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HYDRAULIC EXCAVATOR
PC78US-8
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PC78US-8
Shop Manual
40 Troubleshooting
200 General Information on troubleshoot-
ing
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The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry to 4) Other maintenance items can be checked
disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
after any failure occurs:
Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or as
It will become impossible to find the cause of a problem with the method of operation, etc.
the failure. When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. For this make the problem worse.
reason, when carrying out troubleshooting, it is
necessary to carry out thorough prior investiga- 5. Troubleshooting
tion and to carry out troubleshooting in accor- Use the results of the investigation and inspec-
dance with the fixed procedure. tion in Items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or
2. Points to ask user or operator troubleshooting flowchart to locate the position
1) Have any other problems occurred apart of the failure exactly.
from the problem that has been reported? The basic procedure for troubleshooting is as
2) Was there anything strange about the follows.
machine before the failure occurred? 1] To start from the simple points.
3) Did the failure occur suddenly, or were there 2] To start from the most likely points.
problems with the machine condition before 3] Inspect other related parts or information.
this?
4) Under what conditions did the failure occur? 6. Measures to remove root cause of failure
5) Had any repairs been carried out before the Even if the failure is repaired, if the root cause of
failure? When were these repairs carried the failure is not repaired, the same failure will
out? occur again.To prevent this, always investigate
6) Has the same kind of failure occurred why the problem occurred. Then, remove the
before? root cause.
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1. Procedure for troubleshooting to be taken when user code and failure code are displayed on
machine monitor:
If a user code and a failure code are displayed on the machine monitor, carry out the troubleshooting for
the corresponding "Display of code" according to the displayed failure code.
2. When electrical system failure code or mechanical system failure code is recorded in abnormality
record:
If a user code and a failure code are not displaye d on the machine monitor, check a mechanical system
failure code and an electrical system failure code with the abnormality record function of the machine
monitor.
If a code is recorded, carry out troubleshooting for the corresponding " Display of code" according to the
recorded code.
If an electrical system failure code is recorded, delete all the codes and reproduce them, and then see
if the trouble is still detected.
A failure code of the mechanical system cannot be deleted.
If a trouble is displayed in the air conditioner abnormality record or heater abnormality record by the
abnormality record function, carry out the corresponding troubleshooting in E-mode.
3. When user code and failure code is not displayed and no failure code is recorded in abnormality
record:
If a user code and failure code are not displayed on the machine monitor and no failure code is recorded
in the abnormality record, a trouble that the machine cannot find out by itself may have occurred in the
electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble-
shooting corresponding to that phenomenon in the "E-mode", "H-mode", or "S-mode.
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Troubleshooting
No. Phenomena looking like troubles Display
E-mode H-mode S-mode
of code
34 Work equipment does not move in its single operation H-10
35 Hydraulic drift of work equipment is large H-11
36 Time lag of work equipment is large H-12
Flow rate in attachment circuit cannot be adjusted (when attachment
37 H-27
is installed)
Phenomena related to compound operation
38 Work equipment loaded more is slower during compound operation H-13
Boom RAISE speed is low in compound operation of swing + boom
39 H-14
RAISE
Travel speed lowers largely during compound operation of work
40 H-15
equipment/swing + travel
Phenomena related to travel
41 Machine deviates during travel H-16
42 Travel speed is low H-17
43 Machine cannot be steered easily or steering power is low H-18
44 Travel speed does not change or it is kept low or high E-16 H-19
45 Track does not move (Only either side) H-20
46 Travel alarm does not sound or does not stop sounding E-20
Phenomena related to swing
47 Machine does not swing H-21
48 Swing acceleration or swing speed is low H-22
49 Excessive overrun when stopping swing H-23
50 When upper structure stops swinging, it makes large shock H-24
51 When upper structure stops swinging, it makes large sound H-25
Swing holding brake does not operate normally
52 E-19 H-26
Hydraulic drift of swing is large
Phenomena related to machine monitor
53 When starting switch is turned ON, machine monitor displays nothing E-1
54 Precaution lights up while engine is running E-6
55 Emergency stop item lights up while engine is running E-7
56 Engine coolant temperature gauge does not indicate normally E-8
57 Hydraulic oil temperature gauge does not indicate normally E-9
58 Fuel level gauge does not indicate normally E-10
Contents of display by machine monitor are different from applicable
59 E-11
machine
60 Machine monitor does not display some items E-12
61 Function switch does not work E-13
62 Alarm buzzer cannot be stopped E-17
63 Windshield wiper and window washer do not operate E-18
Air conditioner does not operate normally (including air conditioner
64 E-21
abnormality record)
65 While starting switch is in OFF position, service meter is not displayed E-22
66 Machine monitor cannot be set in service mode E-23
67 Monitoring function does not display lever control signal normally E-24
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Troubleshooting
No. Phenomena looking like troubles Display
E-mode H-mode S-mode
of code
Other phenomena
68 KOMTRAX system does not operate normally E-25
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Identification
Part No. Part name
symbol
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T-adapter kit
Identification
Part No. Part name
symbol
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T-adapter kit
Identification
Part No. Part name
symbol
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©2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09
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