Komatsu PC78US-11 Shop Manual SEN06844-C8

Data Size: 219.71 MB
File Type: PDF
Language: English
Manufacturer: Komatsu
Applicable Machine: Hydraulic Excavator
Document: Shop Manual, Error Code, Electrical Schematic, Hydraulic Schematic
Machine Model: Komatsu PC78US-11 Hydraulic Excavator
Serial Number: C00001 and up
Book Number: SEN06844-C8
Page: 2354 Pages

List Contents:

00 Index and Foreword
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions When You Discard Waste Materials
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
Disconnect and Connect Connector with Lock to Pull
Disconnect and Connect Connector with Lock to Push
Disconnect and Connect Connector with Housing to Rotate
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table
Abbreviation List
01 Specification
Table of Contents
Specifications
Specification Drawing
Working Range Drawings
Specifications
Weight Table
Fuel, Coolant, Lubricants (For North America)
10 Structure and Function
Table of Contents
Boot-up System
Layout Drawing of Boot-up System
System Operating Lamp System
Battery Disconnect Switch
Engine System
Layout Drawing of Engine System
Engine Control System
Auto-Deceleration System
Engine Automatic Warm-up System
Overheat Prevention System
Turbocharger Protection System
Automatic Idle Stop System
Component Parts of Engine System
Cooling System
Layout Drawing of Cooling System
Control System
Layout Drawing of Control System
Machine Monitor System
KOMTRAX System
Component Parts of Control System
Hydraulic System
00 Index and Foreword
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions When You Discard Waste Materials
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
Disconnect and Connect Connector with Lock to Pull
Disconnect and Connect Connector with Lock to Push
Disconnect and Connect Connector with Housing to Rotate
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table
Abbreviation List
01 Specification
Table of Contents
Specifications
Specification Drawing
Working Range Drawings
Specifications
Weight Table
Fuel, Coolant, Lubricants (For North America)
10 Structure and Function
Table of Contents
Boot-up System
Layout Drawing of Boot-up System
System Operating Lamp System
Battery Disconnect Switch
Engine System
Layout Drawing of Engine System
Engine Control System
Auto-Deceleration System
Engine Automatic Warm-up System
Overheat Prevention System
Turbocharger Protection System
Automatic Idle Stop System
Component Parts of Engine System
Cooling System
Layout Drawing of Cooling System
Control System
Layout Drawing of Control System
Machine Monitor System
KOMTRAX System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
CLSS
Engine and Pump Combined Control System
Component Parts of Hydraulic System
Work Equipment System
Layout Drawing of Work Equipment System
PPC Lock System
Work Equipment and Travel Automatic Lock System
Attachment Oil Flow Adjuster System
Component Parts of Work Equipment System
Swing System
Layout Drawing of Swing System
Swing Control System Diagram
Component Parts of Swing System
Travel System
Layout Drawing of Travel System
System Diagram of Travel Control System
Component Parts of Travel System
Undercarriage and Frame
Layout Drawing of Undercarriage
Idler Cushion
Work Equipment
Structure of Work Equipment
Function of Work Equipment
Work Equipment Clearance Adjustment Shim
Bucket Clearance Adjustment Shim
CAB Related Parts
ROPS CAB
CAB Mount
Remove Wiring Harness Out of Cab
20 Standard Value Table
Table of Contents
Standard Value Table for Engine
Standard Value Table for Engine: PC78US-11
Standard Value Table for Machine
Standard Value Table for Machine: PC78US-11
Machine Posture and Procedures to Measure Performance
30 Testing and Adjusting
Table of Contents
Precautions Before Work
Related Information on Testing and Adjusting
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
Examine Exhaust Gas Color
Examine and Adjust Valve Clearance
Examine Compression Pressure
Examine Blowby Pressure
Examine Engine Oil Pressure
Visual Check Inside of EGR Valve
Clean Inside of EGR Valve
Examine Fuel Pressure
Examine Fuel Return Rate and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Handle Cylinder Cut-out Mode Operation
Handle No-Injection Cranking Operation
Failure Code [879BKA]
Failure Code [879BKB]
Failure Code [879CKA]
Failure Code [879CKB]
Failure Code [879DKZ]
Failure Code [879EMC]
Failure Code [879FMC]
Failure Code [879GKX]
Failure Code [989L00]
Failure Code [989M00]
Failure Code [989N00]
Failure Code [A900FR]
Failure Code [A900N6]
Failure Code [A900NY]
Failure Code [AA10NX]
Failure Code [AB00KE]
Failure Code [B@BAZG]
Failure Code [B@BCNS]
Failure Code [B@BCQA]
Failure Code [B@BCZK]
Failure Code [B@HANS]
Failure Code [CA115]
Failure Code [CA122]
Failure Code [CA123]
Failure Code [CA131]
Failure Code [CA132]
Failure Code [CA144]
Failure Code [CA145]
Failure Code [CA153]
Failure Code [CA154]
Failure Code [CA187]
Failure Code [CA221]
Failure Code [CA222]
Failure Code [CA227]
Failure Code [CA234]
Failure Code [CA238]
Failure Code [CA239]
Failure Code [CA271]
Failure Code [CA272]
Failure Code [CA322]
Failure Code [CA324]
Failure Code [CA331]
Failure Code [CA343]
Failure Code [CA351]
Failure Code [CA352]
Failure Code [CA356]
Failure Code [CA357]
Failure Code [CA386]
Failure Code [CA435]
Failure Code [CA441]
Failure Code [CA442]
Failure Code [CA449]
Failure Code [CA451]
Failure Code [CA452]
Failure Code [CA515]
Failure Code [CA516]
Failure Code [CA553]
Failure Code [CA559]
Failure Code [CA689]
Failure Code [CA691]
Failure Code [CA692]
Failure Code [CA697]
Failure Code [CA698]
Failure Code [CA731]
Failure Code [CA778]
Failure Code [CA1117]
Failure Code [CA1896]
Failure Code [CA1961]
Failure Code [CA2185]
Failure Code [CA2186]
Failure Code [CA2249]
Failure Code [CA2272]
Failure Code [CA2311]
Failure Code [CA2349]
Failure Code [CA2353]
Failure Code [CA2357]
Failure Code [CA2765]
Failure Code [CA2973]
Failure Code [CA3419]
Failure Code [CA3421]
Failure Code [CA3724]
Failure Code [CA4264]
Failure Code [CA4952]
Failure Code [D110KB]
Failure Code [D19JKZ]
Failure Code [D811MC]
Failure Code [D862KA]
Failure Code [D8ALKA]
Failure Code [D8ALKB]
Failure Code [D8AQKR]
Failure Code [D8G1KT]
Failure Code [D8G6KT]
Failure Code [DA20MC]
Failure Code [DA22KK]
Failure Code [DA25KP]
Failure Code [DA26KP]
Failure Code [DA29KQ]
Failure Code [DA2LKA]
Failure Code [DA2LKB]
Failure Code [DA2QKR]
Failure Code [DA2RKR]
Failure Code [DAF0MB]
Failure Code [DAF0MC]
Failure Code [DAF8KB]
Failure Code [DAF9KQ]
Failure Code [DAFGMC]
Failure Code [DAFLKA]
Failure Code [DAFLKB]
Failure Code [DAFQKR]
Failure Code [DAZ9KQ]
Failure Code [DAZQKR]
Failure Code [DB2QKR]
Failure Code [DB2RKR]
Failure Code [DDNRKA]
Failure Code [DDNRKY]
Failure Code [DDNS00]
Failure Code [DFB1KZ]
Failure Code [DFB2KZ]
Failure Code [DFB3L8]
Failure Code [DFB4L8]
Failure Code [DFB5KZ]
Failure Code [DFB6KZ]
Failure Code [DGH2KA]
Failure Code [DGH2KB]
Failure Code [DHA4KA]
Failure Code [DHPAMA]
Failure Code [DHS3MA]
Failure Code [DHS4MA]
Failure Code [DHS5MA]
Failure Code [DHS8MA]
Failure Code [DHS9MA]
Failure Code [DHSAMA]
Failure Code [DHSBMA]
Failure Code [DHSCMA]
Failure Code [DHSDMA]
Failure Code [DKR0MA]
Failure Code [DKULKA]
Failure Code [DKULKB]
Failure Code [DKULKY]
Failure Code [DLM5KA]
Failure Code [DLM5MB]
Failure Code [DV20KB]
Failure Code [DW43KA]
Failure Code [DW43KB]
Failure Code [DW43KY]
Failure Code [DW45KA]
Failure Code [DW45KB]
Failure Code [DW45KY]
Failure Code [DW4CKY]
Failure Code [DWA2KA]
Failure Code [DWA2KB]
Failure Code [DWA2KY]
Failure Code [DWJ0KA]
Failure Code [DWJ0KB]
Failure Code [DWJ0KY]
Failure Code [DWN5KA]
Failure Code [DWN5KB]
Failure Code [DWN5KY]
Failure Code [DXA8KA]
Failure Code [DXA8KB]
Failure Code [DXE4KA]
Failure Code [DXE4KB]
Failure Code [DXE4KY]
Failure Code [DXE7KA]
Failure Code [DXE7KB]
Failure Code [DXE7KY]
Failure Code [DXE8KA]
Failure Code [DXE8KB]
Failure Code [DXE8KY]
Failure Code [DXE9KA]
Failure Code [DXE9KB]
Failure Code [DXE9KY]
Failure Code [DXEAKA]
Failure Code [DXEAKB]
Failure Code [DFB1KZ]
Failure Code [DFB2KZ]
Failure Code [DFB3L8]
Failure Code [DFB4L8]
Failure Code [DFB5KZ]
Failure Code [DFB6KZ]
Failure Code [DGH2KA]
Failure Code [DGH2KB]
Failure Code [DHA4KA]
Failure Code [DHPAMA]
Failure Code [DHS3MA]
Failure Code [DHS4MA]
Failure Code [DHS5MA]
Failure Code [DHS8MA]
Failure Code [DHS9MA]
Failure Code [DHSAMA]
Failure Code [DHSBMA]
Failure Code [DHSCMA]
Failure Code [DHSDMA]
Failure Code [DKR0MA]
Failure Code [DKULKA]
Failure Code [DKULKB]
Failure Code [DKULKY]
Failure Code [DLM5KA]
Failure Code [DLM5MB]
Failure Code [DV20KB]
Failure Code [DW43KA]
Failure Code [DW43KB]
Failure Code [DW43KY]
Failure Code [DW45KA]
Failure Code [DW45KB]
Failure Code [DW45KY]
Failure Code [DW4CKY]
Failure Code [DWA2KA]
Failure Code [DWA2KB]
Failure Code [DWA2KY]
Failure Code [DWJ0KA]
Failure Code [DWJ0KB]
Failure Code [DWJ0KY]
Failure Code [DWN5KA]
Failure Code [DWN5KB]
Failure Code [DWN5KY]
Failure Code [DXA8KA]
Failure Code [DXA8KB]
Failure Code [DXE4KA]
Failure Code [DXE4KB]
Failure Code [DXE4KY]
Failure Code [DXE7KA]
Failure Code [DXE7KB]
Failure Code [DXE7KY]
Failure Code [DXE8KA]
Failure Code [DXE8KB]
Failure Code [DXE8KY]
Failure Code [DXE9KA]
Failure Code [DXE9KB]
Failure Code [DXE9KY]
Failure Code [DXEAKA]
Failure Code [DXEAKB]
Failure Code [DXEAKY]
Failure Code [DY20KA]
Failure Code [DY20MA]
Failure Code [DY2CKB]
Failure Code [DY2DKB]
Failure Code [DY2EKB]
Failure code [F311KA]
Failure code [F311KB]
Failure code [F312KA]
Failure code [F312KB]
Failure Code [F313KA]
Failure Code [F313KB]
Failure code [F314KA]
Failure code [F314KB]
Failure Code [F315KB]
Failure Code [F315KY]
Failure code [F316KB]
Failure code [F316KY]
Failure Code [F318KB]
Failure Code [F318KY]
Failure code [F31AKB]
Failure code [F31AKY]
Failure Code [F31BKB]
Failure Code [F31BKY]
Failure Code [F31CKB]
Failure Code [F31CKY]
Failure Code [F31DKB]
Failure Code [F31DKY]
Failure Code [F31EKB]
Failure Code [F31EKY]
Failure Code [FS10ZE]
Troubleshooting of Electrical System (E-Mode)
E-1 Engine Does Not Start (Engine Does Not Crank)
E-2 Manual Preheating System Does Not Operate
E-3 While Preheating is in Operation, Preheating Monitor Does Not Come On
E-4 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing
E-5 Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation
E-6 Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation
E-7 Charge Level Monitor Comes On in Red While Engine is in Operation
E-8 Fuel Level Monitor Comes On in Red While Engine is in Operation
E-9 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation
E-10 Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation
E-11 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation
E-12 Fuel Gauge Does Not Move from Minimum or Maximum
E-13 Display of Fuel Gauge is Different from Actual Fuel Level
E-14 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum
E-15 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature
E-16 Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum
E-17 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature
E-18 Some Areas of Machine Monitor Screen are Not Shown
E-19 Function Switch Does Not Operate
E-20 Automatic Warm-up System Does Not Operate (in Cold Weather)
E-21 Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated
E-22 Auto-Decelerator is Not Operated or Canceled with Lever
E-23 Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated
E-24 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed
E-25 Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated
E-26 Travel Speed Does Not Change Even When You Change Travel Speed
E-27 Alarm Buzzer Does Not Stop
E-28 Service Meter is Not Shown While Starting Switch is in OFF Position
E-29 Service Mode Cannot be Selected
E-30 All Work Equipment, Swing, Travel Do Not Operate
E-31 All Work Equipment, Swing, Travel Cannot be Locked
E-32 Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position
E-33 While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated
E-34 Work Equipment Does Not Operate While Lock Lever Automatic Release Switch is in Release
Position
E-35 Travel Alarm Does Not Operate During Travel
E-36 Travel Alarm Does Not Stop When Machine Stops
E-37 Horn Does Not Sound
E-38 Horn Does Not Make Sound (Machine With Proportional Control Lever)
E-39 Horn Does Not Stop
E-40 Horn Does Not Stop Sounding (Machine With Proportional Control Lever)
E-41 Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated
E-42 Windshield Wiper Does Not Operate When Wiper Switch is Operated
E-43 When Window Washer Switch is Operated, Window Washer Does Not Operate
E-44 "Boom Raise" is Not Shown Correctly with Monitoring Function
E-45 "Boom Lower" is Not Shown Correctly with Monitoring Function
E-46 "Arm OUT" is Not Shown Correctly with Monitoring Function
E-47 "Arm IN" is Not Shown Correctly with Monitoring Function
E-48 Bucket DUMP is Not Shown Correctly with Monitoring Function
E-49 Bucket CURL is Not Shown Correctly with Monitoring Function
E-50 Swing is Not Shown Correctly with Monitoring Function
E-51 Travel is Not Shown Correctly with Monitoring Function
E-52 Service is Not Shown Correctly with Monitoring Function
E-53 Blade RAISE is Not Shown Correctly with Monitoring Function
E-54 Blade LOWER is Not Shown Correctly with Monitoring Function
E-55 KOMTRAX System Does Not Operate Correctly
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
Information Shown in Troubleshooting Table (H-Mode)
Failure Mode and Cause Table
H-1 All Work Equipment, Swing and Travel Do Not Work
H-2 All Work Equipment, Swing, and Travel Lack Speed or Power
H-3 Fine Control Performance or Response is Unsatisfactory
H-4 Unusual Noise is Heard from Around Hydraulic Pump
H-5 Engine Speed Drops Largely or Engine Stops
H-6 Boom Speed or Power is Low
H-7 Arm Speed or Power is Low
H-8 Bucket Speed or Power is Low
H-9 Blade Speed or Power is Low
H-10 Work Equipment Does Not Move in Single Operation
H-11 Hydraulic Drift of Boom is Large
H-12 Hydraulic Drift of Arm is Large
H-13 Hydraulic Drift of Bucket is Large
H-14 Hydraulic Drift of Blade is Large
H-15 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves
H-16 Time Lag of Work Equipment is Large
H-17 Attachment Circuit Cannot be Changed
H-18 Oil Flow in Attachment Circuit Cannot be Changed
H-19 Oil Flow in Attachment Circuit Cannot be Changed (Machine with Proportional Control Lever)
H-20 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower
H-21 In Mixed Operation of Work Equipment or Swing and Travel, Travel Speed Falls Largely
H-22 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low
H-23 Machine Does Not Travel Straight
H-24 Machine is Not Steered Well or Steering Power is Low
H-25 Travel Speed is Low
H-26 One of Tracks Does Not Run
H-27 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast
H-28 Upper Structure Does Not Swing in Two Directions of Right and Left
H-29 Machine Swings Only in One Direction
H-30 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left
H-31 Swing Acceleration or Swing Speed is Low in Only One Direction
H-32 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)
H-33 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)
H-34 Shock is Large When Upper Structure Stops Swing Operation
H-35 Large Unusual Noise is Made When Upper Structure Stops Swing Operation
H-36 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)
H-37 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)
H-38 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)
H-39 Unusual Noise is Heard from Around Fan
Troubleshooting of Engine (S-Mode)
Information Shown in Troubleshooting Table (S-Mode)
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position
S-2 Engine Cranks but No Exhaust Smoke Comes Out
S-3 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)
S-4 Engine Startability is Unsatisfactory
S-5 Engine Does Not Pick Up Smoothly
S-6 Engine Stops During Operation
S-7 Engine Does Not Rotate Smoothly
S-8 Engine Lacks Output (or Lacks Power)
S-9 Exhaust Smoke is Black
S-10 Engine Oil Consumption is Excessive
S-11 Engine Oil Becomes Dirty Quickly
S-12 Fuel Consumption is Excessive
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)
S-14 Engine Oil Pressure Drops
S-15 Fuel Mixes Into Engine Oil
S-16 Water Mixes Into Engine Oil (Milky)
S-17 Coolant Temperature Increases Too High (Overheat)
S-18 Unusual Noise is Heard
S-19 Vibration is Excessive
S-20 Air Cannot be Bled from Fuel Circuit
50 Disassembly and Assembly
Table of Contents
Precautions Before Work
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Prepare
Drain and Add Coolant
Drain and Add Hydraulic Oil
Drain and Add Fuel
Collect and Refill Refrigerant
Engine and Cooling System
Remove and Install Supply Pump Assembly
Remove and Install Injector Assembly
Remove and Install Cylinder Head Assembly
Remove and Install EGR Valve Assembly
Remove and Install EGR Cooler Assembly
Remove and Install Starter Assembly
Remove and Install Fan Belt
Remove and Install Automatic Tensioner
Remove and Install Expansion Tank Assembly
Remove and Install Radiator Assembly
Remove and Install Hydraulic Oil Cooler Assembly
Remove and Install Aftercooler Assembly
Remove and Install Engine and Main Pump Assembly
Remove and Install Engine Front Oil Seal
Remove and Install Engine Rear Oil Seal
Remove and Install Fuel Cooler Assembly
Remove and Install Engine Hood Assembly
Remove and Install KDOC Assembly
Remove and Install Fuel Tank Assembly
Remove and Install Air Cleaner Assembly
Remove and Install Air Conditioner Compressor Assembly
Remove and Install Air Conditioner Condenser Assembly
Power Train
Remove and Install Travel Motor and Final Drive Assembly
Disassemble and Assemble Travel Motor and Final Drive Assembly
Remove and Install Swing Motor and Swing Machinery Assembly
Disassemble and Assemble Swing Machinery Assembly
Remove and Install Swing Circle Assembly
Undercarriage and Frame
Separate and Connect Track Assembly
Remove and Install Sprocket
Remove and Install Idler and Idler Cushion Assembly
Disassemble and Assemble Idler Assembly
Disassemble and Assemble Idler Cushion Assembly
Disassemble and Assemble Track Roller Assembly
Remove and Install Revolving Frame Assembly
Remove and Install Counterweight Assembly
Hydraulic System
Remove and Install Center Swivel Joint Assembly
Disassemble and Assemble Center Swivel Joint Assembly
Remove and Install Hydraulic Tank Assembly
Remove and Install Main Pump Assembly
Remove and Install Control Valve Assembly
Disassemble and Assemble Control Valve Assembly
Disassemble and Assemble Work Equipment PPC Valve Assembly
Disassemble and Assemble Travel PPC Valve Assembly
Work Equipment
Remove and Install Blade Assembly
Remove and Install Work Equipment Assembly
Remove and Install Boom Anti-drop Valve Assembly
Remove and Install Arm Anti-Drop Valve Assembly
Disassemble and Assemble Anti-Drop Valve Assembly
Disassemble and Assemble Boom Cylinder Assembly
Disassemble and Assemble Arm Cylinder Assembly
Disassemble and Assemble Bucket Cylinder Assembly
Disassemble and Assemble Blade Cylinder Assembly
CAB Related Parts
Remove and Install Operator Cab Assembly
Remove and Install Slide Door
Remove and Install Operator Cab Glass (Adhered Glass)
Remove and Install Front Window Assembly
Remove and Install Floor Frame Assembly
Remove and Install Air Conditioner Unit Assembly
Remove and Install Operator Seat
How to Remove and Install Seat Belt
Remove and Install Work Equipment Control Lever Assembly
Remove and Install Front Wiper Assembly
Electrical System
Remove and Install Engine Controller Assembly
Remove and Install Pump Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install Mass Air Flow and Temperature Sensor
Remove and Install Gateway Function Controller
60 Maintenance Standard
Table of Contents
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for PTO
Maintenance Standard for Cooling System
Power Train
Maintenance Standard for Swing Circle
Maintenance Standard for Swing Machinery
Maintenance Standard for Sprocket
Undercarriage and Frame
Maintenance Standard for Track Frame and Idler Cushion
Maintenance Standard for Idler
Maintenance Standard for Track Roller
Maintenance Standard for Carrier Roller
Maintenance Standard for Track Shoes
Maintenance Standard for Triple Shoes
Maintenance Standard for Rubber Shoes
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Main Pump
Maintenance Standard for PC-EPC Valve
Maintenance Standard for Swing Motor
Maintenance Standard for Travel Motor
Maintenance Standard for Control Valve
Maintenance Standard for Boom Anti-Drop Valve
Maintenance Standard for Arm Anti-Drop Valve
Maintenance Standard for Work Equipment and Swing PPC Valve
Maintenance Standard for Blade PPC Valve
Maintenance Standard for Travel PPC Valve
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)
Maintenance Standard for Solenoid Valve
Maintenance Standard for Attachment Oil Flow Adjuster EPC Valve
Maintenance Standard for Attachment Circuit Accumulator (For Low Pressure Circuit)
Maintenance Standard for Center Swivel Joint
Work Equipment
Maintenance Standard for Work Equipment Linkage
Maintenance Standard for Boom Cylinder
Maintenance Standard for Arm Cylinder
Maintenance Standard for Bucket Cylinder
Maintenance Standard for Blade Cylinder
80 Appendix
Table of Contents
Precautions Before Work
Air Conditioner System
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure and Function of Refrigeration Cycle
Outline of Refrigeration Cycle
Component Parts of Air Conditioner System
Air Conditioner Unit
Component Parts of Air Conditioner Unit
Air Conditioner Controller
Compressor
Condenser
Receiver Drier
Air Conditioner Related Sensors
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
System Diagram of Air Conditioner
Input and Output Signals of Air Conditioner Controller
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Leakage (Duct)
How to Examine Air Leakage (Duct)
Examine Air Conditioner with Self-Diagnosis Function
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor
Examine Vent (Mode) Changeover
How to Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Sunlight Sensor
How to Examine Sunlight Sensor
Examine Refrigerant (Dual) Pressure Switch
How to Examine Refrigerant (Dual) Pressure Switch
Examine Relay
How to Examine Relay
Air Conditioner Troubleshooting Chart 1
Air Conditioner Troubleshooting Chart 2
Information Shown in Troubleshooting Table
Failure Code [879AKA]
Failure Code [879AKB]
Failure Code [879BKA]
Failure Code [879BKB]
Failure Code [879CKA]
Failure Code [879CKB]
Failure Code [879DKZ]
Failure Code [879EMC]
Failure Code [879FMC]
Failure Code [879GKX]
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
A-4 Troubleshooting for Fresh/Recirc Air Changeover
Troubleshooting by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Hydraulic Circuit Diagram (3/3)
Hydraulic Circuit Diagram (at Boom Raise Operation 1/3)
Hydraulic Circuit Diagram (at Boom Raise Operation 2/3)
Hydraulic Circuit Diagram (at Boom Raise Operation 3/3)
Hydraulic Circuit Diagram (at Left Swing Operation 1/3)
Hydraulic Circuit Diagram (at Left Swing Operation 2/3)
Hydraulic Circuit Diagram (at Left Swing Operation 3/3)
Hydraulic Circuit Diagram (at Boom Raise and Left Swing Operation 1/3)
Hydraulic Circuit Diagram (at Boom Raise and Left Swing Operation 2/3)
Hydraulic Circuit Diagram (at Boom Raise and Left Swing Operation 3/3)
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram
Electrical Circuit Diagram (1/9)
Electrical Circuit Diagram (2/9)
Electrical Circuit Diagram (3/9)
Electrical Circuit Diagram (4/9)
Electrical Circuit Diagram (5/9)
Electrical Circuit Diagram (6/9)
Electrical Circuit Diagram (7/9)
Electrical Circuit Diagram (8/9)
Electrical Circuit Diagram (9/9)
Electrical Circuit Diagram (Machine with Proportional Control Lever)(1/8)
Electrical Circuit Diagram (Machine with Proportional Control Lever)(2/8)
Electrical Circuit Diagram (Machine with Proportional Control Lever)(3/8)
Electrical Circuit Diagram (Machine with Proportional Control Lever)(4/8)
Electrical Circuit Diagram (Machine with Proportional Control Lever)(5/8)
Electrical Circuit Diagram (Machine with Proportional Control Lever)(6/8)
Electrical Circuit Diagram (Machine with Proportional Control Lever)(7/8)
Electrical Circuit Diagram (Machine with Proportional Control Lever)(8/8)
Index