. digging reach 6,380 6,380 Max.
  • Page 35 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 – – 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] 30.4 {0.31}...
  • Page 36 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 4-95 × 115 Total displacement 3.26 {3,260} {cc} kW/rpm 40.5/1,850 Rated output {HP/rpm}...
  • Page 37 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 ×...
  • Page 38 GENERAL SPECIFICATIONS PC78US-6 Machine model Blade-less specification Blade specification Serial Number 4001 – 5500 Type Reciprocating piston Reciprocating piston ø ø Inside diameter of cylinder ø ø Diameter of piston rod Stroke Max. distance between pins 2,143 2,143 Min. distance between pins 1,285 1,285 Type...
  • Page 39 GENERAL SPECIFICATIONS PC78US-6 Blade-less specification Blade specification 5501 and up Reciprocating piston Reciprocating piston ø ø ø ø 2,143 2,143 1,285 1,285 Reciprocating piston Reciprocating piston ø ø ø ø 2,193 2,193 1,328 1,328 Reciprocating piston Reciprocating piston ø ø ø...
  • Page 40 GENERAL SPECIFICATIONS PC78UU-6 PC78UU-6 Machine model — Serial Number 22832 – 23500 Bucket capacity 0.28 Machine weight 7,700 (7,600) [7,670] Max. digging depth 4,200 Max. vertical wall depth 3,160 Max. digging reach 6,400 Max. reach at ground level 6,240 Max. digging height 7,360 Max.
  • Page 41 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 61.3 {6,250} 10.0 13.0 3.0/4.5 (3.2/4.8) 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]...
  • Page 42 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 4–95 × 115 Total displacement 3.260 {3,260} {cc} kW/rpm 40.5/1,850 Rated output {HP/rpm} {54.0/1,850}...
  • Page 43 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...
  • Page 44 GENERAL SPECIFICATIONS PC78UU-6 Machine model — Serial Number 22832 – 23500 Type Reciprocating piston ø Inside diameter of cylinder ø Diameter of piston rod Stroke 1,015 Max. distance between pins 2,436.5 Min. distance between pins 1,421.5 Type Reciprocating piston ø...
  • Page 45 GENERAL SPECIFICATIONS PC78UU-6 — 23501 and up Reciprocating piston ø ø 1,015 2,436.5 1,421.5 Reciprocating piston ø ø Reciprocating piston ø ø 1,765 1,055 Reciprocating piston ø ø 1,500 1,150 Reciprocating piston ø ø 01-17 PC78US-6...
  • Page 46 GENERAL WEIGHT TABLE WEIGHT TABLE k This mass list is for reference in handling or transporting these components. PC78US-6 PC78UU-6 Machine model Blade-less specification Blade specification — Serial Number 4001 – 5500 22832 – 23500 Engine assembly (without water and oil) •...
  • Page 47 19 x 2 19 x 2 19 x 2 19 x 2 *1. PC78UU-6 (Serial No.: 23501 – 24066) *2. PC78UU-6 (Serial No.: 24067 and up) *3. PC78UU-6 (Serial No.: 23501 – 24085) *4. PC78UU-6 (Serial No.: 24086 and up)
  • Page 48 GENERAL WEIGHT TABLE PC78US-6 PC78UU-6 Machine model Blade-less specification Blade specification — Serial Number 4001 – 5500 22832 – 23500 Track shoe assembly • City pad shoe (450 mm) 410 X 2 410 X 2 410 X 2 • Road liner (450 mm)
  • Page 49 GENERAL WEIGHT TABLE Unit: kg PC78US-6 PC78US-6 PC78UU-6 Blade-less specification Blade specification Blade-less specification Blade specification — 5501 – 6500 6501 and up 23501 and up 410 X 2 410 X 2 410 X 2 410 X 2 410 X 2...
  • Page 50 ASTM D975 No. 1 Grease Greasing system NLGI No. 2 Cooling system Coolant Add antifreeze Unit: l PC78US-6 PC78UU-6 Reservoir Specified capacity Refill capacity Specified capacity Refill capacity Engine oil pan PTO gear case Swing machinery case Final drive case (each)
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