Komatsu HYDRAULIC EXCAVATOR PC78US-10 Shop Manual SEN06518-09 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC78US-10 Shop Manual SEN06518-09 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC78US-10 Shop Manual SEN06518-09 – PDF DOWNLOAD

Language : English
Pages :1924
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC78US-10 Shop Manual SEN06518-09 – PDF DOWNLOAD

SERIAL NUMBERS 30001 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the
same as the terminology in the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
How to Read the Shop Manual 00 Index and Foreword
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC78US-10 Shop Manual SEN06518-09 – PDF DOWNLOAD

SERIAL NUMBERS 30001 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 16
Foreword, Safety, Basic Information 22
How to Read the Shop Manual 22
Safety Notice for Operation 24
Precautions to Prevent Fire 32
Procedures If Fire Occurs 34
Precautions When You Discard Waste Materials 35
Precautions When You Handle Hydraulic Equipment 36
Precautions When You Disconnect and Connect Pipings 39
Precautions When You Handle Electrical Equipment 46
Precautions When You Handle Fuel System Equipment 48
Precautions When You Handle Intake System Equipment 49
Practical Use of KOMTRAX 50
Disconnect and Connect Push-Pull Type Coupler 51
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 51
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 52
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 53
Precautions for Disconnection and Connection of Connectors 55
Disconnect and Connect Deutsch Connector 59
How to Disconnect and Connect Slide Lock Type Connector 60
Disconnect and Connect Connector with Lock to Pull 62
Disconnect and Connect Connector with Lock to Push 63
Disconnect and Connect Connector with Housing to Rotate 65
How to Read the Codes for Electric Cable 66
Explanation of Terms for Maintenance Standard 70
Standard Tightening Torque Table 73
Conversion Table 80
01 Specification 85
Table of Contents 86
Abbreviation List 87
Specifications 93
Specification Drawing 93
Specification Drawing: PC78US-10 93
Working Range Drawings 96
Working Range: PC78US-10 96
Specifications 97
Specifications: PC78US-10 97
Weight Table 101
Weight Table: PC78US-10 101
Table of Fuel, Coolant, and Lubricants 103
10 Structure and Function 105
Table of Contents 106
Abbreviation List 109
Boot-up System 115
Layout Drawing of Boot-up System 115
System Operating Lamp System 116
System Diagram of System Operating Lamp System 116
Function of Operation Lamp System 116
Battery Disconnect Switch 117
Function of Battery Disconnect Switch 117
Engine System 119
Layout Drawing of Engine System 119
Engine Control System 121
System Diagram of Engine Control 121
Function of Engine Control System 122
Auto-Deceleration System 124
System Diagram of Auto-Deceleration System 124
Function of Auto-Deceleration System 124
Operation of Auto-Deceleration System 125
Engine Automatic Warm-up System 126
System Diagram of Engine Automatic Warm-up System 126
Function of Engine Automatic Warm-up System 127
Overheat Prevention System 128
Function of Overheat Prevention System 128
Turbocharger Protection System 129
Function of Turbocharger Protection System 129
Automatic Idle Stop System 130
System Diagram of Automatic Idle Stop System 130
Function of Automatic Idle Stop System 130
Component Parts of Engine System 133
PTO 133
Variable Flow Turbocharger 133
EGR System 137
EGR Valve 139
EGR Cooler 140
KCCV System 142
KCCV Ventilator 144
KDOC 146
Cooling System 148
Layout Drawing of Cooling System 148
Specifications of Cooling System 149
Control System 151
Layout Drawing of Control System 151
Machine Monitor System 153
System Diagram of Machine Monitor System 153
KOMTRAX System 154
System Diagram of KOMTRAX System 154
Function of KOMTRAX System 154
Component Parts of Control System 155
Machine Monitor 155
KOMTRAX Terminal 166
Pump Controller 168
Resistor for PC-EPC Valve 172
CAN Terminating Resistor 172
Engine Controller 174
Fuel Control Dial 179
Hydraulic System 182
Layout Drawing of Hydraulic System 182
CLSS 185
Structure of CLSS 185
Function of CLSS 186
Engine and Pump Combined Control System 188
Engine and Pump Combined Control System Diagram 188
Function of Engine and Pump Combined Control System 189
Component Parts of Hydraulic System 192
Hydraulic Tank 193
Main Pump 195
Control Valve 206
Work Equipment System 260
Layout Drawing of Work Equipment System 260
Structure of Valve Control 263
PPC Lock System 265
System Diagram of PPC Lock 265
Function of PPC Lock System 265
Work Equipment and Travel Automatic Lock System 266
System Diagram of Lock Lever Automatic Lock System 266
Function of Work Equipment and Travel Automatic Lock System 266
Operation of Lock Lever Automatic Lock System 267
Overload Caution System 268
Overload Caution System Diagram 268
Function of Overload Caution System 269
Attachment Oil Flow Adjuster System 270
Attachment Oil Flow Adjuster System Diagram 270
Function of Attachment Oil Flow Adjuster System 270
Component Parts of Work Equipment System 271
Work Equipment and Swing PPC Valve 271
1st-Line Attachment PPC Valve (with EPC Valve) 275
Blade PPC Valve 281
Solenoid Valve 283
Boom Anti-drop Valve 285
Arm Anti-Drop Valve 290
Multi-Control Valve 295
Pilot Circuit Accumulator 297
Attachment Circuit Accumulator (For Low Pressure Circuit) 298
Swing System 299
Layout Drawing of Swing System 299
Swing Control System Diagram 302
Function of Swing Control System 302
Component Parts of Swing System 304
Swing Motor 304
Swing Machinery 312
Swing Circle 314
Travel System 316
Layout Drawing of Travel System 316
System Diagram of Travel Control System 318
Function of Travel Control System 318
Component Parts of Travel System 320
Travel Motor 320
Travel PPC Valve 330
Center Swivel Joint 335
Undercarriage and Frame 336
Layout Drawing of Undercarriage 336
Specifications of Undercarriage 336
Idler Cushion 338
Structure of Idler Cushion 338
Specifications of Idler Cushion 338
Work Equipment 339
Structure of Work Equipment 339
Function of Work Equipment 340
Work Equipment Clearance Adjustment Shim 341
Function of Work Equipment Clearance Adjustment Shim 341
Bucket Clearance Adjustment Shim 342
Function of Bucket Clearance Adjustment Shim 342
CAB Related Parts 343
ROPS CAB 343
Structure of ROPS CAB 343
Function of ROPS CAB 343
CAB Mount 344
Structure of CAB Mount 344
Function of CAB Mount 345
Remove Wiring Harness Out of Cab 346
20 Standard Value Table 347
Table of Contents 348
Abbreviation List 349
Standard Value Table for Engine 355
Standard Value Table for Engine: PC78US-10 355
Standard Value Table for Machine 358
Standard Value Table for Machine: PC78US-10 358
Machine Posture and Procedures to Measure Performance 372
Standard Value Table for Electricity 375
Standard Value Table for Electricity 375
30 Testing and Adjusting 381
Table of Contents 382
Precautions Before Work 385
Abbreviation List 386
Related Information on Testing and Adjusting 392
Tools for Testing and Adjusting 392
Sketch of Tools for Testing and Adjusting 397
Engine and Cooling System 399
Examine Engine Speed 399
How to Examine Engine Speed 399
Examine Exhaust Gas Color 403
How to Examine Exhaust Gas Color with the Handy Smoke Checker 403
How to Examine Exhaust Gas Color with Smoke Meter 403
Examine and Adjust Valve Clearance 405
Check Valve Clearance 405
Adjust Valve Clearance 406
Examine Compression Pressure 407
How to Examine Compression Pressure 407
Examine Blowby Pressure 410
How to Examine Blowby Pressure 410
Examine Engine Oil Pressure 412
How to Examine Engine Oil Pressure 412
Visual Check Inside of EGR Valve 414
How to do the Visual Check Inside of EGR Valve 414
Clean Inside of EGR Valve 416
How to Clean Inside of EGR Valve 416
Examine Fuel Pressure 419
How to Examine Fuel Pressure 419
Examine Fuel Return Rate and Leakage 421
How to Examine Fuel Return Rate and Leakage 422
Bleed Air from Fuel System 425
How to Bleed Air from Fuel System 425
Examine Fuel Circuit for Leakage 427
How to Examine Fuel System for Leakage 427
Handle Cylinder Cut-out Mode Operation 429
Handle No-Injection Cranking Operation 430
Examine and Adjust Air Conditioner Compressor Belt Tension 431
How to Examine Air Conditioner Compressor Belt Tension 431
How to Adjust Air Conditioner Compressor Belt Tension 431
Examine Alternator Belt 432
How to Examine Alternator Belt 432
Examine Automatic Tensioner 433
How to Examine Automatic Tensioner 433
Write Injector Compensation Value to Engine Controller 435
Write Injector Compensation Value 435
Power Train 441
Examine Swing Circle Bearing Clearance 441
How to Examine Swing Circle Bearing Clearance 441
Undercarriage and Frame 442
Examine and Adjust Track Tension 442
How to Examine Track Tension 442
How to Adjust Track Tension 442
Hydraulic System 444
Release Remained Pressure in Hydraulic Circuit 444
How to Release Remained Pressure from Hydraulic Tank 444
How to Release Remained Pressure in Hydraulic Cylinder Circuit 444
How to Release Remained Pressure from Swing Motor Circuit 447
How to Release Remained Pressure from Travel Motor Circuit 447
Examine and Adjust Oil Pressure in Work Equipment and Travel Circuits 448
Examine Oil Pressure in Work Equipment and Travel Circuits 448
Adjust Oil Pressure in Work Equipment and Travel Circuits 454
Examine and Adjust Swing and Blade Circuit Oil Pressure 456
How to Examine Swing and Blade Relief Pressure 456
How to Adjust Swing Relief Pressure 457
Adjust Blade LOWER Relief Pressure 458
Adjust Blade RAISE Relief Pressure 458
Examine Oil Pressure of Control Circuit 460
Examine Oil Pressure in Control Circuit 460
Examine and adjust oil pressure in pump PC control circuit 462
How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 462
How to Examine PC-EPC Valve Outlet Pressure 464
How to Adjust Oil Pressure in Pump PC Control Circuit 464
Examine and Adjust Oil Pressure in Pump LS Control Circuit 467
Examine LS Differential Pressure with Machine Monitor 467
Examine LS Differential Pressure by Testing Tool 468
Adjust LS Valve 470
Examine Outlet Pressure of Solenoid Valve 471
How to Examine Outlet Pressure of Solenoid Valve 471
Operating Condition of Solenoid Valve 473
Examine PPC Valve Outlet Pressure 474
Examine Outlet Pressure in PPC Valve 474
Adjust Play of Work Equipment and Swing PPC Valves 476
How to Adjust Play of Work Equipment and Swing PPC Valves 476
Examine and Adjust Travel Deviation 477
How to Examine Travel Deviation 477
Adjust Travel Deviation 477
Examine Parts Which Cause Hydraulic Drift of Work Equipment 480
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 480
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 480
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 481
Examine Oil Leakage 482
How to Examine Oil Leakage from Boom Cylinder 482
How to Examine Oil Leakage from Arm Cylinder 482
How to Examine Oil Leakage from Bucket Cylinder 483
How to Examine Oil Leakage from Blade Cylinder 483
How to Examine Oil Leakage from Swing Motor 484
How to Examine Oil Leakage from Travel Motor 484
Bleed Air from Hydraulic System 486
How to Bleed Air from Hydraulic System 488
CAB Related Parts 491
How to Adjust Mirrors 491
Procedure to Adjust Machine Left Front Mirror (A) 491
Procedure to Adjust Machine Rear Mirror (B) 492
Examine and Adjust Engine Hood Catcher 493
How to Examine Engine Hood Catcher 493
How to Adjust Engine Hood Catcher 493
How to Examine and Adjust Slide Door 496
How to Examine and Adjust Slide Door When It is Closed and Locked 496
How to Examine and Adjust Slide Door When It is Open and Locked 508
Electrical System 521
Set and Operate Machine Monitor 521
Operator Mode 524
Function to Show Technician Identification Status Screen 524
Function to Show Operator Identification Input Screen 524
Examine Function by LCD (Liquid Crystal Display) 525
Examine Function of Service Meter 526
Usage Limitation and Maintenance Password Change Function 526
Service Mode 528
How to Operate Service Mode 528
How to See Pre-defined Monitoring Information 530
How to Examine Self-Define Monitor Information 534
Abnormality Record Menu 540
How to See Maintenance Record 545
Maintenance Mode Setting 546
Set Phone Number Entry 549
Default Menu 550
Diagnostic Tests Menu 556
Adjustment Menu 559
No-Injection Cranking Operation 561
KOMTRAX Settings Menu 562
Show Service Message 564
How to Start Up KOMTRAX Terminal 566
Adjust Rearview Camera Angle 571
How to Adjust Rearview Camera Angle 571
Adjust Rightview Camera Angle 574
Adjust Right View Camera Angle 574
Handle Voltage Circuit of Engine Controller 577
Handle Battery Disconnect Switch 578
Examine Diodes 579
Examine Diodes by Digital Tester 579
How to Examine Diodes by Analog Tester 579
Pm Clinic 580
Pm Clinic Service 580
Pm Clinic Check Sheet: PC78US-10 582
40 Troubleshooting 593
Table of Contents 594
Precautions Before Work 600
Abbreviation List 601
Related Information to Troubleshooting 607
General Troubleshooting Points 607
Sequence of Events in Troubleshooting 608
Checks Before Troubleshooting 610
Inspection Procedure Before Troubleshooting 612
Walk-Around Check 612
Test in Accordance with Testing Procedure 614
Examine Fuel Level and Type 614
Examine Fuel Prefilter 615
Examine Water Separator, Drain Water and Sediment 615
How to Replace Fuel Prefilter Cartridge 616
Examine Fuel Main Filter 617
Examine Engine Oil Level (Oil Quantity in Oil Pan) 619
Examine Oil Level in PTO Gear Case 620
Examine Coolant Level (Reservoir Tank) 621
Examine Air Cleaner Clogging 622
Clean Outer Element 622
Replace Element 624
Examine Hydraulic Oil Level 625
Examine Hydraulic Oil Strainer 627
Examine Hydraulic Oil Filter 628
Examine Oil Level in Swing Machinery Case 629
Examine Oil Level in Final Drive Case 629
Bleed Air from Fuel System 630
Bleed Air from Hydraulic System 630
How to Examine Electric Equipment 630
Preparation for Troubleshooting of Electrical System 638
Procedure for Troubleshooting 645
Symptom and Troubleshooting Numbers 648
Information Shown in Troubleshooting Table 652
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 654
Connector List and Layout 656
Connector Contact Connection Table 668
T-Branch Box and T-Branch Adapter Table 708
Fuse Location Table 714
Failure Code Table 716
Troubleshooting by Failure Code (Display of Code) 724
Failure Code [879AKA] 724
Failure Code [879AKB] 726
Failure Code [879BKA] 727
Failure Code [879BKB] 729
Failure Code [879CKA] 731
Failure Code [879CKB] 732
Failure Code [879DKZ] 733
Failure Code [879EMC] 735
Failure Code [879FMC] 736
Failure Code [879GKX] 737
Failure Code [989L00] 739
Failure Code [989M00] 740
Failure Code [989N00] 741
Failure Code [A900FR] 742
Failure Code [A900N6] 743
Failure Code [A900NY] 744
Failure Code [AB00KE] 745
Failure Code [B@BAZG] 747
Failure Code [B@BCNS] 748
Failure Code [B@HANS] 749
Failure Code [CA115] 751
Failure Code [CA122] 752
Failure Code [CA123] 754
Failure Code [CA131] 756
Failure Code [CA132] 758
Failure Code [CA144] 760
Failure Code [CA145] 762
Failure Code [CA153] 764
Failure Code [CA154] 766
Failure Code [CA187] 768
Failure Code [CA221] 770
Failure Code [CA222] 772
Failure Code [CA227] 774
Failure Code [CA234] 775
Failure Code [CA238] 776
Failure Code [CA239] 778
Failure Code [CA271] 780
Failure Code [CA272] 782
Failure Code [CA322] 783
Failure Code [CA324] 785
Failure Code [CA331] 787
Failure Code [CA332] 789
Failure Code [CA343] 791
Failure Code [CA351] 792
Failure Code [CA352] 793
Failure Code [CA356] 795
Failure Code [CA357] 797
Failure Code [CA386] 799
Failure Code [CA435] 800
Failure Code [CA441] 802
Failure Code [CA442] 804
Failure Code [CA449] 805
Failure Code [CA451] 806
Failure Code [CA452] 808
Failure Code [CA466] 810
Failure Code [CA515] 812
Failure Code [CA516] 814
Failure Code [CA553] 816
Failure Code [CA555] 817
Failure Code [CA556] 818
Failure Code [CA559] 819
Failure Code [CA689] 823
Failure Code [CA691] 825
Failure Code [CA692] 827
Failure Code [CA697] 829
Failure Code [CA698] 830
Failure Code [CA731] 831
Failure Code [CA778] 833
Failure Code [CA1117] 835
Failure Code [CA1695] 836
Failure Code [CA1696] 837
Failure Code [CA1843] 838
Failure Code [CA1844] 840
Failure Code [CA1896] 842
Failure Code [CA1942] 846
Failure Code [CA1961] 847
Failure Code [CA2185] 848
Failure Code [CA2186] 849
Failure Code [CA2249] 851
Failure Code [CA2272] 852
Failure Code [CA2311] 855
Failure Code [CA2349] 856
Failure Code [CA2353] 858
Failure Code [CA2357] 860
Failure Code [CA2765] 861
Failure Code [CA3419] 862
Failure Code [CA3421] 864
Failure Code [CA3724] 866
Failure Code [CA3918] 868
Failure Code [CA3919] 869
Failure Code [CA3921] 870
Failure Code [CA3922] 871
Failure Code [CA3923] 873
Failure Code [D110KB] 875
Failure Code [D19JKZ] 877
Failure Code [D811MC] 880
Failure Code [D862KA] 881
Failure Code [D8ALKA] 882
Failure Code [D8ALKB] 884
Failure Code [D8AQKR] 886
Failure Code [DA20MC] 888
Failure Code [DA22KK] 889
Failure Code [DA25KP] 892
Failure Code [DA26KP] 895
Failure Code [DA29KQ] 897
Failure Code [DA2LKA] 899
Failure Code [DA2LKB] 901
Failure Code [DA2QKR] 903
Failure Code [DA2RKR] 905
Failure Code [DAF0MB] 906
Failure Code [DAF0MC] 907
Failure Code [DAF8KB] 908
Failure Code [DAF8KB] 910
Failure Code [DAF9KQ] 912
Failure Code [DAFGMC] 913
Failure Code [DAFLKA] 914
Failure Code [DAFLKB] 916
Failure Code [DAFQKR] 917
Failure Code [DAZ9KQ] 918
Failure Code [DAZQKR] 919
Failure Code [DB2QKR] 924
Failure Code [DB2RKR] 929
Failure Code [DDNRKA] 934
Failure Code [DDNRKY] 936
Failure Code [DDNS00] 938
Failure Code [DGH2KB] 940
Failure Code [DHPAMA] 942
Failure Code [DHS3MA] 944
Failure Code [DHS4MA] 947
Failure Code [DHS5MA] 950
Failure Code [DHS8MA] 952
Failure Code [DHS9MA] 955
Failure Code [DHSAMA] 958
Failure Code [DHSBMA] 961
Failure Code [DHSCMA] 964
Failure Code [DHSDMA] 967
Failure Code [DKULKA] 970
Failure Code [DKULKB] 972
Failure Code [DKULKY] 974
Failure Code [DR21KX] 976
Failure Code [DV20KB] 978
Failure Code [DW43KA] 980
Failure Code [DW43KB] 982
Failure Code [DW43KY] 984
Failure Code [DW45KA] 985
Failure Code [DW45KB] 988
Failure Code [DW45KY] 991
Failure Code [DW4CKY] 993
Failure Code [DWJ0KA] 995
Failure Code [DWJ0KB] 997
Failure Code [DWJ0KY] 999
Failure Code [DXA8KA]1000
Failure Code [DXA8KB]1002
Failure Code [DXE4KA]1004
Failure Code [DXE4KB]1006
Failure Code [DXE4KY]1008
Failure Code [DY20KA]1010
Failure Code [DY20MA]1012
Failure Code [DY2CKB]1014
Failure Code [DY2DKB]1017
Failure Code [DY2EKB]1019
Troubleshooting of Electrical System (E-Mode)1021
Engine Does Not Start (Engine Does Not Crank)1021
Manual Preheating System Does Not Operate1027
While Preheating is in Operation, Preheating Monitor Does Not Come On1030
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1032
Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation1035
Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation1036
Charge Level Monitor Comes On in Red While Engine is in Operation1037
Fuel Level Monitor Comes On in Red While Engine is in Operation1038
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1039
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation1040
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation1041
Fuel Gauge Does Not Move from Minimum or Maximum1042
Display of Fuel Gauge is Different from Actual Fuel Level1044
Engine Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum1045
Display of Engine Coolant Temperature Gauge is Different from Actual Coolant Temperature1046
Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum1047
Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature1049
Some Areas of Machine Monitor Screen are Not Shown1050
Function Switch Does Not Operate1051
Automatic Warm-up System Does Not Operate (in Cold Weather)1052
Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated1053
Auto-Decelerator is Not Operated or Canceled with Lever1054
Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated1055
When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed1056
Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated1057
Travel Speed Does Not Change Even When You Change Travel Speed1058
Alarm Buzzer Does Not Stop1059
Service Meter is Not Shown While Starting Switch is in OFF Position1060
Service Mode Cannot be Selected1061
All Work Equipment, Swing, Travel Do Not Operate1062
All Work Equipment, Swing, Travel Cannot be Locked1065
Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position1067
While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated1069
Work Equipment Does Not Operate While Lock Lever Automatic Release Switch is in Release Position1071
Travel Alarm Does Not Operate During Travel1073
Travel Alarm Does Not Stop When Machine Stops1075
Horn Does Not Sound1076
Horn Does Not Stop1078
Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated1079
Windshield Wiper Does Not Operate When Wiper Switch is Operated1080
When Window Washer Switch is Operated, Window Washer Does Not Operate1082
“Boom Raise” is Not Shown Correctly with Monitoring Function1083
“Boom Lower” is Not Shown Correctly with Monitoring Function1084
“Arm OUT” is Not Shown Correctly with Monitoring Function1085
“Arm IN” is Not Shown Correctly with Monitoring Function1086
Bucket DUMP is Not Shown Correctly with Monitoring Function1087
Bucket CURL is Not Shown Correctly with Monitoring Function1088
Swing is Not Shown Correctly with Monitoring Function1089
Travel is Not Shown Correctly with Monitoring Function1090
Service is Not Shown Correctly with Monitoring Function1091
Blade RAISE is Not Shown Correctly with Monitoring Function1094
Blade LOWER is Not Shown Correctly with Monitoring Function1096
KOMTRAX System Does Not Operate Correctly1098
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1099
Information Shown in Troubleshooting Table (H-Mode)1099
System Chart of Hydraulic and Mechanical Systems1100
Failure Mode and Cause Table1102
All Work Equipment, Swing and Travel Do Not Work1111
All Work Equipment, Swing, and Travel Lack Speed or Power1112
Fine Control Performance or Response is Unsatisfactory1114
Unusual Noise is Heard from Around Hydraulic Pump1115
Engine Speed Drops Largely or Engine Stops1116
Boom Speed or Power is Low1118
Arm Speed or Power is Low1122
Bucket Speed or Power is Low1125
Blade Speed or Power is Low1128
Work Equipment Does Not Move in Single Operation1130
Hydraulic Drift of Boom is Large1131
Hydraulic Drift of Arm is Large1132
Hydraulic Drift of Bucket is Large1133
Hydraulic Drift of Blade is Large1134
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves1136
Time Lag of Work Equipment is Large1137
Oil Flow in Attachment Circuit Cannot be Changed1138
In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower1139
In Mixed Operation of Travel with Work Equipment or Swing, Travel Speed Drops Largely1140
In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low1141
Machine Does Not Travel Straight1142
Machine is Not Steered Well or Steering Power is Low1144
Travel Speed is Low1147
One of Tracks Does Not Run1149
Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast1151
Upper Structure Does Not Swing in Two Directions of Right and Left1152
Machine Swings Only in One Direction1154
Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left1155
Swing Acceleration or Swing Speed is Low in Only One Direction1157
Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)1158
Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)1159
Shock is Large When Upper Structure Stops Swing Operation1160
Large Unusual Noise is Made When Upper Structure Stops Swing Operation1161
Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)1162
Swing Drift on a Slope is Large (While Swing Parking Brake is Released)1163
Troubleshooting of Engine (S-Mode)1164
Information Shown in Troubleshooting Table (S-Mode)1164
Engine Does Not Crank When Starting Switch is Turned to Start Position1165
Engine Cranks but No Exhaust Smoke Comes Out1166
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)1167
Engine Startability is Unsatisfactory1168
Engine Does Not Pick Up Smoothly1170
Engine Stops During Operation1172
Engine Does Not Rotate Smoothly1174
Engine Lacks Output (or Lacks Power)1175
Exhaust Smoke is Black1177
Engine Oil Consumption is Excessive1179
Engine Oil Becomes Dirty Quickly1180
Fuel Consumption is Excessive1181
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)1182
Engine Oil Pressure Drops1183
Fuel Mixes Into Engine Oil1185
Water Mixes Into Engine Oil (Milky)1186
Coolant Temperature Increases Too High (Overheat)1187
Unusual Noise is Heard1188
Vibration is Excessive1189
Air Cannot be Bled from Fuel Circuit1190
50 Disassembly and Assembly1191
Table of Contents1192
Precautions Before Work1196
Abbreviation List1197
Related Information on Disassembly and Assembly1203
How to Read This Manual1203
Coating Materials List1204
Special Tool List1209
Sketches of Special Tools1218
Engine and Cooling System1222
Remove and Install Supply Pump Assembly1222
Remove Supply Pump Assembly1222
Install Supply Pump Assembly1226
Remove and Install Injector Assembly1231
How to Remove Injector Assembly1231
How to Install Injector Assembly1236
Remove and Install Cylinder Head Assembly1243
How to Remove Cylinder Head Assembly1243
How to Install Cylinder Head Assembly1253
Remove and Install EGR Valve Assembly1267
Remove EGR Valve Assembly1267
Install EGR Valve Assembly1268
Remove and Install EGR Cooler Assembly1270
How to Remove EGR Cooler Assembly1270
How to Install EGR Cooler Assembly1272
Remove and Install Starter Assembly1274
Remove Starting Motor Assembly1274
Install Starting Motor Assembly1275
Remove and Install Air Conditioner Compressor Belt1277
Remove Air Conditioner Compressor Belt1277
Install Air Conditioner Compressor Belt1278
Remove and Install Alternator Belt1280
Remove Alternator Belt1280
Install Alternator Belt1281
Remove and Install Automatic Tensioner1283
Remove Automatic Tensioner1283
Install Automatic Tensioner1283
Remove and Install Radiator Assembly1284
How to Remove Radiator Assembly1284
How to Install Radiator Assembly1287
Remove and Install Hydraulic Oil Cooler Assembly1293
How to Remove Hydraulic Oil Cooler Assembly1293
How to Install Hydraulic Oil Cooler Assembly1297
Remove and Install Aftercooler Assembly1301
Remove Aftercooler Assembly1301
Install Aftercooler Assembly1303
Remove and Install Engine and Main Pump Assembly1306
Remove Engine and Main Pump Assembly1307
Install Engine and Main Pump Assembly1318
Remove and Install Engine Front Oil Seal1330
How to Remove Engine Front Oil Seal1330
How to Install Engine Front Oil Seal1331
Remove and Install Engine Rear Oil Seal1333
How to Remove Engine Rear Oil Seal1333
How to Install Engine Rear Oil Seal1334
Remove and Install Fuel Cooler Assembly1336
Remove Fuel Cooler Assembly1336
Install Fuel Cooler Assembly1337
Remove and Install Engine Hood Assembly1339
How to Remove Engine Hood Assembly1339
How to Install Engine Hood Assembly1340
Remove and Install KDOC Muffler1342
How to Remove KDOC Muffler1342
How to Install KDOC Muffler1345
Remove and Install Fuel Tank Assembly1350
Remove Fuel Tank Assembly1350
Install Fuel Tank Assembly1352
Remove and Install KCCV Ventilator Assembly1356
How to Remove KCCV Ventilator Assembly1356
How to Install KCCV Ventilator Assembly1358
Remove and Install Air Cleaner Assembly1361
Remove Air Cleaner Assembly1361
Install Air Cleaner Assembly1362
Remove and Install Air Conditioner Compressor Assembly1364
Remove Air Conditioner Compressor Assembly1364
How to Install Air Conditioner Compressor Assembly1366
Remove and Install Air Conditioner Condenser Assembly1369
How to Remove Air Conditioner Condenser Assembly1369
How to Install Air Conditioner Condenser Assembly1370
Power Train1371
Remove and Install Travel Motor and Final Drive Assembly1371
Remove Travel Motor and Final Drive Assembly1371
Install Travel Motor and Final Drive Assembly1372
Disassemble and Assemble Travel Motor and Final Drive Assembly (Applicable Machine: #30001 to 35917)1374
How to Disassemble Travel Motor and Final Drive Assembly (Applicable Machine: #30001 to 35917)1384
How to Assemble Travel Motor and Final Drive Assembly (Applicable Machine: #30001 to 35917)1403
Disassemble and Assemble Travel Motor and Final Drive Assembly (Applicable Machine: #35918 and Up)1421
Disassemble Travel Motor and Final Drive Assembly (Applicable Machine: #35918 and Up)1430
Assemble Travel Motor and Final Drive Assembly (Applicable Machine: #35918 and Up)1451
Remove and Install Swing Motor and Swing Machinery Assembly1470
Remove Swing Motor and Swing Machinery Assembly1470
Install Swing Motor and Swing Machinery Assembly1471
Disassemble and Assemble Swing Machinery Assembly1473
Disassemble Swing Machinery Assembly1473
Assemble Swing Machinery Assembly1476
Remove and Install Swing Circle Assembly1482
Remove Swing Circle Assembly1482
Install Swing Circle Assembly1482
Undercarriage and Frame1484
Separate and Connect Track Assembly1484
Separate Track Assembly1484
Install Track Assembly1485
Remove and Install Sprocket1486
Remove Sprocket1486
Install Sprocket1486
Remove and Install Idler and Idler Cushion Assembly1488
Remove Idler and Idler Cushion Assembly1488
Install Idler and Idler Cushion Assembly1488
Disassemble and Assemble Idler Assembly1490
Disassemble Idler Assembly1490
Assemble Idler Assembly1491
Disassemble and Assemble Idler Cushion Assembly1494
Disassemble Idler Cushion Assembly1494
Assemble Idler Cushion Assembly1495
Disassemble and Assemble Track Roller Assembly1497
Disassemble Track Roller Assembly1497
Assemble Track Roller Assembly1499
Remove and Install Revolving Frame Assembly1502
Remove Revolving Frame Assembly1502
Install Revolving Frame Assembly1504
Remove and Install Counterweight Assembly1507
Remove Counterweight Assembly1507
Install Counterweight Assembly1510
Hydraulic System1513
Remove and Install Center Swivel Joint Assembly1513
Remove Center Swivel Joint Assembly1513
Install Center Swivel Joint Assembly1514
Disassemble and Assemble Center Swivel Joint Assembly1516
Disassemble Center Swivel Joint Assembly1517
Assemble Center Swivel Joint Assembly1518
Remove and Install Hydraulic Tank Assembly1519
Remove Hydraulic Tank Assembly1519
How to Install Hydraulic Tank Assembly1523
Remove and Install Main Pump Assembly1527
Remove Main Pump Assembly1527
Install Main Pump Assembly1532
Remove and Install Control Valve Assembly1537
How to Remove Control Valve Assembly1537
How to Install Control Valve Assembly1541
Disassemble and Assemble Work Equipment PPC Valve Assembly1547
Disassemble Work Equipment PPC Valve Assembly1547
How to Assemble Work Equipment PPC Valve Assembly1547
Disassemble and Assemble Travel PPC Valve Assembly1549
Disassemble Travel PPC Valve Assembly1549
How to Assemble Travel PPC Valve Assembly1550
Work Equipment1552
Remove and Install Blade Assembly1552
Remove Blade Assembly1552
Install Blade Assembly1552
Remove and Install Work Equipment Assembly1555
Remove Work Equipment Assembly1555
Install Work Equipment Assembly1558
Remove and Install Boom Anti-drop Valve Assembly1561
Remove Boom Anti-drop Valve Assembly1561
Install Boom Anti-drop Valve Assembly1563
Remove and Install Arm Anti-Drop Valve Assembly1565
Remove Arm Anti-Drop Valve Assembly1565
Install Arm Anti-Drop Valve Assembly1567
Disassemble and Assemble Anti-Drop Valve Assembly1568
Disassemble Anti-Drop Valve Assembly1568
Assemble Anti-Drop Valve Assembly1568
Disassemble and Assemble Work Equipment Cylinder Assembly1569
How to Disassemble Work Equipment Cylinder Assembly1570
How to Assemble Work Equipment Cylinder Assembly1572
CAB Related Parts1576
Remove and Install Operator Cab Assembly1576
How to Remove Operator Cab Assembly1576
Install Operator CAB Assembly1581
Remove and Install Slide Door1588
How to Remove Slide Door1588
How to Install Slide Door1588
Remove and Install Operator Cab Glass (Adhered Glass)1590
Remove Operator CAB Glass (Adhered Glass)1591
Install Operator CAB Glass (Adhered Glass)1592
Remove and Install Front Window Assembly1601
Remove Front Window Assembly1601
Install Front Window Assembly1602
Remove and Install Floor Frame Assembly1604
How to Remove Floor Frame Assembly1604
How to Install Floor Frame Assembly1610
Remove and Install Air Conditioner Unit Assembly1616
Remove Air Conditioner Unit Assembly1616
Install Air Conditioner Unit Assembly1623
Remove and Install Operator Seat1630
Remove Operator’s Seat1630
Install Operator’s Seat1630
How to Remove and Install Seat Belt1632
How to Remove Seat Belt1632
How to Install Seatbelt1633
Remove and Install Work Equipment Control Lever Assembly1634
How to Remove Work Equipment Control Lever Assembly1634
How to Install Work Equipment Control Lever Assembly1640
Remove and Install Front Wiper Assembly1648
Remove Front Wiper Assembly1648
Install Front Wiper Assembly1653
Electrical System1662
Remove and Install Engine Controller Assembly1662
Remove Engine Controller Assembly1662
Install Engine Controller Assembly1663
Remove and Install Pump Controller Assembly1665
Remove Pump Controller Assembly1665
Install Pump Controller Assembly1666
Remove and Install Machine Monitor Assembly1667
Remove Machine Monitor Assembly1667
Install Machine Monitor Assembly1669
Remove and Install Mass Air Flow and Temperature Sensor1673
How to Remove Mass Air Flow and Temperature Sensor1673
How to Install Mass Air Flow and Temperature Sensor1673
Remove and Install KCCV Crankcase Pressure Sensor1675
How to Remove KCCV Crankcase Pressure Sensor1675
How to Install KCCV Crankcase Pressure Sensor1676
Remove and Install KOMTRAX Terminal Assembly1677
Remove KOMTRAX Terminal Assembly1677
Install KOMTRAX Terminal Assembly1677
60 Maintenance Standard1679
Table of Contents1680
Abbreviation List1681
Engine and Cooling System1687
Maintenance Standard for Engine Mount1687
Maintenance Standard for PTO1688
Maintenance Standard for Cooling System1689
Power Train1691
Maintenance Standard for Swing Circle1691
Maintenance Standard for Swing Machinery1693
Maintenance Standard for Sprocket1695
Undercarriage and Frame1696
Maintenance Standard for Track Frame and Idler Cushion1696
Maintenance Standard for Idler1698
Maintenance Standard for Track Roller1700
Maintenance Standard for Carrier Roller1701
Maintenance Standard for Track Shoes1702
Maintenance Standard for Triple Shoes1705
Maintenance Standard for Road Liner1706
Maintenance Standard for Rubber Shoes1707
Hydraulic System1708
Maintenance Standard for Hydraulic Tank1708
Maintenance Standard for Main Pump1709
Maintenance Standard for Main Pump Servo Valve1711
Maintenance Standard for PC-EPC Valve1712
Maintenance Standard for Swing Motor1713
Maintenance Standard for Travel Motor1716
Maintenance Standard for Control Valve1717
Maintenance Standard for Boom Anti-Drop Valve1727
Maintenance Standard for Arm Anti-Drop Valve1729
Maintenance Standard for Work Equipment and Swing PPC Valve1731
Maintenance Standard for Blade PPC Valve1734
Maintenance Standard for Travel PPC Valve1736
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)1739
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve1740
Maintenance Standard for Solenoid Valve1742
Maintenance Standard for Attachment Circuit Accumulator (For Low Pressure Circuit)1743
Maintenance Standard for Center Swivel Joint1744
Work Equipment1745
Maintenance Standard for Work Equipment Linkage1745
Dimensions of Arm1750
Dimensions of Bucket1752
Maintenance Standard for Boom Cylinder1754
Maintenance Standard for Arm Cylinder1755
Maintenance Standard for Bucket Cylinder1756
Maintenance Standard for Blade Cylinder1757
80 Appendix1759
Table of Contents1760
Precautions Before Work1762
Abbreviation List1763
Air Conditioner System1769
Precautions for Refrigerant1769
Air Conditioner Component1770
Specifications of Air Conditioner1772
Structure and Function of Refrigeration Cycle1773
Outline of Refrigeration Cycle1774
Component Parts of Air Conditioner System1776
Air Conditioner Unit1776
Configuration Diagram of Air Conditioner Unit1776
Function of Air Conditioner Unit1778
Component Parts of Air Conditioner Unit1779
Function of Evaporator as Air Conditioner Unit Component1780
Function of Heater Core as Air Conditioner Unit Component1780
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component1780
Function of Servo Motor as Air Conditioner Unit Component1781
Structure of Expansion Valve as Air Conditioner Unit Component1782
Function of Expansion Valve as Air Conditioner Unit Component1782
Operate Expansion Valve as Air Conditioner Unit Component1782
Function of Dual Pressure Switch1783
Air Conditioner Controller1784
Structure of Air Conditioner Controller1784
Compressor1785
Structure of Compressor1785
Specifications of Compressor1785
Function of Compressor1785
Condenser1786
Structure of Condenser1786
Specifications of Condenser1786
Function of Condenser1786
Receiver Drier1787
Structure of Receiver Dryer1787
Specifications of Receiver Dryer1787
Function of Receiver Dryer1787
Air Conditioner Related Sensors1788
Structure of Sunlight Sensor1788
Function of Sunlight Sensor1788
Structure of Outside Temperature Sensor1788
Function of Outside Air Temperature Sensor1788
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner1790
Circuit Diagram and Configuration of Connector Pins of Air Conditioner1792
System Diagram of Air Conditioner1794
Input and Output Signals of Air Conditioner Controller1795
Function of Air Conditioner Controller1796
Locations of Air Conditioner Parts and Layout of Connectors1797
Examine Air Leakage (Duct)1803
How to Examine Air Leakage (Duct)1803
Examine Air Conditioner with Self-Diagnosis Function1804
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor1805
Examine Vent (Mode) Changeover1806
How to Examine Vent (Mode) Changeover1806
Examine Fresh/Recirc Air Changeover1807
How to Examine Fresh/Recirc Air Changeover1807
Examine Sunlight Sensor1808
How to Examine Sunlight Sensor1808
Examine Refrigerant (Dual) Pressure Switch1809
How to Examine Refrigerant (Dual) Pressure Switch1809
Examine Relay1811
How to Examine Relay1811
Air Conditioner Troubleshooting Chart 11812
Air Conditioner Troubleshooting Chart 21813
Information Shown in Troubleshooting Table1816
Failure Code [879AKA]1817
Failure Code [879AKB]1819
Failure Code [879BKA]1821
Failure Code [879BKB]1823
Failure Code [879CKA]1825
Failure Code [879CKB]1826
Failure Code [879DKZ]1827
Failure Code [879EMC]1829
Failure Code [879FMC]1830
Failure Code [879GKX]1831
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)1833
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)1835
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)1838
Troubleshooting for Fresh/Recirc Air Changeover1840
Troubleshooting by Gauge Pressure1842
Connect Service Tool1845
How to Connect Service Tool1845
Precautions for Disconnection and Connection of Air Conditioner Piping1847
Handle Compressor Oil1849
90 Circuit Diagrams1851
Table of Contents1852
Abbreviation List1853
Hydraulic Circuit Diagram1859
Symbols Used in Hydraulic Circuit Diagram1859
Hydraulic Circuit Diagram (1/2)1863
Hydraulic Circuit Diagram (2/2)1865
Hydraulic Circuit Diagram (For European Union)1867
Electrical Circuit Diagram1869
Symbols Used in Electric Circuit Diagram1869
Electrical Circuit Diagram (1/6)1873
Electrical Circuit Diagram (2/6)1875
Electrical Circuit Diagram (3/6)1877
Electrical Circuit Diagram (4/6)1879
Electrical Circuit Diagram (5/6)1881
Electrical Circuit Diagram (6/6)1883
Electrical Circuit Diagram (For European Union) (Serial Number: 30001 – 33927) (1/6)1885
Electrical Circuit Diagram (For European Union) (Serial Number: 30001 – 33927) (2/6)1887
Electrical Circuit Diagram (For European Union) (Serial Number: 30001 – 33927) (3/6)1889
Electrical Circuit Diagram (For European Union) (Serial Number: 30001 – 33927) (4/6)1891
Electrical Circuit Diagram (For European Union) (Serial Number: 30001 – 33927) (5/6)1893
Electrical Circuit Diagram (For European Union) (Serial Number: 30001 – 33927) (6/6)1895
Electrical Circuit Diagram (For European Union) (Serial Number: 33928 – ) (1/6)1897
Electrical Circuit Diagram (For European Union) (Serial Number: 33928 – ) (2/6)1899
Electrical Circuit Diagram (For European Union) (Serial Number: 33928 – ) (3/6)1901
Electrical Circuit Diagram (For European Union) (Serial Number: 33928 – ) (4/6)1903
Electrical Circuit Diagram (For European Union) (Serial Number: 33928 – ) (5/6)1905
Electrical Circuit Diagram (For European Union) (Serial Number: 33928 – ) (6/6)1907
Index1909

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24