Komatsu Hydraulic Excavator PC78UU-11 Shop Manual SEN06960-01 PDF

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Komatsu Hydraulic Excavator PC78UU-11 Shop Manual SEN06960-01 –  PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC78UU-11 Shop Manual SEN06960-01 –  PDF DOWNLOAD

Language : English
Pages : 2550
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC78UU-11 Shop Manual SEN06960-01 –  PDF DOWNLOAD

• SERIAL NUMBERS 50001 and up

Cover . 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 18
How to Read the Shop Manual 18
Safety Notice for Operation 20
Precautions to Prevent Fire 28
Procedures If Fire Occurs 30
Precautions for Disposing of Waste Materials . 31
Precautions When You Handle Hydraulic Equipment 32
Precautions When You Disconnect and Connect Pipings 35
Precautions When You Handle Electrical Equipment . 42
Precautions When You Handle Fuel System Equipment 44
Precautions When You Handle Intake System Equipment 45
Practical Use of KOMTRAX . 46
Disconnect and Connect Push-Pull Type Coupler 47
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 47
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 48
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 49
Precautions for Disconnection and Connection of Connectors . 51
How to Disconnect and Connect Deutsch Connector 55
How to Disconnect and Connect Slide Lock Type Connector 56
How to Disconnect and Connect Connector with Lock to Pull 58
How to Disconnect and Connect Connector with Lock to Push 59
How to Disconnect and Connect Connector with Housing to Rotate . 61
How to Read the Codes for Electric Cable . 62
Explanation of Terms for Maintenance Standard 66
Standard Tightening Torque Table . 69
Conversion Table . 76
Abbreviation List 81
01 Specifications 85
Table of Contents 86
Specifications . 87
Specification Drawing 87
Specification Drawing: PC78UU-11 . 87
Working Range Drawings . 90
Working Range Drawings: PC78UU-11 90
Specifications . 92
Specifications: PC78UU-11 92
Weight Table . 96
Weight Table: PC78UU-11 96
Fuel, Coolant, Lubricant . 98
How to Use Fuel, Coolant and Lubricants by Ambient Temperature . 99
10 Structure and Function 101
Table of Contents 102
Boot-up System . 105
Layout Drawing of Boot-up System . 105
System Operating Lamp System . 106
System Diagram of System Operating Lamp System . 106
Function of Operation Lamp System 106
Battery Disconnect Switch 107
Function of Battery Disconnect Switch 107
Engine System 108
Layout Drawing of Engine System 108
Engine Control System 110
System Diagram of Engine Control . 110
Function of Engine Control System 111
Auto-Deceleration System . 113
System Diagram of Auto-Deceleration System . 113
Function of Auto-Deceleration System . 113
Operation of Auto-Deceleration System 114
Engine Automatic Warm-up System 115
System Diagram of Engine Automatic Warm-up System 115
Function of Engine Automatic Warm-up System 116
Overheat Prevention System . 117
Function of Overheat Prevention System . 117
Turbocharger Protection System . 118
Function of Turbocharger Protection System . 118
Automatic Idle Stop System . 119
System Diagram of Automatic Idle Stop System . 119
Function of Automatic Idle Stop System . 119
Component Parts of Engine System . 122
PTO 122
Turbocharger . 123
EGR System . 125
EGR Valve 128
EGR Cooler . 130
High Efficiency Breather System 131
High Efficiency Breather . 132
KDOC . 134
Cooling System . 136
Layout Drawing of Cooling System . 136
Specifications of Cooling System . 137
Control System . 138
Layout Drawing of Control System . 138
Layout Drawing of Control System (Machine with KomVision System) . 140
Machine Monitor System . 142
System Diagram of Machine Monitor System . 142
System Diagram of Machine Monitor System (Machine with KomVision System) . 143
Function of Machine Monitor System . 143
KOMTRAX System . 145
System Diagram of KOMTRAX System . 145
Function of KOMTRAX System . 145
KomVision System . 146
Layout Drawing of KomVision System . 146
System Diagram of KomVision System . 147
Function of KomVision System . 147
Component Parts of Control System 149
Machine Monitor 149
KomVision Controller . 164
Gateway Function Controller 168
Communication Terminal . 171
Pump Controller 172
Resistor for PC-EPC Valve 176
Offset PPC Pressure Reducing EPC Valve Resistor 177
Work Equipment Release EPC Valve Resistor 178
CAN Terminating Resistor . 179
Engine Controller 180
Fuel Control Dial 187
Hydraulic System . 188
Layout Drawing of Hydraulic System . 188
CLSS . 191
Structure of CLSS 191
Function of CLSS . 192
Engine and Pump Combined Control System 194
Engine and Pump Combined Control System Diagram 194
Function of Engine and Pump Combined Control System 195
Component Parts of Hydraulic System 198
Hydraulic Tank . 198
Main Pump 200
Control Valve 218
Work Equipment System 280
Layout Drawing of Work Equipment System 280
Structure of Valve Control . 282
PPC Lock System 283
System Diagram of PPC Lock . 283
Function of PPC Lock System 283
Work Equipment and Travel Automatic Lock System 284
System Diagram of Lock Lever Automatic Lock System . 284
Function of Work Equipment and Travel Automatic Lock System 284
Operation of Lock Lever Automatic Lock System 285
Interference Prevention Device . 287
Interference Prevention Function for Bucket and CAB 287
Interference Prevention Function for Bucket, Right Front External Part, and Step . 290
Interference Avoidance Function for Bucket and CAB . 294
Automatic Control Device (UU Mode) . 298
Function of Set Depth Display Mode . 298
Function of Boom Height Restriction Mode . 300
End Cushion Function . 302
Boom End Cushion Function 302
Arm End Cushion Function . 302
Resetting Function . 303
Potentiometer Input Signal Resetting Function 303
Automatic Stop Position at CAB Front Resetting Function 303
Automatic Stop Position at CAB Side Resetting Function . 303
Automatic Stop Position Resetting Function for Right Front External Part, and Step . 304
Depth Display Resetting Function . 304
Attachment Oil Flow Adjuster System 305
Attachment Oil Flow Adjuster System Diagram 305
Function of Attachment Oil Flow Adjuster System 305
Component Parts of Work Equipment System . 307
Work Equipment and Swing PPC Valve . 307
Offset PPC Valve (with EPC Valve) 312
1st-Line Attachment PPC Valve (with EPC Valve) . 313
Blade PPC Valve 318
Solenoid Valve . 320
4-Spool EPC Solenoid Valve . 322
Boom Anti-drop Valve . 326
Arm Anti-Drop Valve 331
Offset Cylinder Anti-Drop Valve 335
Multi-Control Valve 342
Pilot Circuit Accumulator 343
Attachment Circuit Accumulator (For Low Pressure Circuit) 344
Swing System . 345
Layout Drawing of Swing System . 345
Swing Control System Diagram . 347
Function of Swing Control System . 347
Component Parts of Swing System 349
Swing Motor 349
Swing Machinery 358
Swing Circle . 360
Travel System 362
Layout Drawing of Travel System 362
System Diagram of Travel Control System 364
Function of Travel Control System 364
Component Parts of Travel System . 367
Travel Motor . 367
Travel PPC Valve . 375
Center Swivel Joint 380
Undercarriage and Frame 381
Layout Drawing of Undercarriage 381
Specifications of Undercarriage 381
Idler Cushion 383
Structure of Idler Cushion . 383
Specifications of Idler Cushion 383
Work Equipment . 384
Structure of Work Equipment 384
Function of Work Equipment . 386
Work Equipment Clearance Adjustment Shim . 387
Function of Work Equipment Clearance Adjustment Shim . 387
Bucket Clearance Adjustment Shim . 388
Function of Bucket Clearance Adjustment Shim . 388
CAB Related Parts 389
ROPS CAB . 389
Structure of ROPS CAB 389
Function of ROPS CAB . 389
CAB Mount 390
Structure of CAB Mount . 390
Function of CAB Mount 391
Remove Wiring Harness Out of Cab . 392
20 Standard Value Table 393
Table of Contents 394
Standard Value Table for Engine 395
Standard Value Table for Engine: PC78UU-11 . 395
Standard Value Table for Machine . 397
Standard Value Table for Machine: PC78UU-11 397
Machine Posture and Procedures to Measure Performance 410
30 Testing and Adjusting . 415
Table of Contents 416
Precautions Before Work 419
Related Information on Testing and Adjusting . 420
Tools for Testing and Adjusting 420
Sketch of Tools for Testing and Adjusting 425
Engine and Cooling System 427
Examine Engine Speed . 427
How to Examine Engine Speed 427
Examine Exhaust Gas Color 431
How to Examine Exhaust Gas Color with the Handy Smoke Checker 431
How to Examine Exhaust Gas Color with Smoke Meter 432
Examine and Adjust Valve Clearance . 434
How to Examine Valve Clearance . 434
How to Adjust Valve Clearance 435
Examine Compression Pressure . 436
How to Examine Compression Pressure 436
Examine Blowby Pressure 439
How to Examine Blowby Pressure . 439
Examine Engine Oil Pressure 441
How to Examine Engine Oil Pressure . 441
Visual Check Inside of EGR Valve . 443
How to do the Visual Check Inside of EGR Valve . 443
Clean Inside of EGR Valve 445
How to Clean Inside of EGR Valve . 445
Examine Fuel Pressure 448
How to Examine Fuel Pressure . 448
Examine Fuel Return Rate and Leakage . 450
How to Examine Fuel Return Rate and Leakage 452
Bleed Air from Fuel System . 455
How to Bleed Air from Fuel System 455
Examine Fuel Circuit for Leakage . 457
How to Examine Fuel System for Leakage . 457
Handle Cylinder Cut-out Mode Operation . 459
Handle No-Injection Cranking Operation . 460
Examine Fan Belt . 461
How to Examine Fan Belt 461
Examine Automatic Tensioner 462
How to Examine Automatic Tensioner . 462
Write Injector Compensation Value to Engine Controller . 464
How to Write Injector Compensation Value . 464
Power Train 470
Examine Swing Circle Bearing Clearance . 470
How to Examine Swing Circle Bearing Clearance 470
Undercarriage and Frame 472
Examine and Adjust Track Tension . 472
How to Examine Track Tension . 472
How to Adjust Track Tension 472
Hydraulic System . 474
Release Remained Pressure in Hydraulic Circuit . 474
How to Release Remained Pressure from Hydraulic Tank . 474
How to Release Remained Pressure in Hydraulic Cylinder Circuit . 474
How to Release Remained Pressure from Swing Motor Circuit 477
How to Release Remained Pressure from Travel Motor Circuit . 477
Examine and Adjust Oil Pressure in Work Equipment and Travel Circuits 479
How to Examine Oil Pressure in Work Equipment and Travel Circuits 479
How to Adjust Oil Pressure in Work Equipment and Travel Circuits . 487
How to Adjust Work Equipment and Travel Relief Pressure 487
Examine and Adjust Blade Circuit Oil Pressure 489
How to Examine Blade Relief Pressure . 489
Adjust Swing Relief Pressure . 491
Adjust Blade LOWER Relief Pressure . 491
How to Adjust Blade RAISE Relief Pressure 492
Examine Oil Pressure of Control Circuit 493
How to Examine Oil Pressure in Control Circuit . 493
Examine and adjust oil pressure in pump PC control circuit . 495
How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 495
Examine Source Pressure of PC-EPC Valve 496
Examine PC-EPC Valve Output Pressure . 497
How to Adjust Oil Pressure in Pump PC Control Circuit 499
Examine and Adjust Oil Pressure in Pump LS Control Circuit . 501
Examine LS Differential Pressure with Machine Monitor 501
How to Examine LS Differential Pressure by Testing Tool 503
How to Adjust LS Valve . 505
Examine Outlet Pressure of Solenoid Valve 507
How to Examine Outlet Pressure of Solenoid Valve . 507
Operating Condition of Solenoid Valve 509
Examine PPC Valve Outlet Pressure 510
How to Examine PPC Valve Outlet Pressure . 510
Examine and Adjust Travel Deviation 512
How to Examine Travel Deviation 512
How to Adjust Travel Deviation . 513
Adjust Play of Work Equipment and Swing PPC Valves . 515
How to Adjust Play of Work Equipment and Swing PPC Valves 515
Examine Parts Which Cause Hydraulic Drift of Work Equipment 516
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 516
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder . 516
How to Examine Parts that Cause Hydraulic Drift of PPC Valve . 517
Examine Oil Leakage 518
How to Examine Oil Leakage from Boom Cylinder 518
How to Examine Oil Leakage from Arm Cylinder . 519
How to Examine Oil Leakage from Bucket Cylinder 519
How to Examine Oil Leakage from Offset Cylinder 520
How to Examine Oil Leakage from Blade Cylinder . 520
How to Examine Oil Leakage from Swing Motor 521
How to Examine Oil Leakage from Travel Motor . 523
Bleed Air from Hydraulic System 525
How to Bleed Air from Hydraulic System . 526
Electrical System 532
Set and Operate Machine Monitor 532
Operator Mode 536
Function to Show Technician Identification Status Screen . 536
Function to Show Operator Identification Input Screen 536
Examine Function by LCD (Liquid Crystal Display) . 537
Examine Function of Service Meter 537
Usage Limitation and Maintenance Password Change Function 538
Service Mode . 541
How to Operate Service Mode 541
How to See Pre-defined Monitoring Information 544
How to Examine Monitoring Information 549
Abnormality Record Menu 558
How to See Maintenance Record 563
Maintenance Mode Setting . 564
How to Set Phone Number Entry 568
Default Setting Menu . 569
Testing Menu . 579
Adjustment Menu 582
UU Settings Menu . 616
No-Injection Cranking Operation 628
KOMTRAX Settings Menu 631
How to Show Service Message 633
How to Start Up KOMTRAX System . 635
Adjust KomVision Camera Angle 642
How to Adjust KomVision Camera Angle . 643
Adjust KomVision Related Function 645
Setting of KomVision (Main Setting) 646
Setting of KomVision (Camera Setting) 649
Setting of KomVision (Camera Calibration) 651
Setting of KomVision (Human Detection Warning System) 664
Set Region of Bluetooth(R) Compatible Radio 665
How to Set Region of Bluetooth(R) Compatible Radio . 665
Handle Voltage Circuit of Engine Controller 667
Handle Battery Disconnect Switch . 668
Examine Diodes . 669
How to Examine Diodes by Digital Tester 669
How to Examine Diodes by Analog Tester . 669
Pm Clinic 670
Pm Clinic Service 670
Pm Clinic Check Sheet: PC78UU-11 . 672
40 Troubleshooting . 681
Table of Contents 682
Precautions Before Work 690
Related Information to Troubleshooting . 691
General Troubleshooting Points . 691
Sequence of Events in Troubleshooting 692
Checks Before Troubleshooting 694
Inspection Procedure Before Troubleshooting 696
Walk-Around Check 696
Test in Accordance with Testing Procedure 698
Examine Fuel Level and Type 698
Examine Fuel Prefilter . 699
Examine Water Separator, Drain Water and Sediment 699
How to Replace Fuel Prefilter Cartridge 700
Examine Fuel Main Filter . 702
Examine Engine Oil Level (Oil Quantity in Oil Pan) . 703
Examine Oil Level in PTO Gear Case . 704
Examine Coolant Level (Expansion Tank) . 706
Examine Air Cleaner Clogging . 707
Clean Outer Element 707
Replace Element 709
Examine Hydraulic Oil Level 710
Examine Hydraulic Oil Strainer . 712
Examine Hydraulic Oil Filter . 714
Examine Oil Level in Swing Machinery Case 715
Examine Oil Level in Final Drive Case 716
Bleed Air from Fuel System . 717
Bleed Air from Hydraulic System 717
How to Examine Electric Equipment 717
Preparation for Troubleshooting of Electrical System . 722
Preparation for Troubleshooting of Machine Monitor . 722
Preparation for Troubleshooting of Engine Controller . 724
Preparation for Troubleshooting of Pump Controller . 725
Preparation for Troubleshooting of KomVision Controller 725
Preparation for Troubleshooting of Gateway Function Controller . 726
How to Disconnect and Connect Connector with a Special Lock 726
Procedure for Troubleshooting 731
Symptom and Troubleshooting Numbers 734
Information Shown in Troubleshooting Table . 739
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 741
Connector and Wiring Harness Identification Table 744
Connector Layout . 750
Connector Layout (1) . 751
Connector Layout (2) . 753
Connector Layout (3) . 755
Connector Layout (4) . 756
Connector Contact Connection Table . 757
T-Branch Box and T-Branch Adapter Table 804
Fuse Location Table 810
Failure Code Table . 812
Troubleshooting by Failure Code (Display of Code) 823
Failure Code [879AKA] 823
Failure Code [879AKB] 824
Failure Code [879BKA] 825
Failure Code [879BKB] 827
Failure Code [879CKA] 829
Failure Code [879CKB] 830
Failure Code [879DKZ] 831
Failure Code [879EMC] 833
Failure Code [879FMC] 834
Failure Code [879GKX] 835
Failure Code [989H00] 837
Failure Code [989HKM] 838
Failure Code [989L00] 839
Failure Code [989M00] 840
Failure Code [989N00] 841
Failure Code [A900FR] 842
Failure Code [A900N6] 843
Failure Code [A900NY] 844
Failure Code [AA10NX] 845
Failure Code [AB00KE] 847
Failure Code [B@BAZG] 849
Failure Code [B@BCNS] 850
Failure Code [B@BCQA] 851
Failure Code [B@BCZK] 853
Failure Code [B@HANS] 855
Failure Code [CA115] . 857
Failure Code [CA122] . 858
Failure Code [CA123] . 860
Failure Code [CA131] . 862
Failure Code [CA132] . 864
Failure Code [CA144] . 866
Failure Code [CA145] . 868
Failure Code [CA153] . 870
Failure Code [CA154] . 873
Failure Code [CA187] . 876
Failure Code [CA221] . 878
Failure Code [CA222] . 880
Failure Code [CA227] . 882
Failure Code [CA234] . 883
Failure Code [CA238] . 884
Failure Code [CA239] . 886
Failure Code [CA271] . 888
Failure Code [CA272] . 890
Failure Code [CA322] . 892
Failure Code [CA324] . 895
Failure Code [CA331] . 898
Failure Code [CA343] . 901
Failure Code [CA351] . 902
Failure Code [CA352] . 903
Failure Code [CA356] . 905
Failure Code [CA357] . 907
Failure Code [CA386] . 910
Failure Code [CA435] . 911
Failure Code [CA441] . 913
Failure Code [CA442] . 915
Failure Code [CA449] . 916
Failure Code [CA451] . 917
Failure Code [CA452] . 919
Failure Code [CA515] . 921
Failure Code [CA516] . 923
Failure Code [CA553] . 925
Failure Code [CA559] . 926
Failure Code [CA689] . 930
Failure Code [CA691] . 932
Failure Code [CA692] . 934
Failure Code [CA697] . 936
Failure Code [CA698] . 937
Failure Code [CA731] . 938
Failure Code [CA778] . 939
Failure Code [CA1117] 942
Failure Code [CA1896] 943
Failure Code [CA1961] 947
Failure Code [CA2185] 948
Failure Code [CA2186] 950
Failure Code [CA2249] 952
Failure Code [CA2272] 953
Failure Code [CA2311] 956
Failure Code [CA2349] 957
Failure Code [CA2353] 959
Failure Code [CA2357] 961
Failure Code [CA2765] 962
Failure Code [CA2973] 963
Failure Code [CA3419] 964
Failure Code [CA3421] 966
Failure Code [CA3724] 968
Failure Code [CA4264] 969
Failure Code [CA4952] 971
Failure Code [D110KB] 973
Failure Code [D19JKZ] 975
Failure Code [D1EVKA] 977
Failure Code [D1EVKB] 979
Failure Code [D1EVKY] 981
Failure Code [D1EVMA] 983
Failure Code [D811MC] 985
Failure Code [D862KA] 986
Failure Code [D8ALKA] 987
Failure Code [D8ALKB] 989
Failure Code [D8AQKR] 991
Failure Code [D8G1KT] 996
Failure Code [D8G6KT] 997
Failure Code [DA20MC] 998
Failure Code [DA22KK] 999
Failure Code [DA22KT] 1002
Failure Code [DA25KP] 1005
Failure Code [DA26KP] 1008
Failure Code [DA29KQ] 1011
Failure Code [DA2JKT] 1013
Failure Code [DA2JKY] 1014
Failure Code [DA2LKA] 1015
Failure Code [DA2LKB] 1017
Failure Code [DA2QKR] 1019
Failure Code [DA2RKR] 1025
Failure Code [DAF0KM] 1030
Failure Code [DAF0MB] 1031
Failure Code [DAF0MC] 1032
Failure Code [DAF9KQ] 1033
Failure Code [DAFGMC] 1034
Failure Code [DAFLKA] 1035
Failure Code [DAFLKB] 1037
Failure Code [DAFQKR] 1039
Failure Code [DAZ9KQ] 1045
Failure Code [DAZQKR] 1046
Failure Code [DB2QKR] 1050
Failure Code [DB2RKR] 1056
Failure Code [DBP0KM] 1061
Failure Code [DBP0KT] 1062
Failure Code [DBP5KB] 1063
Failure Code [DBP5KY] 1066
Failure Code [DBPQKR] 1068
Failure Code [DDNRKA] 1075
Failure Code [DDNRKY] 1078
Failure Code [DDNS00] 1080
Failure Code [DGH2KA] 1082
Failure Code [DGH2KB] 1084
Failure Code [DHA4KA] 1085
Failure Code [DHPAMA] 1087
Failure Code [DHS3MA] 1089
Failure Code [DHS4MA] 1091
Failure Code [DHS5MA] 1093
Failure Code [DHS8MA] 1095
Failure Code [DHS9MA] 1097
Failure Code [DHSAMA] 1099
Failure Code [DHSBMA] 1101
Failure Code [DHSCMA] 1103
Failure Code [DHSDMA] 1105
Failure Code [DHSRMA] 1107
Failure Code [DHSSMA] 1110
Failure Code [DKA0KA] 1113
Failure Code [DKA0KB] 1116
Failure Code [DKA0PH] 1119
Failure Code [DKC0KA] 1120
Failure Code [DKC0KB] 1123
Failure Code [DKC0PH] 1126
Failure Code [DKP0KA] 1127
Failure Code [DKP0KB] 1130
Failure Code [DKP0PH] 1133
Failure Code [DKR0MA] 1134
Failure Code [DKULKA] 1136
Failure Code [DKULKB] 1138
Failure Code [DKULKY] 1140
Failure Code [DLM5KA] 1142
Failure Code [DLM5MB] 1144
Failure Code [DR10KA] 1146
Failure Code [DR12KA] 1149
Failure Code [DR30KA] 1151
Failure Code [DR40KA] 1153
Failure Code [DUMBKA] 1155
Failure Code [DUMBKB] 1158
Failure Code [DV20KB] 1160
Failure Code [DW43KA] 1162
Failure Code [DW43KB] 1164
Failure Code [DW43KY] 1166
Failure Code [DW45KA] 1167
Failure Code [DW45KB] 1170
Failure Code [DW45KY] 1173
Failure Code [DW4CKY] 1175
Failure Code [DW4GKA] 1177
Failure Code [DW4GKB] 1179
Failure Code [DW4GKY] 1181
Failure Code [DW4HKA] 1183
Failure Code [DW4HKB] 1185
Failure Code [DW4HKY] 1187
Failure Code [DWA2KA] 1189
Failure Code [DWA2KB] 1191
Failure Code [DWA2KY] 1193
Failure Code [DWJ0KA] 1194
Failure Code [DWJ0KB] 1196
Failure Code [DWJ0KY] 1198
Failure Code [DWN5KA] 1199
Failure Code [DWN5KB] 1201
Failure Code [DWN5KY] 1203
Failure Code [DXA8KA] 1205
Failure Code [DXA8KB] 1207
Failure Code [DXE4KA] 1209
Failure Code [DXE4KB] 1211
Failure Code [DXE4KY] 1213
Failure Code [DXEBKA] 1214
Failure Code [DXEBKB] 1216
Failure Code [DXEBKY] 1218
Failure Code [DXEFKA] 1220
Failure Code [DXEFKB] 1222
Failure Code [DXEFKY] 1224
Failure Code [DY20KA] 1226
Failure Code [DY20MA] 1228
Failure Code [DY2CKB] 1230
Failure Code [DY2DKB] 1232
Failure Code [DY2EKB] 1234
Failure code [F311KA] 1236
Failure code [F311KB] 1238
Failure code [F312KA] 1240
Failure code [F312KB] 1242
Failure Code [F313KA] 1244
Failure Code [F313KB] 1245
Failure code [F314KA] 1246
Failure code [F314KB] 1248
Failure Code [F315KB] 1250
Failure Code [F315KY] 1252
Failure code [F316KB] 1254
Failure code [F316KY] 1256
Failure Code [F318KB] 1258
Failure Code [F318KY] 1259
Failure code [F31AKB] 1260
Failure code [F31AKY] 1262
Failure Code [F31BKB] 1264
Failure Code [F31BKY] 1266
Failure Code [F31CKB] 1268
Failure Code [F31CKY] 1270
Failure Code [F31DKB] 1272
Failure Code [F31DKY] 1274
Failure Code [F31EKB] 1276
Failure Code [F31EKY] 1278
Failure Code [FS10ZE] 1280
Troubleshooting of Electrical System (E-Mode) 1281
Engine Does Not Start (Engine Does Not Crank) 1281
Manual Preheating System Does Not Operate 1287
While Preheating is in Operation, Preheating Monitor Does Not Come On 1290
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing .1292
Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation 1295
Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation .1296
Charge Level Monitor Comes On in Red While Engine is in Operation 1297
Fuel Level Monitor Comes On in Red While Engine is in Operation 1298
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1299
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation .1300
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation .1301
Fuel Gauge Does Not Move from Minimum or Maximum .1302
Display of Fuel Gauge is Different from Actual Fuel Level 1304
Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1305
Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1306
Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum 1307
Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1309
Some Areas of Machine Monitor Screen are Not Shown .1310
Function Switch Does Not Operate .1311
Automatic Warm-up System Does Not Operate (in Cold Weather) 1312
Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated 1313
Auto-Decelerator is Not Operated or Canceled with Lever 1314
Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated 1315
Boom Raising Does Not Automatically Stop Correctly and It Interferes (CAB Side) 1316
Arm IN Does Not Automatically Stop Correctly and It Interferes (CAB Side) 1318
Offset Left Does Not Automatically Stop Correctly and It Interferes (CAB Side) .1320
Boom LOWER Does Not Automatically Stop Correctly and It Interferes (Right Exterior Side) .1322
Arm IN Does Not Automatically Stop Correctly and It Interferes (Right External Side) .1324
Offset Right Does Not Automatically Stop Correctly and It Interferes (Right Exterior Side) .1326
Work Equipment Stop Position is Too Far or Near 1328
Cushion for Boom Raise End Does Not Work or is Weak 1330
Cushion for Arm IN End Does Not Work or is Weak 1332
When Automatic Interference Avoidance Function Is “ON”, Boom Stops Within Range of Automatic Stop in Boom RAISE Operation 1334
When Automatic Interference Avoidance Function Is “ON”, Arm Movement is Large on Automatic Interference Avoidance Surface 1335
When Automatic Interference Avoidance Function Is “ON”, Arm Hits Ground in Boom RAISE Operation While Arm is Retracted .1336
Boom Does Not Rise in Boom RAISE Operation While Work Equipment Lock Release Switch is on 1337
Arm is Not Retracted in Arm IN Operation While Work Equipment Lock Release Switch is on 1339
Left Offset Does Not Operate in Offset Left Operation While Work Equipment Lock Release Switch is on .1341
At the Height Restriction, Machine Stops Past Excessive the Restriction or Stops Short of It .1343
Depth Indication Departs or Does Not Show 1345
Buzzer Sounds for 7 Seconds Even If the Work Equipment Lock Release Switch is Not Turned ON 1347
When the Work Equipment Lock Release Switch is Turned ON, the Work Equipment Lock Pilot Lamp Does Not Come On 1348
When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1350
Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated .1351
Travel Speed Does Not Change Even When You Change Travel Speed .1352
Alarm Buzzer Does Not Stop .1353
Service Meter is Not Shown While Starting Switch is in OFF Position 1354
Service Mode Cannot be Selected 1355
All Work Equipment, Swing, Travel Do Not Operate .1356
All Work Equipment, Swing, Travel Cannot be Locked .1359
Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position .1361
While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated .1363
Work Equipment Does Not Operate While Work Equipment Lock Release Switch is on .1365
Travel Alarm Does Not Operate During Travel 1367
Travel Alarm Does Not Stop When Machine Stops 1369
Travel Alarm Operates While Travel Alarm Cancel Switch is Pushed .1370
Horn Does Not Sound 1372
Horn Does Not Stop .1374
Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated 1375
Windshield Wiper Does Not Operate When Wiper Switch is Operated 1376
When Window Washer Switch is Operated, Window Washer Does Not Operate 1378
“Boom Raise” is Not Shown Correctly with Monitoring Function .1379
“Boom Lower” is Not Shown Correctly with Monitoring Function .1380
“Arm OUT” is Not Shown Correctly with Monitoring Function 1381
“Arm IN” is Not Shown Correctly with Monitoring Function .1382
Bucket DUMP is Not Shown Correctly with Monitoring Function 1383
Bucket CURL is Not Shown Correctly with Monitoring Function 1384
Offset Left is Not Shown Correctly with Monitoring Function 1385
Offset Right is Not Shown Correctly with Monitoring Function .1386
Swing is Not Shown Correctly with Monitoring Function 1387
Travel is Not Shown Correctly with Monitoring Function .1388
Service is Not Shown Correctly with Monitoring Function 1389
Blade RAISE is Not Shown Correctly with Monitoring Function 1392
Blade LOWER is Not Shown Correctly with Monitoring Function 1394
KOMTRAX System Does Not Operate Correctly 1396
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1397
Information Shown in Troubleshooting Table (H-Mode) 1397
Failure Mode and Cause Table .1398
All Work Equipment, Swing and Travel Do Not Work .1407
All Work Equipment, Swing, and Travel Lack Speed or Power 1408
Fine Control Performance or Response is Unsatisfactory .1410
Unusual Noise is Heard from Around Hydraulic Pump 1411
Engine Speed Drops Largely or Engine Stops .1412
Boom Speed or Power is Low .1414
Arm Speed or Power is Low 1418
Bucket Speed or Power is Low .1421
Blade Speed or Power is Low 1424
Offset Speed or Power is Low .1426
Work Equipment Does Not Move in Single Operation .1429
Hydraulic Drift of Boom is Large .1431
Hydraulic Drift of Arm is Large 1432
Hydraulic Drift of Bucket is Large .1433
Hydraulic Drift of Offset is Large .1434
Hydraulic Drift of Blade is Large 1435
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves .1437
Boom RAISE and LOWER, Arm IN, or Offset Right and Left Does Not Automatically Stop and It Interfere 1438
Time Lag of Work Equipment is Large 1439
Attachment Circuit Cannot be Changed .1440
Oil Flow in Attachment Circuit Cannot be Changed .1441
In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 1442
In Mixed Operation of Work Equipment or Swing and Travel, Travel Speed Falls Largely .1443
In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low 1444
Machine Does Not Travel Straight .1445
Machine is Not Steered Well or Steering Power is Low .1448
Travel Speed is Low 1451
One of Tracks Does Not Run .1454
Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 1456
Upper Structure Does Not Swing in Two Directions of Right and Left .1457
Machine Swings Only in One Direction .1459
Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left .1461
Swing Acceleration or Swing Speed is Low in Only One Direction .1463
Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) .1465
Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) .1466
Shock is Large When Upper Structure Stops Swing Operation 1467
Large Unusual Noise is Made When Upper Structure Stops Swing Operation .1468
Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) .1469
Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 1470
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1471
Unusual Noise is Heard from Around Fan .1472
Troubleshooting of Engine (S-Mode) .1473
Information Shown in Troubleshooting Table (S-Mode) 1473
Engine Does Not Crank When Starting Switch is Turned to Start Position .1474
Engine Cranks but No Exhaust Smoke Comes Out .1475
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1476
Engine Startability is Unsatisfactory 1477
Engine Does Not Pick Up Smoothly .1479
Engine Stops During Operation 1481
Engine Does Not Rotate Smoothly 1483
Engine Lacks Output (or Lacks Power) .1484
Exhaust Smoke is Black .1486
Engine Oil Consumption is Excessive 1488
Engine Oil Becomes Dirty Quickly .1489
Fuel Consumption is Excessive 1490
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 1491
Engine Oil Pressure Drops 1492
Fuel Mixes Into Engine Oil .1493
Water Mixes Into Engine Oil (Milky) 1494
Coolant Temperature Increases Too High (Overheat) 1495
Unusual Noise is Heard .1496
Vibration is Excessive .1497
Air Cannot be Bled from Fuel Circuit .1498
50 Disassembly and Assembly 1499
Table of Contents 1500
Precautions Before Work 1505
Related Information on Disassembly and Assembly 1506
How to Read This Manual 1506
Coating Materials List .1507
Special Tool List 1512
Sketches of Special Tools 1528
Prepare 1531
Drain and Add Coolant 1531
How to Drain Coolant .1531
How to Add Coolant .1532
Drain and Add Hydraulic Oil 1534
How to Drain Hydraulic Oil .1534
How to Add Hydraulic Oil .1536
Drain and Add Fuel .1538
How to Drain Fuel 1538
How to Add Fuel 1539
Collect and Refill Refrigerant .1540
How to Collect Refrigerant .1540
How to Refill Refrigerant 1541
Engine and Cooling System 1542
Remove and Install Supply Pump Assembly 1542
How to Remove Supply Pump Assembly .1543
How to Install Supply Pump Assembly 1553
Remove and Install Injector Assembly .1561
How to Remove Injector Assembly 1561
How to Install Injector Assembly .1566
Remove and Install Cylinder Head Assembly 1572
How to Remove Cylinder Head Assembly .1573
How to Install Cylinder Head Assembly 1598
Remove and Install EGR Valve Assembly 1632
How to Remove EGR Valve Assembly .1632
How to Install EGR Valve Assembly 1634
Remove and Install EGR Cooler Assembly .1637
How to Remove EGR Cooler Assembly 1638
How to Install EGR Cooler Assembly .1643
Remove and Install Starting Motor Assembly .1649
How to Remove Starting Motor Assembly 1650
How to Install Starting Motor Assembly .1652
Remove and Install Fan Belt 1655
How to Remove Fan Belt .1655
How to Install Fan Belt 1658
Remove and Install Automatic Tensioner .1660
How to Remove Auto-Tensioner .1660
How to Install Auto-Tensioner 1661
Remove and Install Expansion Tank Assembly .1662
How to Remove Expansion Tank Assembly 1662
How to Install Expansion Tank Assembly .1668
Remove and Install Radiator Assembly .1675
How to Remove Radiator Assembly 1676
How to Install Radiator Assembly .1679
Remove and Install Hydraulic Oil Cooler Assembly .1682
How to Remove Hydraulic Oil Cooler Assembly 1683
How to Install Hydraulic Oil Cooler Assembly .1692
Remove and Install Aftercooler Assembly 1701
How to Remove Aftercooler Assembly .1701
How to Install Aftercooler Assembly 1704
Remove and Install Engine and Main Pump Assembly .1707
How to Remove Engine and Main Pump Assembly 1708
How to Install Engine and Main Pump Assembly .1730
Remove and Install Engine Front Oil Seal .1755
How to Remove Engine Front Oil Seal 1756
How to Install Engine Front Oil Seal .1757
Remove and Install Engine Rear Oil Seal 1759
How to Remove Engine Rear Oil Seal .1760
How to Install Engine Rear Oil Seal 1762
Remove and Install Fuel Cooler Assembly 1766
How to Remove Fuel Cooler Assembly .1767
How to Install Fuel Cooler Assembly 1767
Remove and Install Engine Hood Assembly 1769
How to Remove Engine Hood Assembly .1769
How to Install Engine Hood Assembly 1773
Remove and Install KDOC Assembly .1778
How to Remove KDOC Assembly 1779
How to Install KDOC Assembly .1785
Remove and Install Fuel Tank Assembly 1792
How to Remove Fuel Tank Assembly .1793
How to Install Fuel Tank Assembly 1797
Remove and Install Air Cleaner Assembly 1802
How to Remove Air Cleaner Assembly .1802
How to Install Air Cleaner Assembly 1804
Remove and Install Air Conditioner Compressor Assembly .1807
How to Remove Air Conditioner Compressor Assembly 1808
How to Install Air Conditioner Compressor Assembly .1809
Remove and Install Air Conditioner Condenser Assembly 1812
How to Remove Air Conditioner Condenser Assembly .1813
How to Install Air Conditioner Condenser Assembly 1814
Power Train 1817
Remove and Install Travel Motor and Final Drive Assembly .1817
How to Remove Travel Motor and Final Drive Assembly 1818
How to Install Travel Motor and Final Drive Assembly .1821
Disassemble and Assemble Travel Motor and Final Drive Assembly .1825
How to Disassemble Travel Motor and Final Drive Assembly .1834
How to Assemble Travel Motor and Final Drive Assembly 1854
Remove and Install Swing Motor and Swing Machinery Assembly 1873
How to Remove Swing Motor and Swing Machinery Assembly .1874
How to Install Swing Motor and Swing Machinery Assembly 1878
Disassemble and Assemble Swing Machinery Assembly 1883
How to Disassemble Swing Machinery Assembly 1884
How to Assemble Swing Machinery Assembly .1886
Remove and Install Swing Circle Assembly .1892
How to Remove Swing Circle Assembly 1892
How to Install Swing Circle Assembly .1893
Undercarriage and Frame 1894
Separate and Connect Track Assembly 1894
How to Separate Track Assembly .1895
How to Install Track Assembly 1895
Remove and Install Sprocket 1897
How to Remove Sprocket .1897
How to Install Sprocket 1898
Remove and Install Idler and Idler Cushion Assembly 1899
How to Remove Idler and Idler Cushion Assembly .1899
How to Install Idler and Idler Cushion Assembly 1900
Disassemble and Assemble Idler Assembly 1901
How to Disassemble Idler Assembly 1901
How to Assemble Idler Assembly .1902
Disassemble and Assemble Idler Cushion Assembly 1906
How to Disassemble Idler Cushion Assembly 1906
How to Assemble Idler Cushion Assembly .1907
Disassemble and Assemble Track Roller Assembly .1909
How to Disassemble Track Roller Assembly .1909
How to Assemble Track Roller Assembly 1910
Remove and Install Revolving Frame Assembly 1913
How to Remove Revolving Frame Assembly .1914
Install Revolving Frame Assembly .1922
Remove and Install Counterweight Assembly 1930
How to Remove Counterweight Assembly .1930
How to Install Counterweight Assembly 1936
Hydraulic System .1943
Remove and Install Center Swivel Joint Assembly 1943
How to Remove Center Swivel Joint Assembly .1944
How to Install Center Swivel Joint Assembly 1949
Disassemble and Assemble Center Swivel Joint Assembly 1955
How to Disassemble Center Swivel Joint Assembly 1955
How to Assemble Center Swivel Joint Assembly .1956
Remove and Install Hydraulic Tank Assembly .1957
How to Remove Hydraulic Tank Assembly 1958
How to Install Hydraulic Tank Assembly .1962
Remove and Install Main Pump Assembly 1967
How to Remove Main Pump Assembly .1968
How to Install Main Pump Assembly 1976
Remove and Install Control Valve Assembly 1985
How to Remove Control Valve Assembly .1986
How to Install Control Valve Assembly 2005
Disassemble and Assemble Control Valve Assembly 2025
How to Assemble Control Valve Assembly .2025
How to Replace Pressure Reducing Valve Cartridge Assembly 2026
Disassemble and Assemble Work Equipment PPC Valve Assembly .2030
How to Disassemble Work Equipment PPC Valve Assembly .2030
How to Assemble Work Equipment PPC Valve Assembly 2031
Disassemble and Assemble Travel PPC Valve Assembly .2033
How to Disassemble Travel PPC Valve Assembly .2033
How to Assemble Travel PPC Valve Assembly 2034
Work Equipment .2036
Remove and Install Blade Assembly 2036
How to Remove Blade Assembly .2037
How to Install Blade Assembly 2039
Remove and Install Work Equipment Assembly .2042
How to Remove Work Equipment Assembly 2043
How to Install Work Equipment Assembly .2050
Remove and Install 1st Boom Assembly .2058
How to Remove 1st Boom Assembly 2059
How to Install 1st Boom Assembly .2065
Remove and Install 2nd Boom Assembly .2072
How to Remove 2nd Boom Assembly 2072
How to Install 2nd Boom Assembly .2075
Remove and Install 3rd Bracket Assembly 2078
How to Remove 3rd Bracket Assembly .2079
How to Install 3rd Bracket Assembly 2083
Remove and Install Boom Anti-Drop Valve Assembly .2090
How to Remove Boom Anti-Drop Valve Assembly 2091
How to Install Boom Anti-Drop Valve Assembly .2094
Remove and Install Arm Anti-Drop Valve Assembly 2096
How to Remove Arm Anti-Drop Valve Assembly .2096
How to Install Arm Anti-Drop Valve Assembly 2100
Remove and Install Offset Anti-Drop Valve Assembly (Head Side) .2102
How to Remove Offset Anti-Drop Valve Assembly (Head Side) 2102
How to Install Offset Anti-Drop Valve Assembly (Head Side) .2104
Remove and Install Offset Anti-Drop Valve Assembly (Bottom Side) .2106
How to Remove Offset Anti-Drop Valve Assembly (Bottom Side) 2106
How to Install Offset Anti-Drop Valve Assembly (Bottom Side) .2109
Disassemble and Assemble Anti-Drop Valve Assembly 2111
How to Disassemble Anti-Drop Valve Assembly 2111
How to Assemble Anti-Drop Valve Assembly .2111
Remove and Install Boom Potentiometer Assembly .2112
How to Remove Boom Potentiometer Assembly 2112
How to Install Boom Potentiometer Assembly .2112
Remove and Install Arm Potentiometer Assembly 2113
How to Remove Arm Potentiometer Assembly .2113
How to Install Arm Potentiometer Assembly 2114
Remove and Install Offset Potentiometer Assembly .2116
How to Remove Offset Potentiometer Assembly 2116
How to Install Offset Potentiometer Assembly .2116
Disassemble and Assemble Work Equipment Cylinder Assembly 2117
How to Disassemble Work Equipment Cylinder Assembly 2118
How to Assemble Work Equipment Cylinder Assembly .2120
CAB Related Parts 2123
Remove and Install Operator Cab Assembly .2123
How to Remove Operator Cab Assembly 2124
How to Install Operator Cab Assembly .2142
Remove and Install Operator Cab Door .2159
How to Install Operator Cab Door .2160
Remove and Install Operator Cab Glass (Adhered Glass) 2164
How to Remove Operator Cab Glass (Adhered Glass) .2165
How to Install Operator Cab Glass (Adhered Glass) 2166
Remove and Install Front Window Assembly .2175
How to Remove Front Window Assembly 2175
How to Install Front Window Assembly .2177
Remove and Install Floor Frame Assembly 2179
How to Remove Floor Frame Assembly .2180
How to Install Floor Frame Assembly 2189
Remove and Install Air Conditioner Unit Assembly .2199
How to Remove Air Conditioner Unit Assembly 2200
How to Install Air Conditioner Unit Assembly .2213
Remove and Install Operator Seat .2226
How to Remove Operator Seat 2227
How to Install Operator Seat .2228
How to Remove and Install Seat Belt 2231
How to Remove Seat Belt 2232
How to Install Seatbelt 2232
Remove and Install Work Equipment Control Lever Assembly .2233
How to Remove Work Equipment Control Lever Assembly 2233
How to Install Work Equipment Control Lever Assembly .2239
Remove and Install Front Wiper Assembly 2247
How to Remove Front Wiper Assembly .2248
How to Install Front Wiper Assembly 2254
Electrical System 2260
Remove and Install Engine Controller Assembly 2260
How to Remove Engine Controller Assembly .2261
How to Install Engine Controller Assembly 2263
Remove and Install Pump Controller Assembly 2266
How to Remove Pump Controller Assembly .2267
How to Install Pump Controller Assembly 2269
Remove and Install KomVision Controller Assembly .2271
How to Remove KomVision Controller Assembly 2271
How to Install KomVision Controller Assembly .2273
Remove and Install Machine Monitor Assembly 2276
How to Remove Machine Monitor Assembly .2277
How to Install Machine Monitor Assembly 2282
Remove and Install Mass Air Flow and Temperature Sensor 2287
How to Remove Mass Air Flow and Temperature Sensor .2287
How to Install Mass Air Flow and Temperature Sensor 2289
Remove and Install KomVision Camera 2290
How to Remove KomVision Camera .2290
How to Install KomVision Camera 2296
Remove and Install Gateway Function Controller .2302
How to Remove Gateway Function Controller 2303
How to Install Gateway Function Controller .2305
Remove and Install Communication Terminal 2308
How to Remove Communication Terminal .2309
How to Install Communication Terminal 2310
60 Maintenance Standard 2313
Table of Contents 2314
Engine and Cooling System 2315
Maintenance Standard for Engine Mount 2315
Maintenance Standard for PTO .2316
Maintenance Standard for Cooling System 2317
Power Train 2318
Maintenance Standard for Swing Circle 2318
Maintenance Standard for Swing Machinery .2320
Maintenance Standard for Sprocket 2322
Undercarriage and Frame 2323
Maintenance Standard for Track Frame and Idler Cushion .2323
Maintenance Standard for Idler .2325
Maintenance Standard for Track Roller 2327
Maintenance Standard for Carrier Roller 2328
Maintenance Standard for Track Shoes .2329
Maintenance Standard for Triple Shoes 2332
Maintenance Standard for Road Liner 2333
Maintenance Standard for Rubber Shoes 2334
Hydraulic System .2335
Maintenance Standard for Hydraulic Tank 2335
Maintenance Standard for Main Pump .2336
Maintenance Standard for Main Pump Servo Valve .2340
Maintenance Standard for PC-EPC Valve 2341
Maintenance Standard for Swing Motor .2342
Maintenance Standard for Travel Motor 2344
Maintenance Standard for Control Valve .2345
Maintenance Standard for Boom Anti-Drop Valve 2358
Maintenance Standard for Arm Anti-Drop Valve .2360
Maintenance Standard for Offset Cylinder Anti-Drop Valve .2362
Maintenance Standard for Work Equipment and Swing PPC Valve 2364
Maintenance Standard for Blade PPC Valve .2367
Maintenance Standard for Offset PPC Valve (with EPC Valve) .2369
Maintenance Standard for EPC Valve of Offset PPC Valve .2371
Maintenance Standard for Travel PPC Valve 2372
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2375
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2376
Maintenance Standard for Solenoid Valve 2378
Maintenance Standard for Attachment Circuit Accumulator (For Low Pressure Circuit) .2379
Maintenance Standard for Center Swivel Joint .2380
Work Equipment .2381
Maintenance Standard for Work Equipment Linkage 2381
Dimensions of Arm 2388
Dimensions of Bucket .2393
Maintenance Standard for Boom Cylinder .2395
Maintenance Standard for Arm Cylinder 2396
Maintenance Standard for Boom Offset Cylinder 2397
Maintenance Standard for Bucket Cylinder .2398
Maintenance Standard for Blade Cylinder 2399
80 Appendix 2401
Table of Contents 2402
Precautions Before Work 2404
Air Conditioner System .2405
Precautions for Refrigerant 2405
Air Conditioner Component 2406
Specifications of Air Conditioner 2408
Structure and Function of Refrigeration Cycle 2409
Outline of Refrigeration Cycle .2410
Component Parts of Air Conditioner System 2412
Air Conditioner Unit .2412
Configuration Diagram of Air Conditioner Unit 2412
Function of Air Conditioner Unit .2414
Component Parts of Air Conditioner Unit 2415
Function of Evaporator as Air Conditioner Unit Component .2416
Function of Heater Core as Air Conditioner Unit Component 2416
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2416
Function of Servo Motor as Air Conditioner Unit Component 2417
Structure of Expansion Valve as Air Conditioner Unit Component .2418
Function of Expansion Valve as Air Conditioner Unit Component 2418
Operate Expansion Valve as Air Conditioner Unit Component 2418
Function of Dual Pressure Switch .2419
Air Conditioner Controller .2420
Structure of Air Conditioner Controller 2420
Compressor .2421
Structure of Compressor 2421
Specifications of Compressor .2421
Function of Compressor .2421
Condenser 2422
Structure of Condenser .2422
Specifications of Condenser 2422
Function of Condenser 2422
Receiver Drier .2423
Structure of Receiver Dryer 2423
Specifications of Receiver Dryer .2423
Function of Receiver Dryer .2423
Air Conditioner Related Sensors 2424
Structure of Sunlight Sensor .2424
Function of Sunlight Sensor 2424
Structure of Outside Temperature Sensor 2424
Function of Outside Air Temperature Sensor .2424
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2426
Circuit Diagram and Configuration of Connector Pins of Air Conditioner .2428
System Diagram of Air Conditioner 2430
Input and Output Signals of Air Conditioner Controller .2431
Function of Air Conditioner Controller .2432
Locations of Air Conditioner Parts and Layout of Connectors 2433
Examine Air Leakage (Duct) .2439
How to Examine Air Leakage (Duct) 2439
Examine Air Conditioner with Self-Diagnosis Function .2440
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2441
Examine Vent (Mode) Changeover .2442
How to Examine Vent (Mode) Changeover 2442
Examine Fresh/Recirc Air Changeover 2443
How to Examine Fresh/Recirc Air Changeover .2443
Examine Sunlight Sensor 2444
How to Examine Sunlight Sensor .2444
Examine Refrigerant (Dual) Pressure Switch .2445
How to Examine Refrigerant (Dual) Pressure Switch 2445
Examine Relay 2447
How to Examine Relay .2447
Air Conditioner Troubleshooting Chart 1 2448
Air Conditioner Troubleshooting Chart 2 2449
Information Shown in Troubleshooting Table .2452
Failure Code [879AKA] 2453
Failure Code [879AKB] 2454
Failure Code [879BKA] 2455
Failure Code [879BKB] 2457
Failure Code [879CKA] 2459
Failure Code [879CKB] 2460
Failure Code [879DKZ] 2461
Failure Code [879EMC] 2463
Failure Code [879FMC] 2464
Failure Code [879GKX] 2465
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) .2467
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2469
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) .2472
Troubleshooting for Fresh/Recirc Air Changeover 2474
Troubleshooting by Gauge Pressure 2476
Connect Service Tool .2479
How to Connect Service Tool 2479
Precautions for Disconnection and Connection of Air Conditioner Piping .2481
Handle Compressor Oil 2483
90 Circuit Diagrams 2485
Table of Contents 2486
How to Read the Codes for Electric Cable .2487
Hydraulic Circuit Diagram 2491
Symbols Used in Hydraulic Circuit Diagram 2491
Hydraulic Circuit Diagram (1/2) 2495
Hydraulic Circuit Diagram (2/2) 2497
Hydraulic Circuit Diagram (At Boom RAISE Operation 1/ 2) .2499
Hydraulic Circuit Diagram (At Boom RAISE Operation 2/ 2) .2501
Hydraulic Circuit Diagram (At Left Swing Operation 1/ 2) .2503
Hydraulic Circuit Diagram (At Left Swing Operation 2/ 2) .2505
Hydraulic Circuit Diagram (At Boom RAISE and Left Swing Operation 1/ 2) 2507
Hydraulic Circuit Diagram (At Boom RAISE and Left Swing Operation 2/ 2) 2509
Electrical Circuit Diagram .2511
Symbols Used in Electric Circuit Diagram .2511
Electrical Circuit Diagram (1/9) .2515
Electrical Circuit Diagram (2/9) .2517
Electrical Circuit Diagram (3/9) .2519
Electrical Circuit Diagram (4/9) .2521
Electrical Circuit Diagram (5/9) .2523
Electrical Circuit Diagram (6/9) .2525
Electrical Circuit Diagram (7/9) .2527
Electrical Circuit Diagram (8/9) .2529
Electrical Circuit Diagram (9/9) .2531
Index .2533

DESCRIPTION:

Komatsu Hydraulic Excavator PC78UU-11 Shop Manual SEN06960-01 –  PDF DOWNLOAD

• SERIAL NUMBERS 50001 and up

G.B 27/12/24