The Komatsu PC500LC-10R Crawler Excavator is a heavy production machine used for bulk earthmoving, quarry work, and big demolition or construction jobs. The people who usually reach for the Komatsu PC500LC-10R Crawler Excavator Shop Manual (SEN06722-15) are shop mechanics, field techs, and fleet maintenance folks. They’re trying to track down fault codes, strip and rebuild components correctly, and stop guessing so the machine spends more time digging and less time parked.
What this manual helps you do
- Trace hydraulic issues by following system layouts and step‑by‑step pressure and flow test procedures for the main and auxiliary circuits.
- Diagnose electrical faults using wiring diagrams, connector views, and guided checks for sensors, switches, and controllers.
- Follow correct disassembly and reassembly sequences for major groups like the engine, swing system, final drives, and travel system.
- Check adjustment procedures for items like tracks, swing brakes, pilot controls, and work equipment to keep the machine operating smoothly.
- Handle machine error codes and protection warnings using the troubleshooting trees these manuals usually provide for this series.
The Komatsu PC500LC-10R Crawler Excavator Shop Manual normally covers workshop-level diagnostics, teardown procedures, and standard adjustment data used during repairs. In my experience, this is the book you use when you’re actually turning wrenches, not just doing daily checks.
Who this is for
This is aimed at field techs, shop mechanics, and fleet managers who handle in‑house repairs and diagnostics. If you’re just operating the machine or only need basic service intervals, you’d be better off with the Operation & Maintenance manual instead.
FAQ
Q: Is this a PDF I can search and print?
A: Yes, it’s a PDF, so you can search by keyword and print the pages you need in the shop.
Q: Is it deep enough for full component rebuilds?
A: Yes, this type of shop manual usually walks you through teardown, inspection points, and reassembly for the main systems.
Q: How do I know if it matches my exact PC500LC-10R?
A: Check your machine plate and confirm it’s a PC500LC-10R, then match the manual ID SEN06722-15 to what your dealer lists for that model.
Bottom line: If you’re repairing or diagnosing a PC500LC-10R in a workshop or field setting, this is the right manual; if you only need basic operating info, keep looking for the operator’s or O&M book instead.
📘 Show Index
Table of Contents:
- 00 Index and Foreword
- Index
- Abbreviation List
- Foreword, Safety, Basic Information
- How to Read the Shop Manual
- Safety Notice for Operation
- Precautions to Prevent Fire
- Procedures If Fire Occurs
- Precautions for Disposing of 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
- How to Disconnect and Connect Type 1 Push-Pull Type Coupler
- How to Disconnect and Connect Type 2 Push-Pull Type Coupler
- How to Disconnect and Connect Type 3 Push-Pull Type Coupler
- Precautions for Disconnection and Connection of Connectors
- How to Disconnect and Connect Deutsch Connector
- How to Disconnect and Connect Slide Lock Type Connector
- How to Disconnect and Connect Connector with Lock to Pull
- How to Disconnect and Connect Connector with Lock to Push
- How to 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
- 01 Specifications
- Table of Contents
- Abbreviation List
- Specifications
- Specification Drawing
- Specification Drawing: PC500LC-10R
- Specification Drawing: PC500LC-10R (For SE Spec)
- Working Range Drawings
- Working Range: PC500LC-10R
- Working Range: PC500LC-10R (For SE Spec)
- Specifications
- Specifications: PC500LC-10R
- Specifications: PC500LC-10R (For SE Spec)
- Weight Table
- Weight Table: PC500LC-10R
- Weight Table: PC500LC-10R (For SE Spec)
- Table of Fuel, Coolant, and Lubricants
- 10 Structure and Function
- Table of Contents
- Abbreviation List
- Boot-up System
- Layout Drawing of Boot-up System
- System Operating Lamp System
- System Diagram of System Operating Lamp System
- Function of Operation Lamp System
- Battery Disconnect Switch
- Function of Battery Disconnect Switch
- Engine System
- Layout Drawing of Engine System
- Specifications of Engine System
- Engine Control System
- System Diagram of Engine Control
- Function of Engine Control System
- Auto-Deceleration System
- System Diagram of Auto-Deceleration System
- Function of Auto-Deceleration System
- Operation of Auto-Deceleration System
- Engine Automatic Warm-up System
- System Diagram of Engine Automatic Warm-up System
- Function of Engine Automatic Warm-up System
- Overheat Prevention System
- Overheat Prevention System Diagram
- Function of Overheat Prevention System
- Turbocharger Protection System
- System Diagram of Turbocharger Protection System
- Function of Turbocharger Protection System
- Automatic Idle Stop System
- System Diagram of Automatic Idle Stop System
- Function of Automatic Idle Stop System
- Component Parts of Engine System
- Turbocharger
- Blowby Pressure Sensor
- Cooling System
- Layout Drawing of Cooling System
- Specifications of Cooling System
- Fan Speed Control System of Fan Clutch
- Fan Speed Control System Diagram of Fan Clutch
- Function of Fan Speed Control System of Fan Clutch
- Engine Output Control System of Fan Clutch
- Engine Output Control System Diagram of Fan Clutch
- Function of Engine Output Control System of Fan Clutch
- Component Parts of Cooling System
- Control System
- Layout Drawing of Control System
- Machine Monitor System
- System Diagram of Machine Monitor System
- Function of Machine Monitor System
- KOMTRAX System
- System Diagram of KOMTRAX System
- Function of KOMTRAX System
- Component Parts of Control System
- Machine Monitor
- Rearview Camera
- KOMTRAX Terminal
- Pump Controller
- Resistor for PC-EPC Valve
- CAN Terminating Resistor
- Engine Controller
- Fuel Control Dial
- Fuel Feed Pump
- Hydraulic System
- Layout Drawing of Hydraulic System
- CLSS
- Structure of CLSS
- Operation of Unload Valve and LS Pressure
- Pump Swash Plate Angle (Oil Flow) Control
- Pressure Compensation Control
- Engine and Pump Combined Control System
- Engine and Pump Combined Control System Diagram
- Function of Engine and Pump Combined Control System
- Pump and Valve Control System
- Pump and Valve Control System Diagram
- Function of Pump and Valve Control System
- Component Parts of Hydraulic System
- Hydraulic Tank
- Main Pump
- Control Valve
- Work Equipment System
- Layout Drawing of Work Equipment System
- One-Touch Power Maximizing System
- System Diagram of One-Touch Power Maximizing System
- Function of One-Touch Power Maximizing System
- Machine Push-up System
- Machine Push-up System Diagram
- Function of Machine Push-up System
- PPC Lock System
- System Diagram of PPC Lock
- Function of PPC Lock System
- Work Equipment and Travel Automatic Lock System
- System Diagram of Lock Lever Automatic Lock System
- Function of Work Equipment and Travel Automatic Lock System
- Operation of Lock Lever Automatic Lock System
- Attachment Oil Flow Adjuster System
- Attachment Oil Flow Adjuster System Diagram
- Function of Attachment Oil Flow Adjuster System
- Component Parts of Work Equipment System
- Work Equipment and Swing PPC Valve
- 1st-Line Attachment PPC Valve (with EPC Valve)
- Solenoid Valve
- Attachment Circuit Selector Valve
- Pilot Circuit Accumulator
- Hydraulic Oil Additional Filter with Clogging Switch
- Hydraulic Oil Additional Filter Clogging Switch
- Swing System
- Layout Drawing of Swing System
- Swing Control System Diagram
- Function of Swing Control System
- Component Parts of Swing System
- Swing Motor
- Swing Machinery
- Swing Circle
- Travel System
- Layout Drawing of Travel System
- System Diagram of Travel Control System
- Function of Travel Control System
- Component Parts of Travel System
- Travel Motor
- Final Drive
- Travel PPC Valve
- Center Swivel Joint
- Undercarriage and Frame
- Layout Drawing of Undercarriage
- Specifications of Undercarriage
- Work Equipment
- Structure of Work Equipment
- Function of Work Equipment
- Work Equipment Clearance Adjustment Shim
- Function of Work Equipment Clearance Adjustment Shim
- Bucket Clearance Adjustment Shim
- Function of Bucket Clearance Adjustment Shim
- CAB Related Parts
- CAB
- CAB Mount
- Structure of CAB Mount
- Function of CAB Mount
- CAB Tipping Stopper
- Structure of CAB Tipping Stopper
- Function of CAB Tipping Stopper
- 20 Standard Value Table
- Table of Contents
- Abbreviation List
- Standard Value Table for Engine
- Standard Value Table for Engine: PC500LC-10R
- Standard Value Table for Machine
- Standard Value Table for Machine: PC500LC-10R
- Machine Posture and Procedures to Measure Performance
- 30 Testing and Adjusting
- Table of Contents
- Abbreviation List
- 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
- How to Examine Engine Speed
- Examine Boost Pressure
- How to Examine Boost Pressure on Machine Monitor
- How to Examine Boost Pressure by Testing Tool
- Examine Exhaust Gas Temperature
- How to Examine Exhaust Gas Temperature
- Examine Exhaust Gas Color
- How to Examine Exhaust Gas Color with the Handy Smoke Checker
- How to Examine Exhaust Gas Color with Smoke Meter
- Examine and Adjust Valve Clearance
- How to Examine Valve Clearance
- How to Adjust Valve Clearance
- Examine Compression Pressure
- How to Examine Compression Pressure
- Examine Blowby Pressure
- How to Examine Blowby Pressure on Machine Monitor
- How to Examine Blowby Pressure by Testing Tool
- Examine Engine Oil Pressure
- How to Examine Engine Oil Pressure on Machine Monitor
- How to Examine Engine Oil Pressure by Testing Tool
- Examine Fuel Pressure
- How to Examine Fuel Pressure
- Examine Fuel Return Rate and Leakage
- How to Examine Fuel Return Rate and Leakage
- Bleed Air from Fuel System
- How to Bleed Air from Fuel System
- Examine Fuel Circuit for Leakage
- How to Examine Fuel System for Leakage
- Handle Cylinder Cut-out Mode Operation
- Handle No-Injection Cranking Operation
- Examine Fan Belt
- Examine Alternator Belt
- How to Examine Alternator Belt
- Examine Automatic Tensioner
- How to Examine Automatic Tensioner
- Examine Cooling Fan Speed
- How to Examine Cooling Fan Speed
- Power Train
- Examine Swing Circle Bearing Clearance
- How to Examine Swing Circle Bearing Clearance
- Undercarriage and Frame
- Examine and Adjust Track Tension
- How to Examine Track Tension
- How to Adjust Track Tension
- Hydraulic System
- Release Remained Pressure in Hydraulic Circuit
- How to Release Remained Pressure from Hydraulic Tank
- How to Release Remained Pressure in Hydraulic Cylinder Circuit
- How to Release Remained Pressure from Swing Motor Circuit
- How to Release Remained Pressure from Travel Motor Circuit
- Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits
- How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits
- How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits
- Examine Oil Pressure of Control Circuit
- How to Examine Oil Pressure in Control Circuit
- Examine and adjust oil pressure in pump PC control circuit
- Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure)
- Examine PC-EPC Valve Outlet Pressure
- How to Adjust Oil Pressure in Pump PC Control Circuit
- Examine and Adjust Oil Pressure in Pump LS Control Circuit
- How to Examine LS Differential Pressure with Machine Monitor
- How to Examine LS Differential Pressure by Testing Tool
- How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure)
- How to Examine LS-EPC Valve Outlet Pressure
- How to Adjust LS Valve
- Examine Outlet Pressure of Solenoid Valve
- How to Examine Outlet Pressure of Solenoid Valve
- Operating Condition of Solenoid Valve
- Examine PPC Valve Outlet Pressure
- How to Examine Outlet Pressure in PPC Valve
- Adjust Play of Work Equipment and Swing PPC Valves
- How to Adjust Play of Work Equipment and Swing PPC Valves
- Examine Parts Which Cause Hydraulic Drift of Work Equipment
- How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder
- How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder
- How to Examine Parts that Cause Hydraulic Drift of PPC Valve
- Examine Oil Leakage
- How to Examine Oil Leakage from Boom Cylinder
- How to Examine Oil Leakage from Arm Cylinder
- How to Examine Oil Leakage from Bucket Cylinder
- How to Examine Oil Leakage from Swing Motor
- How to Examine Oil Leakage from Travel Motor
- Bleed Air from Hydraulic Circuit
- How to Bleed Air from Hydraulic System
- Examine and Charge Accumulator (Made by HYDAC) Nitrogen Gas Pressure for Attachment (Low Pressure Side)
- How to Examine Accumulator (Made by HYDAC) Nitrogen Gas Pressure for Attachment (Low Pressure Side)
- Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side)
- How to Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side)
- Replace Accumulator Bladder on High Pressure Side for Attachment Piping
- How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping
- CAB Related Parts
- Examine CAB Tipping Stopper
- How to Examine Cab Tipping Stopper
- How to Adjust Mirrors
- Procedure to Adjust Machine Left Front Mirror (A)
- Procedure to Adjust Regular Position of Machine Left Front Mirror (A)
- Procedure to Adjust Machine Right Front Mirror (B)
- Procedure to Adjust Regular Position of Machine Right Front Mirror (B)
- Procedure to Adjust Machine Right Side Mirror (C)
- Procedure to Adjust Machine Rear Counterweight Mirror (D)
- Electrical System
- Set and Operate Machine Monitor
- Operator Mode
- Examine Function by LCD (Liquid Crystal Display)
- Examine Function of Service Meter
- Usage Limitation and Maintenance Password Change Function
- Service Mode
- How to Operate Service Mode
- How to See Pre-defined Monitoring Information
- How to Examine Self-Define Monitor Information
- Abnormality Record Menu
- How to See Maintenance Record
- Maintenance Mode Setting
- How to Set Phone Number Entry
- Default Menu
- Diagnostic Tests Menu
- Adjustment Menu
- No-Injection Cranking Operation
- KOMTRAX Settings Menu
- How to Show Service Message
- How to Start Up KOMTRAX Terminal
- Adjust Rearview Camera Angle
- How to Adjust Rearview Camera Angle
- Handle Voltage Circuit of Engine Controller
- Handle Battery Disconnect Switch
- Examine Diodes
- How to Examine Diodes by Digital Tester
- How to Examine Diodes by Analog Tester
- Pm Clinic
- Pm Clinic Service
- Pm Clinic Check Sheet: PC500LC-10R
- 40 Troubleshooting
- Table of Contents
- Abbreviation List
- Related Information to Troubleshooting
- General Troubleshooting Points
- Sequence of Events in Troubleshooting
- Checks Before Troubleshooting
- Inspection Procedure Before Troubleshooting
- Test in Accordance with Testing Procedure
- Examine Fuel Level and Type
- Examine Fuel Level and Type
- Examine for Impure Ingredient in Fuel
- Examine Fuel Prefilter
- Examine Water Separator, Drain Water and Sediment
- Examine Water Separator, Drain Water and Sediment
- Replace Fuel Prefilter Cartridge
- Replace Fuel Prefilter Cartridge
- Examine Fuel Main Filter
- Examine Fuel Main Filter
- Examine Water Pump for Leakage
- Examine Engine Oil Level (Oil Quantity in Oil Pan)
- Examine Engine Oil Level (Oil Quantity in Oil Pan)
- Examine Coolant Level (Reservoir Tank)
- Examine Coolant Level (Reservoir Tank)
- Examine Air Cleaner Clogging
- Examine Air Cleaner Clogging
- Clean Outer Element
- Clean Outer Element
- Replace Element
- Replace Element
- Examine Hydraulic Oil Level
- Examine Hydraulic Oil Level
- Examine Hydraulic Oil Strainer
- Examine Hydraulic Oil Strainer
- Examine Hydraulic Oil Filter
- Examine Hydraulic Oil Filter
- Examine Oil Level in Swing Machinery Case
- Examine Oil Level in Swing Machinery Case
- Examine Oil Level in Damper Case
- Examine Oil Level in Damper Case
- Examine Oil Level in Final Drive Case
- Examine Oil Level in Final Drive Case
- Bleed Air from Fuel System
- Bleed Air from Hydraulic System
- How to Examine Electric Equipment
- Preparation for Troubleshooting of Electrical System
- Preparation for Troubleshooting of Machine Monitor
- Preparation for Troubleshooting of Engine Controller
- Preparation for Troubleshooting of Pump Controller
- Preparation for Troubleshooting of KOMTRAX Terminal
- How to Disconnect and Connect Connector with a Special Lock
- Procedure for Troubleshooting
- Symptom and Troubleshooting Numbers
- Information Shown in Troubleshooting Table
- How to Diagnose Wiring Harness for Open Circuit of Pressure Sensor System
- Connector and Wiring Harness Identification Table
- Connector Layout
- Connector Contact Connection Table
- T-Branch Box and T-Branch Adapter Table
- Fuse Location Table
- Fuse Location Table
- Precautions When You Clean and Replace KDPF (KCSF and KDOC)
- Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])
- Failure Code Table
- Troubleshooting by Failure Code (Display of Code)
- Failure Code [602KNX]
- 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]
- 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@BAZK]
- Failure Code [B@BCNS]
- Failure Code [B@BCQA]
- Failure Code [B@BCZK]
- Failure Code [CA111]
- Failure Code [CA115]
- Failure Code [CA122]
- Failure Code [CA123]
- Failure Code [CA131]
- Failure Code [CA132]
- Failure Code [CA135]
- Failure Code [CA141]
- 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 [CA263]
- Failure Code [CA265]
- Failure Code [CA271]
- Failure Code [CA272]
- Failure Code [CA273]
- Failure Code [CA274]
- Failure Code [CA322]
- Failure Code [CA323]
- Failure Code [CA324]
- Failure Code [CA325]
- Failure Code [CA331]
- Failure Code [CA332]
- Failure Code [CA342]
- Failure Code [CA351]
- Failure Code [CA352]
- Failure Code [CA386]
- Failure Code [CA441]
- Failure Code [CA442]
- Failure Code [CA449]
- Failure Code [CA451]
- Failure Code [CA452]
- Failure Code [CA553]
- Failure Code [CA554]
- Failure Code [CA559]
- Failure Code [CA689]
- Failure Code [CA731]
- Failure Code [CA757]
- Failure Code [CA778]
- Failure Code [CA2185]
- Failure Code [CA2186]
- Failure Code [CA2249]
- Failure Code [CA2555]
- Failure Code [CA2556]
- Failure Code [D110KB]
- Failure Code [D19JKZ]
- Failure Code [D1N0KA]
- Failure Code [D1N0KB]
- Failure Code [D1N0KY]
- Failure Code [D811MC]
- Failure Code [D8ALKA]
- Failure Code [D8ALKB]
- Failure Code [D8AQKR]
- 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 [DDNRKA]
- Failure Code [DDNRKY]
- Failure Code [DDNS00]
- Failure Code [DDPAKA]
- Failure Code [DGH2KA]
- Failure Code [DGH2KB]
- Failure Code [DHA4KA]
- Failure Code [DHE5MA]
- Failure Code [DHPAMA]
- Failure Code [DHPBMA]
- Failure Code [DHS3MA]
- Failure Code [DHS4MA]
- Failure Code [DHS8MA]
- Failure Code [DHS9MA]
- Failure Code [DHSAMA]
- Failure Code [DHSBMA]
- Failure Code [DHSCMA]
- Failure Code [DHSDMA]
- Failure Code [DHSFMA]
- Failure Code [DHSGMA]
- Failure Code [DHSHMA]
- Failure Code [DHSJMA]
- Failure Code [DJG1KX]
- Failure Code [DKR2MA]
- Failure Code [DKR2NX]
- Failure Code [DKULKA]
- Failure Code [DKULKB]
- Failure Code [DKULKY]
- Failure Code [DLM5KA]
- Failure Code [DLM5MB]
- Failure Code [DR21KX]
- Failure Code [DR31KX]
- Failure Code [DUMBKA]
- Failure Code [DUMBKB]
- 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 [DW91KA]
- Failure Code [DW91KB]
- Failure Code [DW91KY]
- Failure Code [DWA2KA]
- Failure Code [DWA2KB]
- Failure Code [DWA2KY]
- Failure Code [DWK0KA]
- Failure Code [DWK0KB]
- Failure Code [DWK0KY]
- Failure Code [DWK2KA]
- Failure Code [DWK2KB]
- Failure Code [DWK2KY]
- Failure Code [DWK8KA]
- Failure Code [DWK8KB]
- Failure Code [DWK8KY]
- Failure Code [DWN5KA]
- Failure Code [DWN5KB]
- Failure Code [DWN5KY]
- Failure Code [DXA8KA]
- Failure Code [DXA8KB]
- Failure Code [DXA9KA]
- Failure Code [DXA9KB]
- Failure Code [DXE0KA]
- Failure Code [DXE0KB]
- Failure Code [DXE4KA]
- Failure Code [DXE4KB]
- Failure Code [DXE4KY]
- Failure Code [DXE5KA]
- Failure Code [DXE5KB]
- Failure Code [DXE6KA]
- Failure Code [DXE6KB]
- Failure Code [DY20KA]
- Failure Code [DY20MA]
- Failure Code [DY2CKB]
- Failure Code [DY2DKB]
- Failure Code [DY2EKB]
- Failure Code [F@BBZL]
- 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 Automatic Preheating System Does Not Operate
- E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On
- E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing
- E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow
- E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow
- E-8 Engine Coolant Temperature Monitor Comes On in White While Engine Runs
- E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs
- E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs
- E-11 Charge Level Monitor Comes On in Red While Engine is in Operation
- E-12 Fuel Level Monitor Comes On in Red While Engine Runs
- E-13 Water Separator Monitor Comes On in Red While Engine Runs
- E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation
- E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation
- E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation
- E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum
- E-18 Display of Fuel Gauge is Different from Actual Fuel Level
- E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum
- E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature
- E-21 Some Areas of Machine Monitor Screen are Not Shown
- E-22 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum
- E-23 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature
- E-24 Function Switch Does Not Operate
- E-25 Automatic Warm-up System Does Not Work (in Cold Weather)
- E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out
- E-27 Auto-Decelerator is Not Operated or Canceled with Lever
- E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown
- E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed
- E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change
- E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change
- E-32 Service Meter is Not Shown, While Starting Switch is in OFF Position
- E-33 Service Mode Cannot be Selected
- E-34 All of Work Equipment, Swing, and Travel Mechanism Do Not Move
- E-35 All Work Equipment, Swing and Travel Do Not Lock
- E-36 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing
- E-37 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate
- E-38 One-Touch Power Maximizing Function Does Not Operate Correctly, or Indicator Not Shown on Monitor
- E-39 One-Touch Power Maximizing Function is Not Cancelled
- E-40 Horn Does Not Sound
- E-41 Horn Does Not Stop
- E-42 Alarm Does Not Sound During Travel
- E-43 Travel Alarm Does Not Stop When Machine Stops
- E-44 Alarm Buzzer Cannot be Canceled
- E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out
- E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate
- E-47 Window Washer Does Not Operate When Window Washer Switch is Operated
- E-48 "Boom RAISE" is Not Shown Correctly with Monitoring Function
- E-49 "Boom LOWER" is Not Shown Correctly with Monitoring Function
- E-50 "Arm OUT" is Not Shown Correctly with Monitoring Function
- E-51 "Arm IN" is Not Shown Correctly with Monitoring Function
- E-52 "Bucket DUMP" is Not Shown Correctly with Monitoring Function
- E-53 "Bucket CURL" is Not Shown Correctly with Monitoring Function
- E-54 "Swing" is Not Shown Correctly with Monitoring Function
- E-55 "Travel" is Not Shown Correctly with Monitoring Function
- E-56 Service is Not Shown Correctly with Monitoring Function
- E-57 Attachment Hydraulic Circuit Cannot be Changed
- E-58 KOMTRAX System Does Not Operate Correctly
- R-55 Machine Push-Up Function is Not Canceled
- E-60 Machine Push-Up Function Does Not Operate
- Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
- H-1 All Work Equipment, Swing and Travel Do Not Work
- H-2 All Work Equipment, Swing and Travel Lack Speed and Power
- H-3 Fine Control Performance or Response is Unsatisfactory
- H-4 Engine Speed Drops Largely or Engine Stops
- H-5 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves
- H-6 Work Equipment Does Not Move in Single Operation
- H-7 Time Lag of Work Equipment is Large
- H-8 One-Touch Power Maximizing Function Does Not Operate
- H-9 Machine Push-Up Function Does Not Operate
- H-10 Attachment Circuit Cannot be Changed
- H-11 Oil Flow in Attachment Circuit Cannot be Changed
- H-12 In Mixed Operation of Work Equipment, Equipment with Heavier Load Moves Slower
- H-13 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely
- H-14 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low
- H-15 Machine Does Not Travel Straight
- H-16 Machine is Not Steered Correctly or Steering Power is Low
- H-17 Travel Speed is Low
- H-18 One of Tracks Does Not Run
- H-19 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast
- H-20 Upper Structure Does Not Swing to the Right and Left
- H-21 Swings Only in One Direction
- H-22 Swing Acceleration or Swing Speed is Low in Lateral Directions (Right and Left)
- H-23 Swing Acceleration Performance is Unsatisfactory or Swing Speed is Slow in Only One Direction
- H-24 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)
- H-25 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction, Right or Left)
- H-26 Shock is Large When Upper Structure Stops Swing Operation
- H-27 There is Large Unusual Noise When It Stops Swing Operation
- H-28 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)
- H-29 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)
- H-30 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)
- H-31 Unusual Noise is Heard from Around Fan
- H-32 Unusual Noise is Heard from Around Hydraulic Pump
- H-33 Speed or Power of Boom is Low
- H-34 Arm Speed or Power is Low
- H-35 Bucket Speed or Power is Low
- H-36 Hydraulic Drift of Boom is Large
- H-37 Hydraulic Drift of Arm is Large
- H-38 Hydraulic Drift of Bucket is Large
- Troubleshooting of Engine (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 Injected 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 Runs Rough or is Not Stable
- S-8 Engine Lacks Power
- S-9 Exhaust is Black (Incomplete Combustion)
- S-10 Engine Oil Consumption is Excessive
- S-11 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 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 (Overheating)
- 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
- Abbreviation List
- Related Information on Disassembly and Assembly
- How to Read This Manual
- Coating Materials List
- Special Tool List
- Sketches of Special Tools
- Engine and Cooling System
- Remove and Install Supply Pump Assembly
- How to Remove Supply Pump Assembly
- How to Install Supply Pump Assembly
- Remove and Install Injector Assembly
- How to Remove Injector Assembly
- How to Install Injector Assembly
- Remove and Install Cylinder Head Assembly
- How to Remove Cylinder Head Assembly
- How to Install Cylinder Head Assembly
- Remove and Install Starter Assembly
- How to Remove Starting Motor Assembly
- How to Install Starting Motor Assembly
- Remove and Install Muffler Assembly
- How to Remove Muffler Assembly
- How to Install Muffler Assembly
- Remove and Install Alternator Belt
- How to Remove Alternator Belt
- How to Install Alternator Belt
- Remove and Install Fan Belt
- How to Remove Fan Belt
- How to Install Fan Belt
- Remove and Install Radiator Assembly
- How to Remove Radiator Assembly
- How to Install Radiator Assembly
- Remove and Install Hydraulic Oil Cooler Assembly
- How to Remove Hydraulic Oil Cooler Assembly
- How to Install Hydraulic Oil Cooler Assembly
- Remove and Install Aftercooler Assembly
- How to Remove Aftercooler Assembly
- How to Install Aftercooler Assembly
- Remove and Install Fan Clutch Assembly
- Remove Fan Clutch Assembly
- Install Fan Clutch Assembly
- Remove and Install Fan
- How to Remove Fan
- How to Install Fan
- Remove and Install Engine and Main Pump Assembly
- How to Remove Engine and Main Pump Assembly
- How to Install Engine and Main Pump Assembly
- Remove and Install Engine Front Oil Seal
- How to Remove Engine Front Oil Seal
- How to Install Engine Front Oil Seal
- Remove and Install Engine Rear Oil Seal
- How to Remove Engine Rear Oil Seal
- How to Install Engine Rear Oil Seal
- Remove and Install Engine Hood Assembly
- How to Remove Engine Hood Assembly
- How to Install Engine Hood Assembly
- Remove and Install Fuel Tank Assembly
- How to Remove Fuel Tank Assembly
- How to Install Fuel Tank Assembly
- Remove and Install Air Cleaner Assembly
- How to Remove Air Cleaner Assembly
- How to Install Air Cleaner Assembly
- Remove and Install Air Conditioner Condenser Assembly
- How to Remove Air Conditioner Condenser Assembly
- How to Install Air Conditioner Condenser Assembly
- Power Train
- Remove and Install Travel Motor and Final Drive Assembly
- How to Remove Travel Motor and Final Drive Assembly
- How to Install Travel Motor and Final Drive Assembly
- Disassemble and Assemble Final Drive Assembly
- How to Disassemble Final Drive Assembly
- How to Assemble Final Drive Assembly
- Remove and Install Swing Motor and Swing Machinery Assembly
- How to Remove Swing Motor and Swing Machinery Assembly
- How to Install Swing Motor and Swing Machinery Assembly
- Disassemble and Assemble Swing Machinery Assembly
- How to Disassemble Swing Machinery Assembly
- How to Assemble Swing Machinery Assembly
- Remove and Install Swing Circle Assembly
- How to Remove Swing Circle Assembly
- How to Install Swing Circle Assembly
- Undercarriage and Frame
- Separate and Connect Track Assembly
- How to Separate Track Assembly
- How to Install Track Assembly
- Remove and Install Sprocket
- How to Remove Sprocket
- How to Install Sprocket
- Remove and Install Idler and Idler Cushion Assembly
- How to Remove Idler and Idler Cushion Assembly
- How to Install Idler and Idler Cushion Assembly
- Disassemble and Assemble Idler Assembly
- How to Disassemble Idler Assembly
- How to Assemble Idler Assembly
- Disassemble and Assemble Idler Cushion Assembly
- How to Disassemble Idler Cushion Assembly
- How to Assemble Idler Cushion Assembly
- Disassemble and Assemble Track Roller Assembly
- How to Disassemble Track Roller Assembly
- How to Assemble Track Roller Assembly
- Disassemble and Assemble Carrier Roller Assembly
- How to Disassemble Carrier Roller Assembly
- How to Assemble Carrier Roller Assembly
- Remove and Install Revolving Frame Assembly
- How to Remove Revolving Frame Assembly
- How to Install Revolving Frame Assembly
- Remove and Install Counterweight Assembly
- How to Remove Counterweight Assembly
- How to Install Counterweight Assembly
- Hydraulic System
- Remove and Install Center Swivel Joint Assembly
- How to Remove Center Swivel Joint Assembly
- How to Install Center Swivel Joint Assembly
- Disassemble and Assemble Center Swivel Joint Assembly
- How to Disassemble Center Swivel Joint Assembly
- How to Assemble Center Swivel Joint Assembly
- Remove and Install Hydraulic Tank Assembly
- How to Remove Hydraulic Tank Assembly
- How to Install Hydraulic Tank Assembly
- Remove and Install Main Pump Assembly
- How to Remove Main Pump Assembly
- How to Install Main Pump Assembly
- Remove and Install Control Valve Assembly
- How to Remove Control Valve Assembly
- How to Install Control Valve Assembly
- Disassemble and Assemble Control Valve Assembly
- How to Replace Pressure Compensation Valve Seal Ring
- How to Assemble Control Valve Assembly
- Disassemble and Assemble Work Equipment PPC Valve Assembly
- How to Disassemble Work Equipment PPC Valve Assembly
- How to Assemble Work Equipment PPC Valve Assembly
- Disassemble and Assemble Travel PPC Valve Assembly
- How to Disassemble Travel PPC Valve Assembly
- How to Assemble Travel PPC Valve Assembly
- Work Equipment
- Remove and Install Work Equipment Assembly
- How to Remove Work Equipment Assembly
- How to Install Work Equipment Assembly
- Disassemble and Assemble Work Equipment Cylinder Assembly
- How to Disassemble Work Equipment Cylinder Assembly
- How to Assemble Work Equipment Cylinder Assembly
- CAB Related Parts
- Remove and Install Operator Cab Assembly
- How to Remove Operator Cab Assembly
- How to Install Operator Cab Assembly
- Remove and Install Operator Cab Glass (Adhered Glass)
- How to Remove Operator Cab Glass (Adhered Glass)
- How to Install Operator Cab Glass (Adhered Glass)
- Remove and Install Front Window Assembly
- How to Remove Front Window Assembly
- How to Install Front Window Assembly
- Remove and Install Floor Frame Assembly
- How to Remove Floor Frame Assembly
- How to Install Floor Frame Assembly
- Remove and Install Air Conditioner Unit Assembly
- How to Remove Air Conditioner Unit Assembly
- How to Install Air Conditioner Unit Assembly
- Remove and Install Operator Seat
- How to Remove Operator Seat
- How to Install Operator Seat
- How to Remove and Install Seat Belt
- How to Remove Seat Belt
- How to Install Seat Belt
- Remove and Install Work Equipment Control Lever Assembly
- How to Remove Work Equipment Control Lever Assembly
- How to Install Work Equipment Control Lever Assembly
- Remove and Install Front Wiper Assembly
- How to Remove Front Wiper Assembly
- How to Install Front Wiper Assembly
- Electrical System
- Remove and Install Engine Controller Assembly
- How to Remove Engine Controller Assembly
- How to Install Engine Controller Assembly
- Remove and Install Pump Controller Assembly
- How to Remove Pump Controller Assembly
- How to Install Pump Controller Assembly
- Remove and Install Machine Monitor Assembly
- How to Remove Machine Monitor Assembly
- How to Install Machine Monitor Assembly
- Remove and Install KOMTRAX Terminal Assembly
- How to Remove KOMTRAX Terminal Assembly
- How to Install KOMTRAX Terminal Assembly
- 60 Maintenance Standard
- Table of Contents
- Abbreviation List
- Engine and Cooling System
- Maintenance Standard for Engine Mount
- Maintenance Standard for Cooling System
- Power Train
- Maintenance Standard for Swing Circle
- Maintenance Standard for Swing Machinery
- Maintenance Standard for Final Drive
- Maintenance Standard for Sprocket
- Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing
- 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
- Hydraulic System
- Maintenance Standard for Main Pump
- Maintenance Standard for Swing Motor
- Maintenance Standard for Travel Motor
- Maintenance Standard for Control Valve
- Maintenance Standard for Work Equipment and Swing PPC Valve
- Maintenance Standard for Travel PPC Valve
- Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)
- Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve
- Maintenance Standard for Solenoid Valve
- Maintenance Standard for Attachment Circuit Selector Valve
- Maintenance Standard for Center Swivel Joint
- Work Equipment
- Maintenance Standard for Work Equipment Linkage
- Dimensions of Arm
- Dimensions of Bucket
- Maintenance Standard for Work Equipment Linkage (SE Specification)
- Dimension of Arm (SE Specification)
- Dimensions of Bucket (SE Specification)
- Maintenance Standard for Boom Cylinder
- Maintenance Standard for Arm Cylinder
- Maintenance Standard for Bucket Cylinder
- Maintenance Standard for Bucket Cylinder (SE Specification)
- 80 Appendix
- Table of Contents
- Abbreviation List
- 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
- Configuration Diagram of Air Conditioner Unit
- Function of Air Conditioner Unit
- Component Parts of Air Conditioner Unit
- Function of Evaporator as Air Conditioner Unit Component
- Function of Heater Core as Air Conditioner Unit Component
- Function of Evaporator Temperature Sensor as Air Conditioner Unit Component
- Function of Servo Motor as Air Conditioner Unit Component
- Structure of Expansion Valve as Air Conditioner Unit Component
- Function of Expansion Valve as Air Conditioner Unit Component
- Operate Expansion Valve as Air Conditioner Unit Component
- Function of Dual Pressure Switch
- Air Conditioner Controller
- Structure of Air Conditioner Controller
- Compressor
- Structure of Compressor
- Specifications of Compressor
- Function of Compressor
- Condenser
- Structure of Condenser
- Specifications of Condenser
- Function of Condenser
- Receiver Drier
- Structure of Receiver Dryer
- Specifications of Receiver Dryer
- Function of Receiver Dryer
- Air Conditioner Related Sensors
- Structure of Sunlight Sensor
- Function of Sunlight Sensor
- Structure of Outside Temperature Sensor
- Function of Outside Air Temperature Sensor
- 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
- Function 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
- Air Conditioner Troubleshooting Chart 1
- Air Conditioner Troubleshooting Chart 2
- Information Shown in Troubleshooting Table
- Failure Code [879AKA]
- Failure Code [879AKB]
- Failure Code [879CKA]
- Failure Code [879CKB]
- 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
- Handle Compressor Oil
- 90 Circuit Diagrams
- Table of Contents
- Abbreviation List
- Hydraulic Circuit Diagram
- Symbols Used in Hydraulic Circuit Diagram
- Hydraulic Circuit Diagram (at Boom RAISE Operation)
- Hydraulic Circuit Diagram (at Left Swing Operation)
- Hydraulic Circuit Diagram (at Boom RAISE and Left Swing Operation)
- Hydraulic Circuit Diagram (1/2)
- Hydraulic Circuit Diagram (2/2)
- Electrical Circuit Diagram
- Symbols Used in Electric Circuit Diagram
- Electrical Circuit Diagram (1/7)
- Electrical Circuit Diagram (2/7)
- Electrical Circuit Diagram (3/7)
- Electrical Circuit Diagram (4/7)
- Electrical Circuit Diagram (5/7)
- Electrical Circuit Diagram (6/7)
- Electrical Circuit Diagram (7/7)
- Connector and Wiring Harness Chart
- Wiring Harness Diagram (1/15)
- Wiring Harness Diagram (2/15)
- Wiring Harness Diagram (3/15)
- Wiring Harness Diagram (4/15)
- Wiring Harness Diagram (5/15)
- Wiring Harness Diagram (6/15)
- Wiring Harness Diagram (7/15)
- Wiring Harness Diagram (8/15)
- Wiring Harness Diagram (9/15)
- Wiring Harness Diagram (10/15)
- Wiring Harness Diagram (11/15)
- Wiring Harness Diagram (12/15)
- Wiring Harness Diagram (13/15)
- Wiring Harness Diagram (14/15)
- Wiring Harness Diagram (15/15)
- Index
Komatsu
