The Komatsu PC78US-10 Crawler Excavator is a tight-tail machine that usually works in streets, small sites, and around utilities where you don’t have much swing room. People who reach for the Komatsu PC78US-10 Crawler Excavator Shop Manual (SEN06518-12) are usually field techs, shop mechanics, or anyone actually turning wrenches on the machine. They’re trying to sort fault codes, chase hydraulic issues, or tear down components without guessing and wasting downtime. If you’re trying to keep a fleet digging and not parked, this is the kind of book you want on your laptop or tablet.
What this manual helps you do
- Trace hydraulic problems by following circuit layouts and standard test points for the PC78US-10’s multi-pump system.
- Diagnose engine and machine control issues using the usual Komatsu procedures, flowcharts, and wiring logic you’d expect in a shop manual.
- Follow step-by-step disassembly and reassembly sequences for major components so you know what to pull, in what order, and what to watch for.
- Check adjustment procedures for items like travel, swing, and work equipment functions so the excavator behaves correctly after repairs.
- Verify troubleshooting steps for error codes and symptoms before you start throwing parts at an electrical or sensor problem.
Who this is for
This is aimed at field technicians, shop mechanics, and fleet managers who handle repair and overhaul work, not just daily checks. If you only need basic operation, greasing points, and simple intervals, you’re better off with the Operation & Maintenance manual instead of this shop manual.
FAQ
Q: Is this a PDF I can download and search?
A: Yes, it’s a digital PDF, so you can download it, run keyword searches, and print specific sections for the toolbox.
Q: Is this deep enough for full component rebuilds, or just light service?
A: This is a shop manual, so it’s meant for workshop-level diagnostics, teardown, and reassembly, not just routine maintenance.
Q: How do I know if it matches my exact PC78US-10 machine?
A: Check your machine’s model designation and compare your book number to SEN06518-12; if your plate and manual reference line up, you’re in the right place.
Bottom line: If you’re repairing or troubleshooting a Komatsu PC78US-10 in the field or shop, this is the right manual; if you just run the machine and do daily service, keep looking for the 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 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
- 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: PC78US-10
- Working Range Drawings
- Specifications
- Specifications: PC78US-10
- Weight Table
- 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
- 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
- Function of Overheat Prevention System
- 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
- PTO
- Variable Flow Turbocharger
- EGR System
- EGR Valve
- EGR Cooler
- KCCV System
- KCCV Ventilator
- KDOC
- Cooling System
- Layout Drawing of Cooling System
- Specifications of Cooling System
- Control System
- Layout Drawing of Control System
- Machine Monitor System
- System Diagram of Machine Monitor System
- KOMTRAX System
- System Diagram of KOMTRAX System
- Function of KOMTRAX System
- Component Parts of Control System
- Machine Monitor
- KOMTRAX Terminal
- Pump Controller
- Resistor for PC-EPC Valve
- CAN Terminating Resistor
- Engine Controller
- Fuel Control Dial
- Hydraulic System
- Layout Drawing of Hydraulic System
- CLSS
- Structure of CLSS
- Function of CLSS
- Engine and Pump Combined Control System
- Engine and Pump Combined Control System Diagram
- Function of Engine and Pump Combined Control System
- Component Parts of Hydraulic System
- Hydraulic Tank
- Main Pump
- Control Valve
- Work Equipment System
- Layout Drawing of Work Equipment System
- Structure of Valve Control
- 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
- Overload Caution System
- Overload Caution System Diagram
- Function of Overload Caution 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)
- Blade PPC Valve
- Solenoid Valve
- Boom Anti-drop Valve
- Arm Anti-Drop Valve
- Multi-Control Valve
- Pilot Circuit Accumulator
- Attachment Circuit Accumulator (For Low Pressure Circuit)
- 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
- Travel PPC Valve
- Center Swivel Joint
- Undercarriage and Frame
- Layout Drawing of Undercarriage
- Specifications of Undercarriage
- Idler Cushion
- Structure of Idler Cushion
- Specifications of Idler Cushion
- 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
- ROPS CAB
- Structure of ROPS CAB
- Function of ROPS CAB
- CAB Mount
- Structure of CAB Mount
- Function of CAB Mount
- Remove Wiring Harness Out of Cab
- 20 Standard Value Table
- Table of Contents
- Abbreviation List
- Standard Value Table for Engine
- Standard Value Table for Engine: PC78US-10
- Standard Value Table for Machine
- Standard Value Table for Machine: PC78US-10
- Machine Posture and Procedures to Measure Performance
- Standard Value Table for Electricity
- Standard Value Table for Electricity
- 30 Testing and Adjusting
- Table of Contents
- Precautions Before Work
- 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 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
- Examine Engine Oil Pressure
- How to Examine Engine Oil Pressure
- Visual Check Inside of EGR Valve
- How to do the Visual Check Inside of EGR Valve
- Clean Inside of EGR Valve
- How to Clean Inside of EGR Valve
- 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 and Adjust Air Conditioner Compressor Belt Tension
- How to Examine Air Conditioner Compressor Belt Tension
- How to Adjust Air Conditioner Compressor Belt Tension
- Examine Alternator Belt
- How to Examine Alternator Belt
- Examine Automatic Tensioner
- How to Examine Automatic Tensioner
- Write Injector Compensation Value to Engine Controller
- How to Write Injector Compensation Value
- 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 and Travel Circuits
- How to Examine Oil Pressure in Work Equipment and Travel Circuits
- How to Adjust Oil Pressure in Work Equipment and Travel Circuits
- Examine and Adjust Swing and Blade Circuit Oil Pressure
- How to Examine Swing and Blade Relief Pressure
- How to Adjust Swing Relief Pressure
- How to Adjust Blade LOWER Relief Pressure
- How to Adjust Blade RAISE Relief Pressure
- Examine Oil Pressure of Control Circuit
- How to Examine Oil Pressure in Control Circuit
- Examine and adjust oil pressure in pump PC control circuit
- How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure)
- How to 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 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 and Adjust Travel Deviation
- How to Examine Travel Deviation
- How to Adjust Travel Deviation
- 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 Blade 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
- CAB Related Parts
- How to Adjust Mirrors
- Procedure to Adjust Machine Left Front Mirror (A)
- Procedure to Adjust Machine Rear Mirror (B)
- Examine and Adjust Engine Hood Catcher
- How to Examine Engine Hood Catcher
- How to Adjust Engine Hood Catcher
- How to Examine and Adjust Slide Door
- How to Examine and Adjust Slide Door When It is Closed and Locked
- How to Examine and Adjust Slide Door When It is Open and Locked
- Electrical System
- Set and Operate Machine Monitor
- Operator Mode
- Function to Show Technician Identification Status Screen
- Function to Show Operator Identification Input Screen
- 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
- Adjust Rightview Camera Angle
- How to Adjust Right View 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: PC78US-10
- 40 Troubleshooting
- Table of Contents
- Precautions Before Work
- 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 Prefilter
- Examine Water Separator, Drain Water and Sediment
- How to Replace Fuel Prefilter Cartridge
- Examine Fuel Main Filter
- Examine Engine Oil Level (Oil Quantity in Oil Pan)
- Examine Oil Level in PTO Gear Case
- Examine Coolant Level (Reservoir Tank)
- Examine Air Cleaner Clogging
- Clean Outer Element
- Replace Element
- Examine Hydraulic Oil Level
- Examine Hydraulic Oil Strainer
- Examine Hydraulic Oil Filter
- Examine Oil Level in Swing Machinery 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
- 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 List and Layout
- Connector Contact Connection Table
- T-Branch Box and T-Branch Adapter Table
- Fuse Location Table
- Failure Code Table
- Troubleshooting by Failure Code (Display of Code)
- 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 [AB00KE]
- Failure Code [B@BAZG]
- Failure Code [B@BCNS]
- 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 [CA332]
- 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 [CA466]
- Failure Code [CA515]
- Failure Code [CA516]
- Failure Code [CA553]
- Failure Code [CA555]
- Failure Code [CA556]
- 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 [CA1695]
- Failure Code [CA1696]
- Failure Code [CA1843]
- Failure Code [CA1844]
- Failure Code [CA1896]
- Failure Code [CA1942]
- 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 [CA3419]
- Failure Code [CA3421]
- Failure Code [CA3724]
- Failure Code [CA3918]
- Failure Code [CA3919]
- Failure Code [CA3921]
- Failure Code [CA3922]
- Failure Code [CA3923]
- Failure Code [D110KB]
- Failure Code [D19JKZ]
- Failure Code [D811MC]
- Failure Code [D862KA]
- 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 [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 [DGH2KB]
- 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 [DKULKA]
- Failure Code [DKULKB]
- Failure Code [DKULKY]
- Failure Code [DR21KX]
- 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 [DWJ0KA]
- Failure Code [DWJ0KB]
- Failure Code [DWJ0KY]
- Failure Code [DXA8KA]
- Failure Code [DXA8KB]
- Failure Code [DXE4KA]
- Failure Code [DXE4KB]
- Failure Code [DXE4KY]
- Failure Code [DY20KA]
- Failure Code [DY20MA]
- Failure Code [DY2CKB]
- Failure Code [DY2DKB]
- Failure Code [DY2EKB]
- Troubleshooting of Electrical System (E-Mode)
- Engine Does Not Start (Engine Does Not Crank)
- Manual Preheating System Does Not Operate
- While Preheating is in Operation, Preheating Monitor Does Not Come On
- When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing
- Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation
- Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation
- Charge Level Monitor Comes On in Red While Engine is in Operation
- Fuel Level Monitor Comes On in Red While Engine is in Operation
- Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation
- Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation
- Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation
- Fuel Gauge Does Not Move from Minimum or Maximum
- Display of Fuel Gauge is Different from Actual Fuel Level
- Engine Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum
- Display of Engine Coolant Temperature Gauge is Different from Actual Coolant Temperature
- Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum
- Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature
- Some Areas of Machine Monitor Screen are Not Shown
- Function Switch Does Not Operate
- Automatic Warm-up System Does Not Operate (in Cold Weather)
- When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Light Up or Does Not Go Off
- Auto-Decelerator is Not Operated or Canceled with Lever
- Working Mode Selector Screen is Not Shown While Working Mode Switch is Operated
- When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed
- Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated
- Travel Speed Does Not Change Even When You Change Travel Speed
- Alarm Buzzer Does Not Stop
- Service Meter is Not Shown While Starting Switch is in OFF Position
- Service Mode Cannot be Selected
- All Work Equipment, Swing, Travel Do Not Operate
- All Work Equipment, Swing, Travel Cannot be Locked
- Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position
- While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated
- Work Equipment Does Not Operate While Lock Lever Automatic Release Switch is in Release Position
- Travel Alarm Does Not Operate During Travel
- Travel Alarm Does Not Stop When Machine Stops
- Horn Does Not Sound
- Horn Does Not Stop
- Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated
- Windshield Wiper Does Not Operate When Wiper Switch is Operated
- When Window Washer Switch is Operated, Window Washer Does Not Operate
- "Boom Raise" is Not Shown Correctly with Monitoring Function
- "Boom Lower" is Not Shown Correctly with Monitoring Function
- "Arm OUT" is Not Shown Correctly with Monitoring Function
- "Arm IN" is Not Shown Correctly with Monitoring Function
- Bucket DUMP is Not Shown Correctly with Monitoring Function
- Bucket CURL is Not Shown Correctly with Monitoring Function
- Swing is Not Shown Correctly with Monitoring Function
- Travel Indicator is Not Displayed Properly with Monitoring Function
- Service is Not Shown Correctly with Monitoring Function
- Blade RAISE is Not Shown Correctly with Monitoring Function
- Blade LOWER is Not Shown Correctly with Monitoring Function
- KOMTRAX System Does Not Operate Correctly
- Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
- Information Shown in Troubleshooting Table (H-Mode)
- System Chart of Hydraulic and Mechanical Systems
- Failure Mode and Cause Table
- All Work Equipment, Swing and Travel Do Not Work
- All Work Equipment and Travel Speeds are Low or Power is Low
- Fine Control Performance or Response is Unsatisfactory
- Unusual Noise is Heard from Around Hydraulic Pump
- Engine Speed Drops Largely or Engine Stops
- Boom Speed or Power is Low
- Arm Speed or Power is Low
- Bucket Speed or Power is Low
- Blade Speed or Power is Low
- Work Equipment Does Not Move in Single Operation
- Hydraulic Drift of Boom is Large
- Hydraulic Drift of Arm is Large
- Hydraulic Drift of Bucket is Large
- Hydraulic Drift of Blade is Large
- When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves
- Time Lag of Work Equipment is Large
- Oil Flow in Attachment Circuit Cannot be Changed
- In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower
- In Mixed Operation of Travel with Work Equipment or Swing, Travel Speed Drops Largely
- In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low
- Machine Does Not Travel Straight
- Machine is Not Steered Well or Steering Power is Low
- Travel Speed is Low
- One of Tracks Does Not Run
- Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast
- Upper Structure Does Not Swing in Two Directions of Right and Left
- Machine Swings Only in One Direction
- Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left
- Swing Acceleration or Swing Speed is Low in Only One Direction
- Upper Structure Overruns Excessively When It Stops Swinging (Both Right and Left)
- Upper Structure Overruns Excessively When It Stops Swinging (Only One Direction Either Right or Left)
- Shock is Large When Upper Structure Stops Swing Operation
- Large Unusual Noise is Made When Upper Structure Stops Swing Operation
- Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)
- Swing Drift on a Slope is Large (While Swing Parking Brake is Released)
- Troubleshooting of Engine (S-Mode)
- Information Shown in Troubleshooting Table (S-Mode)
- Engine Does Not Crank When Starting Switch is Turned to Start Position
- Engine Cranks but No Exhaust Smoke Comes Out
- Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)
- Engine Startability is Unsatisfactory
- Engine Does Not Pick Up Smoothly
- Engine Stops During Operation
- Engine Does Not Rotate Smoothly
- Engine Lacks Output (or Lacks Power)
- Exhaust Smoke is Black
- Engine Oil Consumption is Excessive
- Engine Oil Becomes Dirty Quickly
- Fuel Consumption is Excessive
- Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)
- Engine Oil Pressure Drops
- Fuel Mixes Into Engine Oil
- Water Mixes Into Engine Oil (Milky)
- Coolant Temperature Increases Too High (Overheat)
- Unusual Noise is Heard
- Vibration is Excessive
- Air Cannot be Bled from Fuel Circuit
- 50 Disassembly and Assembly
- Table of Contents
- Precautions Before Work
- 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 EGR Valve Assembly
- How to Remove EGR Valve Assembly
- How to Install EGR Valve Assembly
- Remove and Install EGR Cooler Assembly
- How to Remove EGR Cooler Assembly
- How to Install EGR Cooler Assembly
- Remove and Install Starter Assembly
- How to Remove Starting Motor Assembly
- How to Install Starting Motor Assembly
- Remove and Install Air Conditioner Compressor Belt
- How to Remove Air Conditioner Compressor Belt
- How to Install Air Conditioner Compressor Belt
- Remove and Install Alternator Belt
- How to Remove Alternator Belt
- How to Install Alternator Belt
- Remove and Install Automatic Tensioner
- How to Remove Automatic Tensioner
- How to Install Automatic Tensioner
- 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 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 Fuel Cooler Assembly
- How to Remove Fuel Cooler Assembly
- How to Install Fuel Cooler Assembly
- Remove and Install Engine Hood Assembly
- How to Remove Engine Hood Assembly
- How to Install Engine Hood Assembly
- Remove and Install KDOC Muffler
- How to Remove KDOC Muffler
- How to Install KDOC Muffler
- Remove and Install Fuel Tank Assembly
- How to Remove Fuel Tank Assembly
- How to Install Fuel Tank Assembly
- Remove and Install KCCV Ventilator Assembly
- How to Remove KCCV Ventilator Assembly
- How to Install KCCV Ventilator Assembly
- Remove and Install Air Cleaner Assembly
- How to Remove Air Cleaner Assembly
- How to Install Air Cleaner Assembly
- Remove and Install Air Conditioner Compressor Assembly
- How to Remove Air Conditioner Compressor Assembly
- How to Install Air Conditioner Compressor 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 Travel Motor and Final Drive Assembly (Applicable Machine: #30001 to 35917)
- How to Disassemble Travel Motor and Final Drive Assembly (Applicable Machine: #30001 to 35917)
- How to Assemble Travel Motor and Final Drive Assembly (Applicable Machine: #30001 to 35917)
- Disassemble and Assemble Travel Motor and Final Drive Assembly (Applicable Machine: #35918 and Up)
- How to Disassemble Travel Motor and Final Drive Assembly (Applicable Machine: #35918 and Up)
- How to Assemble Travel Motor and Final Drive Assembly (Applicable Machine: #35918 and Up)
- 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
- 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 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 Blade Assembly
- How to Remove Blade Assembly
- How to Install Blade Assembly
- Remove and Install Work Equipment Assembly
- How to Remove Work Equipment Assembly
- How to Install Work Equipment Assembly
- Remove and Install Boom Anti-drop Valve Assembly
- How to Remove Boom Anti-drop Valve Assembly
- How to Install Boom Anti-drop Valve Assembly
- Remove and Install Arm Anti-Drop Valve Assembly
- How to Remove Arm Anti-Drop Valve Assembly
- How to Install Arm Anti-Drop Valve Assembly
- Disassemble and Assemble Anti-Drop Valve Assembly
- How to Disassemble Anti-Drop Valve Assembly
- How to Assemble Anti-Drop Valve 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 Slide Door
- How to Remove Slide Door
- How to Install Slide Door
- 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 Mass Air Flow and Temperature Sensor
- How to Remove Mass Air Flow and Temperature Sensor
- How to Install Mass Air Flow and Temperature Sensor
- Remove and Install KCCV Crankcase Pressure Sensor
- How to Remove KCCV Crankcase Pressure Sensor
- How to Install KCCV Crankcase Pressure Sensor
- 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 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 Road Liner
- Maintenance Standard for Rubber Shoes
- Hydraulic System
- Maintenance Standard for Hydraulic Tank
- Maintenance Standard for Main Pump
- Maintenance Standard for Main Pump Servo Valve
- 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 EPC Valve of 1st-Line Attachment PPC Valve
- Maintenance Standard for Solenoid 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
- Dimensions of Arm
- Dimensions of Bucket
- 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
- 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 [879BKA]
- Failure Code [879BKB]
- Failure Code [879CKA]
- Failure Code [879CKB]
- Failure Code [879DKZ]
- Failure Code [879EMC]
- Failure Code [879FMC]
- Failure Code [879GKX]
- Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
- Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)
- Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
- 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 (1/2)
- Hydraulic Circuit Diagram (2/2)
- Hydraulic Circuit Diagram (For European Union)
- Electrical Circuit Diagram
- Symbols Used in Electric Circuit Diagram
- Electrical Circuit Diagram (1/6)
- Electrical Circuit Diagram (2/6)
- Electrical Circuit Diagram (3/6)
- Electrical Circuit Diagram (4/6)
- Electrical Circuit Diagram (5/6)
- Electrical Circuit Diagram (6/6)
- Electrical Circuit Diagram (For European Union) (Serial Number: 30001 – 33927) (1/6)
- Electrical Circuit Diagram (For European Union) (Serial Number: 30001 – 33927) (2/6)
- Electrical Circuit Diagram (For European Union) (Serial Number: 30001 – 33927) (3/6)
- Electrical Circuit Diagram (For European Union) (Serial Number: 30001 – 33927) (4/6)
- Electrical Circuit Diagram (For European Union) (Serial Number: 30001 – 33927) (5/6)
- Electrical Circuit Diagram (For European Union) (Serial Number: 30001 – 33927) (6/6)
- Electrical Circuit Diagram (For European Union) (Serial Number: 33928 – ) (1/6)
- Electrical Circuit Diagram (For European Union) (Serial Number: 33928 – ) (2/6)
- Electrical Circuit Diagram (For European Union) (Serial Number: 33928 – ) (3/6)
- Electrical Circuit Diagram (For European Union) (Serial Number: 33928 – ) (4/6)
- Electrical Circuit Diagram (For European Union) (Serial Number: 33928 – ) (5/6)
- Electrical Circuit Diagram (For European Union) (Serial Number: 33928 – ) (6/6)
- Index
Komatsu
