Komatsu PC78UU-10 Hydraulic Excavator Shop Manual SEN06659-05 PDF

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Komatsu PC78UU-10 Hydraulic Excavator Shop Manual SEN06659-05 –  PDF DOWNLOAD

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Komatsu PC78UU-10 Hydraulic Excavator Shop Manual SEN06659-05 –  PDF DOWNLOAD

Language : English
Pages : 2188
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC78UU-10 Hydraulic Excavator Shop Manual SEN06659-05 –  PDF DOWNLOAD

• SERIAL NUMBERS 30001 and up

Cover . 1
00 Index and Foreword 3
Index 4
Abbreviation List 18
Foreword, Safety, Basic Information 24
How to Read the Shop Manual 24
Safety Notice for Operation 26
Precautions to Prevent Fire 34
Procedures If Fire Occurs 36
Precautions When You Discard Waste Materials . 37
Procedures for Exhaust Gas Regulations . 38
Precautions for DEF 39
General Character and Precautions for Handling . 39
Precautions When You Add . 39
Precautions for Storage 39
Precautions for Fire Hazard and Leakage 39
Other Precautions 39
Store DEF 40
Precautions When You Handle Hydraulic Equipment 41
Precautions When You Disconnect and Connect Pipings 44
Precautions When You Handle Electrical Equipment . 51
Precautions When You Handle Fuel System Equipment 53
Precautions When You Handle Intake System Equipment 54
Practical Use of KOMTRAX . 55
Disconnect and Connect Push-Pull Type Coupler 56
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 58
Precautions for Disconnection and Connection of Connectors . 60
Disconnect and Connect Deutsch Connector . 64
How to Disconnect and Connect Slide Lock Type Connector 65
Disconnect and Connect Connector with Lock to Pull . 67
Disconnect and Connect Connector with Lock to Push . 68
Disconnect and Connect Connector with Housing to Rotate 70
How to Read the Codes for Electric Cable . 71
Explanation of Terms for Maintenance Standard 75
Standard Tightening Torque Table . 78
Conversion Table . 85
01 Specification . 91
Table of Contents 92
Abbreviation List 93
Specifications . 99
Specification Drawing 99
Specification Drawing: PC78UU-10 . 99
Working Range Drawings . 100
Working Range: PC78UU-10 . 100
Specifications . 102
Specifications: PC78UU-10 102
Weight Table . 106
Weight Table: PC78UU-10 106
10 Structure and Function 109
Table of Contents 110
Abbreviation List 113
Boot-up System . 119
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) . 119
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 120
System Operating Lamp System . 121
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) . 121
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 121
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) . 121
Function of System Operating Lamp System (Machine with Gateway Function Controller) 122
Battery Disconnect Switch 124
Function of Battery Disconnect Switch 124
Engine System 126
Layout Drawing of Engine System 126
Engine Control System 128
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) 128
System Diagram of Engine Control System (Machine with Gateway Function Controller) . 129
Function of Engine Control System (Machine with KOMTRAX Terminal) 129
Function of Engine Control System (Machine with Gateway Function Controller) . 131
Auto-Deceleration System . 134
System Diagram of Auto-Deceleration System . 134
Function of Auto-Deceleration System . 134
Operation of Auto-Deceleration System 135
Engine Automatic Warm-up System 136
System Diagram of Engine Automatic Warm-up System 136
Function of Engine Automatic Warm-up System 136
Overheat Prevention System . 138
Function of Overheat Prevention System . 138
Turbocharger Protection System . 139
Function of Turbocharger Protection System . 139
Automatic Idle Stop System . 140
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) . 140
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) 140
Function of Automatic Idle Stop System . 141
Component Parts of Engine System . 144
PTO 144
Variable Flow Turbocharger . 144
EGR System . 148
EGR Valve 150
EGR Cooler . 151
KCCV System 153
KCCV Ventilator 155
KDOC . 157
Cooling System . 159
Layout Drawing of Cooling System . 159
Specifications of Cooling System . 160
Control System . 162
Layout Drawing of Control System . 162
Machine Monitor System . 165
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) . 165
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 166
KOMTRAX System . 167
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) . 167
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 167
Function of KOMTRAX System . 168
Component Parts of Control System 169
Machine Monitor 169
KOMTRAX Terminal . 180
Gateway Function Controller 182
Communication Terminal . 185
Pump Controller 186
Resistor for PC-EPC Valve 190
Offset PPC Pressure Reducing EPC Valve Resistor 191
3-Spool EPC Valve Resistor . 192
CAN Terminating Resistor . 192
Engine Controller 194
Fuel Control Dial 199
Hydraulic System . 202
Layout Drawing of Hydraulic System . 202
CLSS . 206
Structure of CLSS 206
Function of CLSS . 207
Engine and Pump Combined Control System 209
Engine and Pump Combined Control System Diagram 209
Function of Engine and Pump Combined Control System 210
Component Parts of Hydraulic System 213
Hydraulic Tank . 213
Main Pump 215
Control Valve 226
Work Equipment System 280
Layout Drawing of Work Equipment System 280
Structure of Valve Control . 284
PPC Lock System 285
System Diagram of PPC Lock . 285
Function of PPC Lock System 285
Work Equipment and Travel Automatic Lock System 286
System Diagram of Lock Lever Automatic Lock System . 286
Function of Work Equipment and Travel Automatic Lock System 286
Operation of Lock Lever Automatic Lock System 287
Interference Prevention Device . 289
Interference Prevention Function for Bucket and CAB 289
Interference Prevention Function for Bucket, Right Front External Part, and Step . 292
Automatic Control Device (UU Mode) . 297
Function of Set Depth Display Mode . 297
Function of Boom Height Restriction Mode . 299
End Cushion Function . 301
Boom End Cushion Function 301
Arm End Cushion Function . 301
Resetting Function . 302
Potentiometer Input Signal Resetting Function 302
Automatic Stop Position at CAB Front Resetting Function 302
Automatic Stop Position at CAB Side Resetting Function . 302
Automatic Stop Position Resetting Function for Right Front Exterior Part, and Step . 303
Depth Display Resetting Function . 303
Bucket DUMP Control Lock System 304
Bucket DUMP Control Lock System Diagram 304
Function of Bucket DUMP Control Lock System 304
Component Parts of Work Equipment System . 305
Work Equipment and Swing PPC Valve . 305
Offset PPC Valve (with EPC Valve) 310
Blade PPC Valve 311
Solenoid Valve . 313
Bucket DUMP Control Lock Solenoid Valve 315
3-Spool EPC Valve 318
Boom Anti-drop Valve . 321
Arm Anti-Drop Valve 326
Multi-Control Valve 333
Pilot Circuit Accumulator 334
Swing System . 336
Layout Drawing of Swing System . 336
Swing Control System Diagram . 339
Function of Swing Control System . 339
Component Parts of Swing System 341
Swing Motor 341
Swing Machinery 349
Swing Circle . 351
Travel System 353
Layout Drawing of Travel System 353
System Diagram of Travel Control System 355
Function of Travel Control System 355
Component Parts of Travel System . 357
Travel Motor . 357
Travel PPC Valve . 367
Center Swivel Joint 372
Undercarriage and Frame 373
Layout Drawing of Undercarriage 373
Specifications of Undercarriage 373
Idler Cushion 375
Structure of Idler Cushion . 375
Specifications of Idler Cushion 375
Work Equipment . 376
Structure of Work Equipment 376
Function of Work Equipment . 378
Work Equipment Clearance Adjustment Shim . 379
Function of Work Equipment Clearance Adjustment Shim . 379
Bucket Clearance Adjustment Shim . 380
Function of Bucket Clearance Adjustment Shim . 380
CAB Related Parts 381
ROPS CAB . 381
Structure of ROPS CAB (Machine with KOMTRAX Terminal) 381
Structure of ROPS CAB (Machine with Gateway Function Controller) . 382
Function of ROPS CAB . 382
CAB Mount 383
Structure of CAB Mount . 383
Function of CAB Mount 384
Remove Wiring Harness Out of Cab . 385
20 Standard Value Table 387
Table of Contents 388
Abbreviation List 389
Standard Value Table for Engine 395
Standard Value Table for Engine: PC78UU-10 . 395
Standard Value Table for Machine . 398
Standard Value Table for Machine: PC78UU-10 398
Machine Posture and Procedures to Measure Performance 412
30 Testing and Adjusting . 417
Table of Contents 418
Precautions Before Work 421
Abbreviation List 422
Related Information on Testing and Adjusting . 428
Tools for Testing and Adjusting 428
Sketch of Tools for Testing and Adjusting 433
Engine and Cooling System 435
Examine Engine Speed . 435
How to Examine Engine Speed 435
Examine Exhaust Gas Color 438
How to Examine Exhaust Gas Color with the Handy Smoke Checker 438
How to Examine Exhaust Gas Color with Smoke Meter 438
Examine and Adjust Valve Clearance . 440
Check Valve Clearance 440
Adjust Valve Clearance . 441
Examine Compression Pressure . 442
How to Examine Compression Pressure 442
Examine Blowby Pressure 445
How to Examine Blowby Pressure . 445
Examine Engine Oil Pressure 447
How to Examine Engine Oil Pressure . 447
Visual Check Inside of EGR Valve . 449
How to do the Visual Check Inside of EGR Valve . 449
Clean Inside of EGR Valve 451
How to Clean Inside of EGR Valve . 451
Examine Fuel Pressure 454
How to Examine Fuel Pressure . 454
Examine Fuel Return Rate and Leakage . 456
How to Examine Fuel Return Rate and Leakage 457
Bleed Air from Fuel System . 460
How to Bleed Air from Fuel System 460
Examine Fuel Circuit for Leakage . 462
How to Examine Fuel System for Leakage . 462
Handle Cylinder Cut-out Mode Operation . 464
Handle No-Injection Cranking Operation . 465
Examine and Adjust Air Conditioner Compressor Belt Tension . 466
How to Examine Air Conditioner Compressor Belt Tension . 466
How to Adjust Air Conditioner Compressor Belt Tension 466
Examine Alternator Belt 467
How to Examine Alternator Belt . 467
Examine Automatic Tensioner 468
How to Examine Automatic Tensioner . 468
Write Injector Compensation Value to Engine Controller . 470
Write Injector Compensation Value 470
Power Train 476
Examine Swing Circle Bearing Clearance . 476
How to Examine Swing Circle Bearing Clearance 476
Undercarriage and Frame 477
Examine and Adjust Track Tension . 477
How to Examine Track Tension . 477
How to Adjust Track Tension 477
Hydraulic System . 479
Release Remained Pressure in Hydraulic Circuit . 479
How to Release Remained Pressure from Hydraulic Tank . 479
How to Release Remained Pressure in Hydraulic Cylinder Circuit . 479
How to Release Remained Pressure from Swing Motor Circuit 479
How to Release Remained Pressure from Travel Motor Circuit . 480
Examine and Adjust Oil Pressure in Work Equipment and Travel Circuits 481
Examine Oil Pressure in Work Equipment and Travel Circuits . 481
Adjust Oil Pressure in Work Equipment and Travel Circuits 485
Examine and Adjust Swing and Blade Circuit Oil Pressure 487
How to Examine Swing and Blade Relief Pressure . 487
How to Adjust Swing Relief Pressure 488
Adjust Blade LOWER Relief Pressure . 489
Adjust Blade RAISE Relief Pressure . 489
Examine Oil Pressure of Control Circuit 491
Examine Oil Pressure in Control Circuit 491
Examine and adjust oil pressure in pump PC control circuit . 493
How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 493
How to Examine PC-EPC Valve Outlet Pressure 495
How to Adjust Oil Pressure in Pump PC Control Circuit 495
Examine and Adjust Oil Pressure in Pump LS Control Circuit . 498
Examine LS Differential Pressure with Machine Monitor 498
Examine LS Differential Pressure by Testing Tool . 499
Adjust LS Valve 501
Examine Outlet Pressure of Solenoid Valve 502
How to Examine Outlet Pressure of Solenoid Valve . 502
Operating Condition of Solenoid Valve 505
Examine PPC Valve Outlet Pressure 507
Examine Outlet Pressure in PPC Valve . 507
Adjust Play of Work Equipment and Swing PPC Valves . 509
How to Adjust Play of Work Equipment and Swing PPC Valves 509
Examine and Adjust Travel Deviation 510
How to Examine Travel Deviation 510
Adjust Travel Deviation 510
Examine Parts Which Cause Hydraulic Drift of Work Equipment 513
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 513
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder . 513
How to Examine Parts that Cause Hydraulic Drift of PPC Valve . 514
Examine Oil Leakage 515
How to Examine Oil Leakage from Boom Cylinder 515
How to Examine Oil Leakage from Arm Cylinder . 515
How to Examine Oil Leakage from Bucket Cylinder 516
How to Examine Oil Leakage from Offset Cylinder 516
How to Examine Oil Leakage from Blade Cylinder . 517
How to Examine Oil Leakage from Swing Motor 517
How to Examine Oil Leakage from Travel Motor . 518
Bleed Air from Hydraulic System 520
How to Bleed Air from Hydraulic System . 522
CAB Related Parts 525
How to Adjust Mirrors 525
Procedure to Adjust Machine Rear Mirror (A) 525
Procedure to Adjust Machine Rear Mirror (B) 525
Examine and Adjust Engine Hood Catcher . 527
How to Examine Engine Hood Catcher . 527
How to Adjust Engine Hood Catcher 527
How to Examine and Adjust Slide Door . 530
How to Examine and Adjust Slide Door When It is Closed and Locked 530
How to Examine and Adjust Slide Door When It is Open and Locked 542
Electrical System 555
Set and Operate Machine Monitor 555
Operator Mode 559
Function to Show Technician Identification Status Screen . 559
Function to Show Operator Identification Input Screen 559
Examine Function by LCD (Liquid Crystal Display) . 560
Examine Function of Service Meter 560
Usage Limitation and Maintenance Password Change Function 560
Service Mode . 563
How to Operate Service Mode 563
How to See Pre-defined Monitoring Information 565
How to Examine Self-Define Monitor Information . 569
Abnormality Record Menu 577
How to See Maintenance Record 581
Maintenance Mode Setting . 582
Set Phone Number Entry . 585
Default Menu . 587
Diagnostic Tests Menu 593
Adjustment Menu 596
No-Injection Cranking Operation 604
UU Settings Menu . 606
KOMTRAX Settings Menu 617
Show Service Message . 621
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 623
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) . 628
Start Up KOMTRAX System (Machine with Gateway Function Controller) . 630
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 636
Adjust Rearview Camera Angle . 638
How to Adjust Rearview Camera Angle 638
Handle Voltage Circuit of Engine Controller 641
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) . 642
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) 643
Examine Diodes . 644
Examine Diodes by Digital Tester . 644
How to Examine Diodes by Analog Tester . 644
Pm Clinic 645
Pm Clinic Service 645
Pm Clinic Check Sheet: PC78UU-10 . 647
40 Troubleshooting . 659
Table of Contents 660
Precautions Before Work 667
Abbreviation List 668
Related Information to Troubleshooting . 674
General Troubleshooting Points . 674
Sequence of Events in Troubleshooting 675
Checks Before Troubleshooting 677
Inspection Procedure Before Troubleshooting 679
Walk-Around Check 679
Test in Accordance with Testing Procedure 681
Examine Fuel Level and Type 681
Examine Fuel Prefilter . 682
Examine Water Separator, Drain Water and Sediment 682
How to Replace Fuel Prefilter Cartridge 683
Examine Fuel Main Filter . 684
Examine Engine Oil Level (Oil Quantity in Oil Pan) . 686
Examine Oil Level in PTO Gear Case . 687
Examine Coolant Level (Reservoir Tank) . 688
Examine Air Cleaner Clogging . 688
Clean Outer Element 689
Replace Element 691
Examine Hydraulic Oil Level 692
Examine Hydraulic Oil Strainer . 694
Examine Hydraulic Oil Filter . 694
Examine Oil Level in Swing Machinery Case 695
Examine Oil Level in Final Drive Case 696
Bleed Air from Fuel System . 697
Bleed Air from Hydraulic System 697
How to Examine Electric Equipment 697
Preparation for Troubleshooting of Electrical System . 705
Procedure for Troubleshooting 712
Symptom and Troubleshooting Numbers 715
Information Shown in Troubleshooting Table . 719
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness . 721
Connector List and Layout (Machine with KOMTRAX Terminal) 723
Connector List and Layout (Machine with Gateway Function Controller) . 734
Connector Contact Connection Table . 745
T-Branch Box and T-Branch Adapter Table 786
Fuse Location Table (Machine with KOMTRAX Terminal) 792
Fuse Location Table (Machine with Gateway Function Controller) . 794
Failure Code Table . 796
Troubleshooting by Failure Code (Display of Code) 806
Failure Code [879AKA] 806
Failure Code [879AKB] 808
Failure Code [879BKA] 809
Failure Code [879BKB] 811
Failure Code [879CKA] 813
Failure Code [879CKB] 814
Failure Code [879DKZ] 815
Failure Code [879EMC] 817
Failure Code [879FMC] 818
Failure Code [879GKX] 819
Failure Code [989H00] 821
Failure Code [989HKM] 822
Failure Code [989L00] 823
Failure Code [989M00] 824
Failure Code [989N00] 825
Failure Code [A900FR] 826
Failure Code [A900N6] 827
Failure Code [A900NY] 828
Failure Code [AB00KE] 829
Failure Code [B@BAZG] 831
Failure Code [B@BCNS] 832
Failure Code [B@HANS] 833
Failure Code [CA115] . 835
Failure Code [CA122] . 836
Failure Code [CA123] . 838
Failure Code [CA131] . 840
Failure Code [CA132] . 842
Failure Code [CA144] . 844
Failure Code [CA145] . 846
Failure Code [CA153] . 848
Failure Code [CA154] . 850
Failure Code [CA187] . 852
Failure Code [CA221] . 854
Failure Code [CA222] . 856
Failure Code [CA227] . 858
Failure Code [CA234] . 859
Failure Code [CA238] . 860
Failure Code [CA239] . 862
Failure Code [CA271] . 864
Failure Code [CA272] . 866
Failure Code [CA322] . 867
Failure Code [CA324] . 869
Failure Code [CA331] . 871
Failure Code [CA332] . 873
Failure Code [CA343] . 875
Failure Code [CA351] . 876
Failure Code [CA352] . 877
Failure Code [CA356] . 879
Failure Code [CA357] . 881
Failure Code [CA386] . 883
Failure Code [CA435] . 884
Failure Code [CA441] . 886
Failure Code [CA442] . 888
Failure Code [CA449] . 889
Failure Code [CA451] . 890
Failure Code [CA452] . 892
Failure Code [CA466] . 894
Failure Code [CA515] . 896
Failure Code [CA516] . 898
Failure Code [CA553] . 900
Failure Code [CA555] . 901
Failure Code [CA556] . 902
Failure Code [CA559] . 903
Failure Code [CA689] . 907
Failure Code [CA691] . 909
Failure Code [CA692] . 911
Failure Code [CA697] . 913
Failure Code [CA698] . 914
Failure Code [CA731] . 915
Failure Code [CA778] . 917
Failure Code [CA1117] 919
Failure Code [CA1695] 920
Failure Code [CA1696] 921
Failure Code [CA1843] 922
Failure Code [CA1844] 924
Failure Code [CA1896] 926
Failure Code [CA1942] 930
Failure Code [CA1961] 931
Failure Code [CA2185] 932
Failure Code [CA2186] 933
Failure Code [CA2249] 935
Failure Code [CA2272] 936
Failure Code [CA2311] 939
Failure Code [CA2349] 940
Failure Code [CA2353] 942
Failure Code [CA2357] 944
Failure Code [CA2765] 945
Failure Code [CA3419] 946
Failure Code [CA3421] 948
Failure Code [CA3724] 950
Failure Code [CA3918] 952
Failure Code [CA3919] 953
Failure Code [CA3921] 954
Failure Code [CA3922] 955
Failure Code [CA3923] 957
Failure Code [D110KB] 959
Failure Code [D19JKZ] 961
Failure Code [D811MC] (Machine with KOMTRAX Terminal) 964
Failure Code [D811MC] (Machine with Gateway Function Controller) . 965
Failure Code [D862KA] (Machine with KOMTRAX Terminal) 966
Failure Code [D862KA] (Machine with Gateway Function Controller) . 967
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) 968
Failure Code [D8ALKA] (Machine with Gateway Function Controller) . 970
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) 972
Failure Code [D8ALKB] (Machine with Gateway Function Controller) . 974
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal) 976
Failure Code [D8AQKR] (Machine with Gateway Function Controller) . 978
Failure Code [D8G1KT] 980
Failure Code [D8G6KT] 981
Failure Code [DA20MC] 982
Failure Code [DA22KK] 983
Failure Code [DA25KP] 986
Failure Code [DA26KP] 989
Failure Code [DA29KQ] 992
Failure Code [DA2LKA] (Machine with KOMTRAX Terminal) 994
Failure Code [DA2LKA] (Machine with Gateway Function Controller) . 996
Failure Code [DA2LKB] (Machine with KOMTRAX Terminal) 998
Failure Code [DA2LKB] (Machine with Gateway Function Controller) .1000
Failure Code [DA2QKR] (Machine with KOMTRAX Terminal) 1002
Failure Code [DA2QKR] (Machine with Gateway Function Controller) .1005
Failure Code [DA2RKR] 1008
Failure Code [DAF0MB] 1009
Failure Code [DAF0MC] 1010
Failure Code [DAF8KB] 1011
Failure Code [DAF9KQ] 1013
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal) 1014
Failure Code [DAFGMC] (Machine with Gateway Function Controller) .1015
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal) 1016
Failure Code [DAFLKA] (Machine with Gateway Function Controller) .1018
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal) 1020
Failure Code [DAFLKB] (Machine with Gateway Function Controller) .1021
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal) 1023
Failure Code [DAFQKR] (Machine with Gateway Function Controller) .1024
Failure Code [DAZ9KQ] 1025
Failure Code [DAZQKR] (Machine with KOMTRAX Terminal) 1026
Failure Code [DAZQKR] (Machine with Gateway Function Controller) .1028
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) 1030
Failure Code [DB2QKR] (Machine with Gateway Function Controller) .1035
Failure Code [DB2RKR] (Machine with KOMTRAX Terminal) 1040
Failure Code [DB2RKR] (Machine with Gateway Function Controller) .1045
Failure Code [DDNRKA] 1050
Failure Code [DDNRKY] 1052
Failure Code [DDNS00] 1054
Failure Code [DGH2KB] 1056
Failure Code [DHPAMA] 1058
Failure Code [DHS3MA] 1061
Failure Code [DHS4MA] 1064
Failure Code [DHS5MA] 1067
Failure Code [DHS8MA] 1069
Failure Code [DHS9MA] 1072
Failure Code [DHSAMA] 1075
Failure Code [DHSBMA] 1078
Failure Code [DHSCMA] 1081
Failure Code [DHSDMA] 1084
Failure Code [DHSRMA] 1087
Failure Code [DHSSMA] 1090
Failure Code [DKA0KA] 1093
Failure Code [DKA0KB] 1096
Failure Code [DKA0PH] 1099
Failure Code [DKC0KA] 1100
Failure Code [DKC0KB] 1103
Failure Code [DKC0PH] 1106
Failure Code [DKP0KA] 1107
Failure Code [DKP0KB] 1110
Failure Code [DKP0PH] 1113
Failure Code [DKULKA] 1114
Failure Code [DKULKB] 1116
Failure Code [DKULKY] 1118
Failure Code [DV20KB] 1120
Failure Code [DW43KA] 1122
Failure Code [DW43KB] 1124
Failure Code [DW43KY] 1126
Failure Code [DW45KA] 1128
Failure Code [DW45KB] 1131
Failure Code [DW45KY] 1134
Failure Code [DW4CKY] 1136
Failure Code [DW4FKA] 1138
Failure Code [DW4FKB] 1140
Failure Code [DW4FKY] 1142
Failure Code [DW4GKA] 1144
Failure Code [DW4GKB] 1146
Failure Code [DW4GKY] 1148
Failure Code [DW4HKA] 1150
Failure Code [DW4HKB] 1152
Failure Code [DW4HKY] 1154
Failure Code [DWJ0KA] 1156
Failure Code [DWJ0KB] 1158
Failure Code [DWJ0KY] 1160
Failure Code [DXA8KA] 1162
Failure Code [DXA8KB] 1164
Failure Code [DXEBKA] 1166
Failure Code [DXEBKB] 1168
Failure Code [DXEBKY] 1170
Failure Code [DY20KA] 1172
Failure Code [DY20MA] 1174
Failure Code [DY2CKB] 1176
Failure Code [DY2DKB] 1179
Failure Code [DY2EKB] 1181
Failure code [F311KA] 1183
Failure code [F311KB] 1185
Failure code [F312KA] 1187
Failure code [F312KB] 1189
Failure Code [F313KA] 1191
Failure Code [F313KB] 1192
Failure code [F314KA] 1193
Failure code [F314KB] 1195
Failure code [F316KB] 1197
Failure code [F316KY] 1199
Failure Code [F318KB] 1201
Failure Code [F318KY] 1202
Failure code [F31AKB] 1203
Failure code [F31AKY] 1205
Failure Code [F31BKB] 1207
Failure Code [F31BKY] 1209
Failure Code [F31CKB] 1211
Failure Code [F31CKY] 1213
Failure Code [F31DKB] 1215
Failure Code [F31DKY] 1217
Failure Code [F31EKB] 1219
Failure Code [F31EKY] 1221
Failure Code [FS10ZE] 1223
Troubleshooting of Electrical System (E-Mode) 1224
Engine Does Not Start (Engine Does Not Crank) 1224
Manual Preheating System Does Not Operate 1230
While Preheating is in Operation, Preheating Monitor Does Not Come On 1233
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing .1235
Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation 1238
Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation .1239
Charge Level Monitor Comes On in Red While Engine is in Operation 1240
Fuel Level Monitor Comes On in Red While Engine is in Operation 1241
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1242
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation .1243
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation .1244
Fuel Gauge Does Not Move from Minimum or Maximum .1245
Display of Fuel Gauge is Different from Actual Fuel Level 1247
Engine Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum .1248
Display of Engine Coolant Temperature Gauge is Different from Actual Coolant Temperature .1249
Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum 1250
Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1252
Some Areas of Machine Monitor Screen are Not Shown .1253
Function Switch Does Not Operate .1254
Automatic Warm-up System Does Not Operate (in Cold Weather) 1255
Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated 1256
Auto-Decelerator is Not Operated or Canceled with Lever 1257
Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated 1258
Boom Raising Does Not Automatically Stop Correctly and It Interferes (CAB Side) 1259
Arm IN Does Not Automatically Stop Correctly and It Interferes (CAB Side) 1261
Offset Left Does Not Automatically Stop Correctly and It Interferes (CAB Side) .1263
Boom LOWER Does Not Automatically Stop Correctly and It Interferes (Right Exterior Side) .1265
Arm IN Does Not Automatically Stop Correctly and It Interferes (Right External Side) .1267
Offset Right Does Not Automatically Stop Correctly and It Interferes (Right Exterior Side) .1269
Work Equipment Stop Position is Too Far or Near 1271
Cushion for Boom Raise End Does Not Work or is Weak 1273
Cushion for Arm IN End Does Not Work or is Weak 1275
At the Height Restriction, Machine Stops Past Excessive the Restriction or Stops Short of It .1277
Depth Indication Departs or Does Not Show 1279
Buzzer Sounds for 7 Seconds Even If the Work Equipment Lock Release Switch is Not Turned ON 1281
When the Work Equipment Lock Release Switch is Turned ON, the Work Equipment Lock Pilot Lamp Does Not Come On 1282
When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1284
Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated .1285
Travel Speed Does Not Change Even When You Change Travel Speed .1286
Alarm Buzzer Does Not Stop .1287
Service Meter is Not Shown While Starting Switch is in OFF Position 1288
Service Mode Cannot be Selected 1289
All Work Equipment, Swing, Travel Do Not Operate .1290
All Work Equipment, Swing, Travel Cannot be Locked .1293
Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position .1295
While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated .1297
Travel Alarm Does Not Operate During Travel 1299
Travel Alarm Does Not Stop When Machine Stops 1301
Horn Does Not Sound 1302
Horn Does Not Stop .1304
Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated 1305
Windshield Wiper Does Not Operate When Wiper Switch is Operated 1306
When Window Washer Switch is Operated, Window Washer Does Not Operate 1308
“Boom Raise” is Not Shown Correctly with Monitoring Function .1309
“Boom Lower” is Not Shown Correctly with Monitoring Function .1310
“Arm OUT” is Not Shown Correctly with Monitoring Function 1311
“Arm IN” is Not Shown Correctly with Monitoring Function .1312
Bucket DUMP is Not Shown Correctly with Monitoring Function 1313
Bucket CURL is Not Shown Correctly with Monitoring Function 1314
Offset Left is Not Shown Correctly with Monitoring Function 1315
Offset Right is Not Shown Correctly with Monitoring Function .1316
Swing is Not Shown Correctly with Monitoring Function 1317
Travel is Not Shown Correctly with Monitoring Function .1318
Blade RAISE is Not Shown Correctly with Monitoring Function 1319
Blade LOWER is Not Shown Correctly with Monitoring Function 1321
KOMTRAX System Does Not Operate Correctly 1323
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1324
Information Shown in Troubleshooting Table (H-Mode) 1324
System Chart of Hydraulic and Mechanical Systems .1325
Failure Mode and Cause Table .1327
All Work Equipment, Swing and Travel Do Not Work .1335
All Work Equipment, Swing, and Travel Lack Speed or Power 1336
Fine Control Performance or Response is Unsatisfactory .1338
Unusual Noise is Heard from Around Hydraulic Pump 1339
Engine Speed Drops Largely or Engine Stops .1340
Boom Speed or Power is Low .1342
Arm Speed or Power is Low 1346
Bucket Speed or Power is Low .1349
Blade Speed or Power is Low 1352
Offset Speed or Power is Low .1354
Work Equipment Does Not Move in Single Operation .1356
Hydraulic Drift of Boom is Large .1358
Hydraulic Drift of Arm is Large 1359
Hydraulic Drift of Bucket is Large .1360
Hydraulic Drift of Offset is Large .1361
Hydraulic Drift of Blade is Large 1362
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves .1364
Boom RAISE and LOWER, Arm IN, or Offset Right and Left Does Not Automatically Stop and It Interfere 1365
Time Lag of Work Equipment is Large 1366
In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 1367
In Mixed Operation of Work Equipment and Travel, Travel Speed Falls Largely 1368
In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low 1369
Machine Does Not Travel Straight .1370
Machine is Not Steered Well or Steering Power is Low .1372
Travel Speed is Low 1375
One of Tracks Does Not Run .1378
Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 1380
Upper Structure Does Not Swing in Two Directions of Right and Left .1381
Machine Swings Only in One Direction .1383
Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left .1384
Swing Acceleration or Swing Speed is Low in Only One Direction .1386
Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) .1387
Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) .1388
Shock is Large When Upper Structure Stops Swing Operation 1389
Large Unusual Noise is Made When Upper Structure Stops Swing Operation .1390
Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) .1391
Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 1392
Troubleshooting of Engine (S-Mode) .1393
Information Shown in Troubleshooting Table (S-Mode) 1393
Engine Does Not Crank When Starting Switch is Turned to Start Position .1394
Engine Cranks but No Exhaust Smoke Comes Out .1395
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1396
Engine Startability is Unsatisfactory 1397
Engine Does Not Pick Up Smoothly .1399
Engine Stops During Operation 1401
Engine Does Not Rotate Smoothly 1403
Engine Lacks Output (or Lacks Power) .1404
Exhaust Smoke is Black .1406
Engine Oil Consumption is Excessive 1408
Engine Oil Becomes Dirty Quickly .1409
Fuel Consumption is Excessive 1410
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 1411
Engine Oil Pressure Drops 1412
Fuel Mixes Into Engine Oil .1414
Water Mixes Into Engine Oil (Milky) 1415
Coolant Temperature Increases Too High (Overheat) 1416
Unusual Noise is Heard .1417
Vibration is Excessive .1418
Air Cannot be Bled from Fuel Circuit .1419
50 Disassembly and Assembly 1421
Table of Contents 1422
Precautions Before Work 1427
Abbreviation List 1428
Related Information on Disassembly and Assembly 1434
How to Read This Manual 1434
Coating Materials List .1435
Special Tool List 1440
Sketches of Special Tools 1449
Engine and Cooling System 1453
Remove and Install Supply Pump Assembly 1453
Remove Supply Pump Assembly 1453
Install Supply Pump Assembly .1457
Remove and Install Injector Assembly .1462
How to Remove Injector Assembly 1462
How to Install Injector Assembly .1466
Remove and Install Cylinder Head Assembly 1473
How to Remove Cylinder Head Assembly .1473
How to Install Cylinder Head Assembly 1483
Remove and Install EGR Valve Assembly 1497
Remove EGR Valve Assembly 1497
Install EGR Valve Assembly .1498
Remove and Install EGR Cooler Assembly .1500
How to Remove EGR Cooler Assembly 1500
How to Install EGR Cooler Assembly .1502
Remove and Install Starter Assembly 1504
Remove Starting Motor Assembly .1504
Install Starting Motor Assembly 1505
Remove and Install Air Conditioner Compressor Belt .1507
Remove Air Conditioner Compressor Belt .1507
Install Air Conditioner Compressor Belt 1508
Remove and Install Alternator Belt .1510
Remove Alternator Belt .1510
Install Alternator Belt 1511
Remove and Install Automatic Tensioner .1513
Remove Automatic Tensioner .1513
Install Automatic Tensioner 1513
Remove and Install Radiator Assembly .1514
How to Remove Radiator Assembly 1514
How to Install Radiator Assembly .1517
Remove and Install Hydraulic Oil Cooler Assembly .1523
How to Remove Hydraulic Oil Cooler Assembly 1523
How to Install Hydraulic Oil Cooler Assembly .1527
Remove and Install Aftercooler Assembly 1531
Remove Aftercooler Assembly 1531
Install Aftercooler Assembly .1532
Remove and Install Engine and Main Pump Assembly .1536
Remove Engine and Main Pump Assembly .1537
Install Engine and Main Pump Assembly 1548
Remove and Install Engine Front Oil Seal .1559
How to Remove Engine Front Oil Seal 1559
How to Install Engine Front Oil Seal .1560
Remove and Install Engine Rear Oil Seal 1562
How to Remove Engine Rear Oil Seal .1562
How to Install Engine Rear Oil Seal 1563
Remove and Install Fuel Cooler Assembly 1565
Remove Fuel Cooler Assembly 1565
Install Fuel Cooler Assembly .1566
Remove and Install Engine Hood Assembly 1568
How to Remove Engine Hood Assembly .1568
How to Install Engine Hood Assembly 1569
Remove and Install KDOC Muffler 1571
How to Remove KDOC Muffler .1571
How to Install KDOC Muffler 1574
Remove and Install Fuel Tank Assembly 1579
Remove Fuel Tank Assembly 1579
Install Fuel Tank Assembly .1581
Remove and Install KCCV Ventilator Assembly 1584
How to Remove KCCV Ventilator Assembly .1584
How to Install KCCV Ventilator Assembly 1586
Remove and Install Air Cleaner Assembly 1588
Remove Air Cleaner Assembly 1588
Install Air Cleaner Assembly .1589
Remove and Install Air Conditioner Compressor Assembly .1591
Remove Air Conditioner Compressor Assembly .1591
How to Install Air Conditioner Compressor Assembly .1593
Remove and Install Air Conditioner Condenser Assembly 1596
How to Remove Air Conditioner Condenser Assembly .1596
How to Install Air Conditioner Condenser Assembly 1597
Power Train 1598
Remove and Install Travel Motor and Final Drive Assembly .1598
Remove Travel Motor and Final Drive Assembly .1598
Install Travel Motor and Final Drive Assembly 1599
Disassemble and Assemble Travel Motor and Final Drive Assembly (Applicable Machine: #30001 to 35917) .1601
How to Disassemble Travel Motor and Final Drive Assembly (Applicable Machine: #30001 to 35917) .1611
How to Assemble Travel Motor and Final Drive Assembly (Applicable Machine: #30001 to 35917) 1630
Disassemble and Assemble Travel Motor and Final Drive Assembly (Applicable Machine: #35918 and Up) .1648
Disassemble Travel Motor and Final Drive Assembly (Applicable Machine: #35918 and Up) 1657
Assemble Travel Motor and Final Drive Assembly (Applicable Machine: #35918 and Up) .1678
Remove and Install Swing Motor and Swing Machinery Assembly 1697
Remove Swing Motor and Swing Machinery Assembly 1697
Install Swing Motor and Swing Machinery Assembly .1698
Disassemble and Assemble Swing Machinery Assembly 1700
Disassemble Swing Machinery Assembly .1700
Assemble Swing Machinery Assembly 1703
Remove and Install Swing Circle Assembly .1709
Remove Swing Circle Assembly .1709
Install Swing Circle Assembly 1709
Undercarriage and Frame 1711
Separate and Connect Track Assembly 1711
Separate Track Assembly 1711
Install Track Assembly .1712
Remove and Install Sprocket 1713
Remove Sprocket 1713
Install Sprocket .1713
Remove and Install Idler and Idler Cushion Assembly 1715
Remove Idler and Idler Cushion Assembly 1715
Install Idler and Idler Cushion Assembly .1715
Disassemble and Assemble Idler Assembly 1717
Disassemble Idler Assembly .1717
Assemble Idler Assembly 1718
Disassemble and Assemble Idler Cushion Assembly 1721
Disassemble Idler Cushion Assembly .1721
Assemble Idler Cushion Assembly 1722
Disassemble and Assemble Track Roller Assembly .1724
Disassemble Track Roller Assembly 1724
Assemble Track Roller Assembly .1725
Remove and Install Revolving Frame Assembly 1728
Remove Revolving Frame Assembly 1728
Install Revolving Frame Assembly .1730
Remove and Install Counterweight Assembly 1733
Remove Counterweight Assembly 1733
Install Counterweight Assembly .1736
Hydraulic System .1739
Remove and Install Center Swivel Joint Assembly 1739
Remove Center Swivel Joint Assembly 1739
Install Center Swivel Joint Assembly .1740
Disassemble and Assemble Center Swivel Joint Assembly 1742
Disassemble Center Swivel Joint Assembly .1743
Assemble Center Swivel Joint Assembly 1744
Remove and Install Hydraulic Tank Assembly .1745
Remove Hydraulic Tank Assembly .1745
How to Install Hydraulic Tank Assembly .1749
Remove and Install Main Pump Assembly 1753
Remove Main Pump Assembly 1753
Install Main Pump Assembly .1757
Remove and Install Control Valve Assembly 1763
How to Remove Control Valve Assembly .1763
How to Install Control Valve Assembly 1767
Disassemble and Assemble Work Equipment PPC Valve Assembly .1773
Disassemble Work Equipment PPC Valve Assembly 1773
How to Assemble Work Equipment PPC Valve Assembly 1773
Disassemble and Assemble Travel PPC Valve Assembly .1775
Disassemble Travel PPC Valve Assembly 1775
How to Assemble Travel PPC Valve Assembly 1776
Work Equipment .1778
Remove and Install Blade Assembly 1778
Remove Blade Assembly 1778
Install Blade Assembly .1778
Remove and Install Work Equipment Assembly .1781
Remove Work Equipment Assembly .1781
Install Work Equipment Assembly 1786
Remove and Install 1st Boom Assembly .1790
How to Remove 1st Boom Assembly 1790
How to Install 1st Boom Assembly .1795
Remove and Install 2nd Boom Assembly .1800
How to Remove 2nd Boom Assembly 1800
How to Install 2nd Boom Assembly .1802
Remove and Install 3rd Bracket Assembly 1804
How to Remove 3rd Bracket Assembly .1804
How to Install 3rd Bracket Assembly 1807
Remove and Install Boom Anti-drop Valve Assembly .1812
Remove Boom Anti-drop Valve Assembly .1812
Install Boom Anti-drop Valve Assembly 1814
Remove and Install Anti-Drop Valve Assembly for Arm (Head Side) 1816
How to Remove Anti-Drop Valve Assembly for Arm (Head Side) .1816
How to Install Anti-Drop Valve Assembly for Arm (Head Side) 1818
Remove and Install Anti-Drop Valve Assembly for Arm (Bottom Side) 1819
How to Remove Anti-Drop Valve Assembly for Arm (Bottom Side) .1819
How to Install Anti-Drop Valve Assembly for Arm (Bottom Side) 1821
Disassemble and Assemble Anti-Drop Valve Assembly 1823
Disassemble Anti-Drop Valve Assembly .1823
Assemble Anti-Drop Valve Assembly 1823
Remove and Install Boom Potentiometer Assembly .1824
How to Remove Boom Potentiometer Assembly 1824
How to Install Boom Potentiometer Assembly .1824
Remove and Install Arm Potentiometer Assembly 1825
How to Remove Arm Potentiometer Assembly .1825
How to Install Arm Potentiometer Assembly 1826
Remove and Install Offset Potentiometer Assembly .1828
How to Remove Offset Potentiometer Assembly 1828
How to Install Offset Potentiometer Assembly .1828
Disassemble and Assemble Work Equipment Cylinder Assembly 1829
How to Disassemble Work Equipment Cylinder Assembly 1830
How to Assemble Work Equipment Cylinder Assembly .1832
CAB Related Parts 1836
Remove and Install Operator Cab Assembly .1836
How to Remove Operator Cab Assembly 1836
Install Operator CAB Assembly 1841
Remove and Install Slide Door 1847
How to Remove Slide Door .1847
How to Install Slide Door 1847
Remove and Install Operator Cab Glass (Adhered Glass) 1849
Remove Operator CAB Glass (Adhered Glass) 1850
Install Operator CAB Glass (Adhered Glass) .1851
Remove and Install Front Window Assembly .1860
Remove Front Window Assembly .1860
Install Front Window Assembly 1861
Remove and Install Floor Frame Assembly 1863
How to Remove Floor Frame Assembly .1863
How to Install Floor Frame Assembly 1871
Remove and Install Air Conditioner Unit Assembly .1879
Remove Air Conditioner Unit Assembly .1879
Install Air Conditioner Unit Assembly 1886
Remove and Install Operator Seat .1893
Remove Operator’s Seat .1893
Install Operator’s Seat 1893
How to Remove and Install Seat Belt 1895
How to Remove Seat Belt 1895
How to Install Seatbelt 1896
Remove and Install Work Equipment Control Lever Assembly .1897
How to Remove Work Equipment Control Lever Assembly 1897
How to Install Work Equipment Control Lever Assembly .1903
Remove and Install Front Wiper Assembly 1911
Remove Front Wiper Assembly 1911
Install Front Wiper Assembly .1916
Electrical System 1925
Remove and Install Engine Controller Assembly 1925
Remove Engine Controller Assembly 1925
Install Engine Controller Assembly .1926
Remove and Install Pump Controller Assembly 1928
Remove Pump Controller Assembly 1928
Install Pump Controller Assembly .1929
Remove and Install Machine Monitor Assembly 1930
Remove Machine Monitor Assembly 1930
Install Machine Monitor Assembly .1932
Remove and Install Mass Air Flow and Temperature Sensor 1936
How to Remove Mass Air Flow and Temperature Sensor .1936
How to Install Mass Air Flow and Temperature Sensor 1936
Remove and Install KCCV Crankcase Pressure Sensor 1938
How to Remove KCCV Crankcase Pressure Sensor .1938
How to Install KCCV Crankcase Pressure Sensor 1939
Remove and Install KOMTRAX Terminal Assembly .1940
Remove KOMTRAX Terminal Assembly .1940
Install KOMTRAX Terminal Assembly 1940
Remove and Install Gateway Function Controller .1942
How to Remove Gateway Function Controller 1943
How to Install Gateway Function Controller .1945
Remove and Install Communication Terminal 1948
How to Remove Communication Terminal .1949
How to Install Communication Terminal 1950
60 Maintenance Standard 1953
Table of Contents 1954
Abbreviation List 1955
Engine and Cooling System 1961
Maintenance Standard for Engine Mount 1961
Maintenance Standard for PTO .1962
Maintenance Standard for Cooling System 1963
Power Train 1965
Maintenance Standard for Swing Circle 1965
Maintenance Standard for Swing Machinery .1967
Maintenance Standard for Sprocket 1969
Undercarriage and Frame 1970
Maintenance Standard for Track Frame and Idler Cushion .1970
Maintenance Standard for Idler .1972
Maintenance Standard for Track Roller 1974
Maintenance Standard for Carrier Roller 1975
Maintenance Standard for Track Shoes .1976
Maintenance Standard for Triple Shoes 1979
Maintenance Standard for Road Liner 1980
Maintenance Standard for Rubber Shoes 1981
Hydraulic System .1982
Maintenance Standard for Hydraulic Tank 1982
Maintenance Standard for Main Pump .1983
Maintenance Standard for Main Pump Servo Valve .1985
Maintenance Standard for PC-EPC Valve 1986
Maintenance Standard for Swing Motor .1987
Maintenance Standard for Travel Motor 1990
Maintenance Standard for Control Valve .1991
Maintenance Standard for Boom Anti-Drop Valve 2001
Maintenance Standard for Arm Anti-Drop Valve .2003
Maintenance Standard for Work Equipment and Swing PPC Valve 2005
Maintenance Standard for Blade PPC Valve .2008
Maintenance Standard for Offset PPC Valve (with EPC Valve) .2010
Maintenance Standard for EPC Valve of Offset PPC Valve .2011
Maintenance Standard for Travel PPC Valve 2013
Maintenance Standard for Solenoid Valve 2016
Maintenance Standard for Center Swivel Joint .2017
Work Equipment .2018
Maintenance Standard for Work Equipment Linkage 2018
Dimensions of Arm 2025
Dimensions of Bucket .2027
Maintenance Standard for Boom Cylinder .2029
Maintenance Standard for Arm Cylinder 2030
Maintenance Standard for Boom Offset Cylinder 2031
Maintenance Standard for Bucket Cylinder .2032
Maintenance Standard for Blade Cylinder 2033
80 Appendix 2035
Table of Contents 2036
Precautions Before Work 2038
Abbreviation List 2039
Air Conditioner System .2045
Precautions for Refrigerant 2045
Air Conditioner Component 2046
Specifications of Air Conditioner 2048
Structure and Function of Refrigeration Cycle 2049
Outline of Refrigeration Cycle .2050
Component Parts of Air Conditioner System 2052
Air Conditioner Unit .2052
Configuration Diagram of Air Conditioner Unit 2052
Function of Air Conditioner Unit .2054
Component Parts of Air Conditioner Unit 2055
Function of Evaporator as Air Conditioner Unit Component .2056
Function of Heater Core as Air Conditioner Unit Component 2056
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2056
Function of Servo Motor as Air Conditioner Unit Component 2057
Structure of Expansion Valve as Air Conditioner Unit Component .2058
Function of Expansion Valve as Air Conditioner Unit Component 2058
Operate Expansion Valve as Air Conditioner Unit Component 2058
Function of Dual Pressure Switch .2059
Air Conditioner Controller .2060
Structure of Air Conditioner Controller 2060
Compressor .2061
Structure of Compressor 2061
Specifications of Compressor .2061
Function of Compressor .2061
Condenser 2062
Structure of Condenser .2062
Specifications of Condenser 2062
Function of Condenser 2062
Receiver Drier .2063
Structure of Receiver Dryer 2063
Specifications of Receiver Dryer .2063
Function of Receiver Dryer .2063
Air Conditioner Related Sensors 2064
Structure of Sunlight Sensor .2064
Function of Sunlight Sensor 2064
Structure of Outside Temperature Sensor 2064
Function of Outside Air Temperature Sensor .2064
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2066
Circuit Diagram and Configuration of Connector Pins of Air Conditioner .2068
System Diagram of Air Conditioner 2070
Input and Output Signals of Air Conditioner Controller .2071
Function of Air Conditioner Controller .2072
Locations of Air Conditioner Parts and Layout of Connectors 2073
Examine Air Leakage (Duct) .2079
How to Examine Air Leakage (Duct) 2079
Examine Air Conditioner with Self-Diagnosis Function .2080
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2081
Examine Vent (Mode) Changeover .2082
How to Examine Vent (Mode) Changeover 2082
Examine Fresh/Recirc Air Changeover 2083
How to Examine Fresh/Recirc Air Changeover .2083
Examine Sunlight Sensor 2084
How to Examine Sunlight Sensor .2084
Examine Refrigerant (Dual) Pressure Switch .2085
How to Examine Refrigerant (Dual) Pressure Switch 2085
Examine Relay 2087
How to Examine Relay .2087
Air Conditioner Troubleshooting Chart 1 2088
Air Conditioner Troubleshooting Chart 2 2089
Information Shown in Troubleshooting Table .2092
Failure Code [879AKA] 2093
Failure Code [879AKB] 2095
Failure Code [879BKA] 2097
Failure Code [879BKB] 2099
Failure Code [879CKA] 2101
Failure Code [879CKB] 2102
Failure Code [879DKZ] 2103
Failure Code [879EMC] 2105
Failure Code [879FMC] 2106
Failure Code [879GKX] 2107
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) .2109
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2111
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) .2114
Troubleshooting for Fresh/Recirc Air Changeover 2116
Troubleshooting by Gauge Pressure 2118
Connect Service Tool .2121
How to Connect Service Tool 2121
Precautions for Disconnection and Connection of Air Conditioner Piping .2123
Handle Compressor Oil 2125
90 Circuit Diagrams 2127
Table of Contents 2128
Abbreviation List 2129
Hydraulic Circuit Diagram 2135
Symbols Used in Hydraulic Circuit Diagram 2135
Hydraulic Circuit Diagram 2139
Electrical Circuit Diagram .2141
Symbols Used in Electric Circuit Diagram .2141
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (1/6) .2145
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (2/6) .2147
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (3/6) .2149
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (4/6) .2151
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (5/6) .2153
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (6/6) .2155
Electrical Circuit Diagram (Machine with Gateway Function Controller) (1/7) 2157
Electrical Circuit Diagram (Machine with Gateway Function Controller) (2/7) 2159
Electrical Circuit Diagram (Machine with Gateway Function Controller) (3/7) 2161
Electrical Circuit Diagram (Machine with Gateway Function Controller) (4/7) 2163
Electrical Circuit Diagram (Machine with Gateway Function Controller) (5/7) 2165
Electrical Circuit Diagram (Machine with Gateway Function Controller) (6/7) 2167
Electrical Circuit Diagram (Machine with Gateway Function Controller) (7/7) 2169
Index .2171

DESCRIPTION:

Komatsu PC78UU-10 Hydraulic Excavator Shop Manual SEN06659-05 –  PDF DOWNLOAD

• SERIAL NUMBERS 30001 and up

G.B 26/12/24