Komatsu Hydraulic Excavator PC490LC-11E0 Shop Manual SEN06954-00 – PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC490LC-11E0 Shop Manual SEN06954-00 – PDF DOWNLOAD

Language : English
Pages :3060
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Excavator PC490LC-11E0 Shop Manual SEN06954-00 – PDF DOWNLOAD

SERIAL NUMBERS 86088 and up

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC490LC-11E0 Shop Manual SEN06954-00 – PDF DOWNLOAD

SERIAL NUMBERS 86088 and up

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 22
FOREWORD, SAFETY, BASIC INFORMATION 28
HOW TO READ THE SHOP MANUAL 28
SAFETY NOTICE FOR OPERATION 30
PRECAUTIONS TO PREVENT FIRE 38
ACTIONS IF FIRE OCCURS 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 42
METHOD FOR CHECKING ENGINE TYPE 43
PRECAUTIONS FOR DEF 45
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 45
PRECAUTIONS FOR ADDING 45
PRECAUTIONS FOR STORING 45
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 45
THE OTHER PRECAUTIONS 45
STORE AdBlue/DEF 46
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 47
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 50
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 57
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 59
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 60
PRACTICAL USE OF KOMTRAX 61
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 64
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 66
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 70
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 74
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 76
HOW TO READ ELECTRICAL WIRE CODE 77
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 81
STANDARD TIGHTENING TORQUE TABLE 84
CONVERSION TABLE 91
01 SPECIFICATIONS 97
CONTENTS 98
ABBREVIATION LIST 99
SPECIFICATIONS 105
SPECIFICATION DRAWING 105
SPECIFICATION DRAWING: PC490LC-11E0 105
WORKING RANGE DRAWINGS 107
WORKING RANGE: PC490LC-11E0 107
SPECIFICATIONS 108
SPECIFICATIONS: PC490LC-11E0 108
WEIGHT TABLE 111
WEIGHT TABLE: PC490LC-11E0 111
TABLE OF FUEL, COOLANT, AND LUBRICANTS 113
10 STRUCTURE AND FUNCTION 115
CONTENTS 116
ABBREVIATION LIST 120
UREA SCR SYSTEM 126
LAYOUT DRAWING OF UREA SCR SYSTEM 126
UREA SCR SYSTEM DIAGRAM 130
FUNCTION OF UREA SCR SYSTEM 131
FUNCTION OF AdBlue/DEF SYSTEM 131
INDUCEMENT STRATEGY 133
COMPONENT PARTS OF UREA SCR SYSTEM 152
AdBlue/DEF MIXING TUBE 152
SCR ASSEMBLY 152
AdBlue/DEF TANK 155
AdBlue/DEF PUMP 157
AdBlue/DEF INJECTOR 158
AdBlue/DEF HOSE 159
AdBlue/DEF TANK HEATING VALVE 160
BOOT-UP SYSTEM 161
LAYOUT DRAWING OF BOOT-UP SYSTEM 161
SYSTEM OPERATING LAMP SYSTEM 163
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 163
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 164
OPERATION OF SYSTEM OPERATING LAMP SYSTEM 165
BATTERY DISCONNECT SWITCH 166
FUNCTION OF BATTERY DISCONNECT SWITCH 166
ENGINE SYSTEM 167
LAYOUT DRAWING OF ENGINE SYSTEM 167
SPECIFICATIONS OF ENGINE SYSTEM 168
FUNCTION OF ENGINE SYSTEM 169
ENGINE CONTROL SYSTEM 170
ENGINE CONTROL SYSTEM DIAGRAM 170
OPERATION OF ENGINE CONTROL SYSTEM 171
AUTO-DECELERATION SYSTEM 173
AUTO-DECELERATION SYSTEM DIAGRAM 173
FUNCTION OF AUTO-DECELERATION SYSTEM 173
OPERATION OF AUTO-DECELERATION SYSTEM 174
ENGINE AUTOMATIC WARM-UP SYSTEM 175
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 175
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 176
OVERHEAT PREVENTION SYSTEM 177
OVERHEAT PREVENTION SYSTEM DIAGRAM 177
FUNCTION OF OVERHEAT PREVENTION SYSTEM 178
TURBOCHARGER PROTECTION SYSTEM 180
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 180
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 181
AUTOMATIC IDLE STOP SYSTEM 182
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 182
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 182
OPERATION OF AUTOMATIC IDLE STOP SYSTEM 182
COMPONENT PARTS OF ENGINE SYSTEM 185
VGT 185
EGR SYSTEM 188
EGR VALVE 190
EGR COOLER 192
KCCV SYSTEM 193
KCCV VENTILATOR 194
KDPF 196
COOLING SYSTEM 201
LAYOUT DRAWING OF COOLING SYSTEM 201
SPECIFICATIONS OF COOLING SYSTEM 202
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 204
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 204
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 205
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 206
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 206
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 207
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 209
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN 209
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 209
COMPONENT PARTS OF COOLING SYSTEM 211
COOLING FAN PUMP 211
COOLING FAN MOTOR 218
CONTROL SYSTEM 225
LAYOUT DRAWING OF CONTROL SYSTEM 225
MACHINE MONITOR SYSTEM 228
MACHINE MONITOR SYSTEM DIAGRAM 228
FUNCTION OF MACHINE MONITOR SYSTEM 228
KomVision SYSTEM 229
LAYOUT DRAWING OF KOMVISION SYSTEM 229
KomVision SYSTEM DIAGRAM 231
FUNCTION OF KomVision SYSTEM 231
KOMTRAX SYSTEM 233
KOMTRAX SYSTEM DIAGRAM 233
FUNCTION OF KOMTRAX SYSTEM 233
PPC LEVERS 234
LH PPC LEVER 234
RH PPC LEVER 235
COMPONENT PARTS OF CONTROL SYSTEM 236
MACHINE MONITOR 236
KomVision CONTROLLER 249
KomVision CAMERA 253
GATEWAY FUNCTION CONTROLLER 254
COMMUNICATION TERMINAL 257
PUMP CONTROLLER 259
RESISTOR FOR PC-EPC VALVE 263
CAN TERMINATING RESISTOR 263
ENGINE CONTROLLER 265
FUEL CONTROL DIAL 271
FUEL FEED PUMP 273
FUEL FEED PUMP SWITCH 274
SENSOR 275
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 275
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 275
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 275
FUNCTION OF AUTO GREASE PRESSURE SWITCH 275
STRUCTURE OF OVERLOAD CAUTION SENSOR 275
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 276
FUNCTION OF OVERLOAD CAUTION SENSOR 276
HYDRAULIC SYSTEM 277
LAYOUT DRAWING OF HYDRAULIC SYSTEM 277
CLSS 279
STRUCTURE OF CLSS 279
OPERATION OF UNLOAD VALVE AND LS PRESSURE 281
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 282
PRESSURE COMPENSATION CONTROL 295
ENGINE AND PUMP COMBINED CONTROL SYSTEM 299
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 299
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 301
PUMP AND VALVE CONTROL SYSTEM 306
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 306
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 307
COMPONENT PARTS OF HYDRAULIC SYSTEM 309
HYDRAULIC TANK 309
MAIN PUMP 311
PILOT OIL FILTER 337
CONTROL VALVE 337
WORK EQUIPMENT SYSTEM 399
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 399
STRUCTURE OF VALVE CONTROL 404
ONE-TOUCH POWER MAXIMIZING SYSTEM 405
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 405
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 406
MACHINE PUSH-UP SYSTEM 407
MACHINE PUSH-UP SYSTEM DIAGRAM 407
FUNCTION OF MACHINE PUSH-UP SYSTEM 408
PPC LOCK SYSTEM 409
PPC LOCK SYSTEM DIAGRAM 409
FUNCTION OF PPC LOCK SYSTEM 409
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 410
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 410
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 410
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 411
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 412
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT 412
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 413
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 414
WORK EQUIPMENT AND SWING PPC VALVE 414
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 419
SOLENOID VALVE 425
VARIABLE PRESSURE COMPENSATION VALVE 427
ATTACHMENT CIRCUIT SELECTOR VALVE 428
ATTACHMENT BYPASS SOLENOID VALVE 430
PILOT CIRCUIT ACCUMULATOR 432
SWING SYSTEM 433
LAYOUT DRAWING OF SWING SYSTEM 433
SWING CONTROL SYSTEM DIAGRAM 439
FUNCTION OF SWING CONTROL SYSTEM 439
COMPONENT PARTS OF SWING SYSTEM 443
SWING MOTOR 443
SWING MACHINERY 454
SWING CIRCLE 456
TRAVEL SYSTEM 458
LAYOUT DRAWING OF TRAVEL SYSTEM 458
TRAVEL CONTROL SYSTEM DIAGRAM 462
FUNCTION OF TRAVEL CONTROL SYSTEM 463
COMPONENT PARTS OF TRAVEL SYSTEM 464
TRAVEL MOTOR 464
FINAL DRIVE 478
TRAVEL PPC VALVE 479
CENTER SWIVEL JOINT 484
UNDERCARRIAGE AND FRAME 486
LAYOUT DRAWING OF UNDERCARRIAGE 486
SPECIFICATIONS OF UNDERCARRIAGE 486
WORK EQUIPMENT 487
STRUCTURE OF WORK EQUIPMENT 487
FUNCTION OF WORK EQUIPMENT 488
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 489
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 489
BUCKET CLEARANCE ADJUSTMENT SHIM 490
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 490
CAB AND ITS ATTACHMENTS 491
ROPS CAB 491
STRUCTURE OF ROPS CAB 491
FUNCTION OF ROPS CAB 491
CAB MOUNT 492
STRUCTURE OF CAB MOUNT 492
FUNCTION OF CAB MOUNT 492
CAB TIPPING STOPPER 493
STRUCTURE OF CAB TIPPING STOPPER 493
FUNCTION OF CAB TIPPING STOPPER 493
20 STANDARD VALUE TABLE 495
CONTENTS 496
ABBREVIATION LIST 497
STANDARD VALUE TABLE FOR ENGINE 503
STANDARD VALUE TABLE FOR ENGINE: PC490LC-11E0 503
STANDARD VALUE TABLE FOR MACHINE 506
STANDARD VALUE TABLE FOR MACHINE: PC490LC-11E0 506
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 522
STANDARD VALUE TABLE FOR ELECTRICAL 526
STANDARD VALUE TABLE FOR ELECTRICAL 526
30 TESTING AND ADJUSTING 537
CONTENTS 538
ABBREVIATION LIST 541
RELATED INFORMATION ON TESTING AND ADJUSTING 547
TOOLS FOR TESTING AND ADJUSTING 547
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 555
ENGINE AND COOLING SYSTEM 557
TEST ENGINE SPEED 557
METHOD FOR TESTING ENGINE SPEED 557
TEST BOOST PRESSURE 560
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 560
METHOD FOR TESTING BOOST PRESSURE 561
TEST EXHAUST GAS COLOR 562
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 562
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 563
TEST AND ADJUST VALVE CLEARANCE 564
METHOD FOR TESTING VALVE CLEARANCE 564
METHOD FOR ADJUSTING VALVE CLEARANCE 567
TEST COMPRESSION PRESSURE 568
METHOD FOR TESTING COMPRESSION PRESSURE 568
TEST BLOWBY PRESSURE 571
METHOD FOR TESTING BLOWBY PRESSURE 571
TEST ENGINE OIL PRESSURE 573
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 573
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 573
TEST EGR VALVE AND VGT OIL PRESSURE 575
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 575
TEST FUEL PRESSURE 577
METHOD FOR TESTING FUEL PRESSURE 577
TEST FUEL RETURN RATE AND LEAKAGE 579
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 579
BLEED AIR FROM FUEL SYSTEM 582
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 582
TEST FUEL CIRCUIT FOR LEAKAGE 584
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 584
HANDLE CYLINDER CUT-OUT MODE OPERATION 586
HANDLE NO-INJECTION CRANKING OPERATION 587
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 588
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 588
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 588
CLEAN FUEL DOSER 590
METHOD FOR CLEANING FUEL DOSER 590
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 592
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 592
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 598
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 598
TEST SCR RELATED FUNCTIONS 599
TEST AdBlue/DEF PUMP RAISED PRESSURE 602
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 605
TEST AdBlue/DEF LINE HEATER RELAY 1 609
TEST AdBlue/DEF LINE HEATER RELAY 2 611
TEST AdBlue/DEF PUMP HEATER RELAY 614
TEST AdBlue/DEF TANK HEATER VALVE 617
TEST DENITRATION EFFICIENCY OF SCR 620
CLEAN AdBlue/DEF TANK 624
METHOD FOR CLEANING AdBlue/DEF TANK 624
POWER TRAIN 628
TEST SWING CIRCLE BEARING CLEARANCE 628
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 628
UNDERCARRIAGE AND FRAME 629
TEST AND ADJUST TRACK TENSION 629
METHOD FOR TESTING TRACK TENSION 629
METHOD FOR ADJUSTING TRACK TENSION 629
HYDRAULIC SYSTEM 631
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 631
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 631
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 631
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 637
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 638
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 645
TEST OIL PRESSURE OF CONTROL CIRCUIT 649
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 649
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 651
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 651
TEST PC-EPC VALVE OUTLET PRESSURE 652
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 653
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 655
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 655
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE 656
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 657
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 658
METHOD FOR ADJUSTING LS VALVE 659
TEST OUTLET PRESSURE OF SOLENOID VALVE 660
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 660
OPERATING CONDITION OF SOLENOID VALVE 661
TEST PPC VALVE OUTLET PRESSURE 663
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 663
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 665
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 665
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 666
TEST PUMP SWASH PLATE SENSOR 667
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 667
TEST COOLING FAN SPEED 668
METHOD FOR TESTING COOLING FAN SPEED 668
TEST OIL PRESSURE IN FAN PUMP CIRCUIT 669
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT 669
TEST FAN PUMP EPC ELECTRIC CURRENT 671
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 671
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 672
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 672
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 674
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 674
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 674
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 675
TEST OIL LEAKAGE 676
TEST OIL LEAKAGE OF BOOM CYLINDER 676
TEST OIL LEAKAGE OF ARM CYLINDER 676
TEST OIL LEAKAGE OF BUCKET CYLINDER 677
METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR 677
METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR 678
BLEED AIR FROM HYDRAULIC CIRCUIT 679
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 681
CAB AND ITS ATTACHMENTS 684
TEST CAB TIPPING STOPPER 684
METHOD FOR TESTING CAB TIPPING STOPPER 684
METHOD FOR ADJUSTING MIRRORS 685
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 685
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 686
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 687
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 688
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 689
ELECTRICAL SYSTEM 691
SET AND OPERATE MACHINE MONITOR 691
OPERATOR MODE 694
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 695
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 695
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 696
CHECKING FUNCTION OF SERVICE METER 696
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 696
SERVICE MODE 699
METHOD FOR OPERATING SERVICE MODE 701
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 704
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 711
ABNORMALITY RECORD MENU 723
METHOD FOR CONFIRMING MAINTENANCE RECORD 727
METHOD FOR OPERATING MAINTENANCE MODE SETTING 728
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 732
DEFAULT MENU 734
DIAGNOSTIC TESTS MENU 745
ADJUSTMENT MENU 754
METHOD FOR PERFORMING NO-INJECTION CRANKING 777
KOMTRAX SETTINGS MENU 778
METHOD FOR DISPLAYING SERVICE MESSAGE 781
METHOD FOR STARTING UP KOMTRAX SYSTEM 783
ADJUST REARVIEW CAMERA ANGLE 789
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 789
ADJUST KomVision CAMERA ANGLE 792
Angle adjustment method for KomVision camera 793
ADJUST KomVision RELATED ITEMS 797
SETTING OF KomVision (MAIN SETTING) 797
SETTING OF KomVision (CAMERA SETTING) 799
SET KomVision (camera calibration) 799
KomVision screen – Check 12 m visibility 826
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 829
HANDLE BATTERY DISCONNECT SWITCH 830
TEST DIODES 831
METHOD FOR TESTING DIODE USING DIGITAL TESTER 831
METHOD FOR TESTING DIODE USING ANALOG TESTER 831
Pm CLINIC 832
Pm CLINIC SERVICE 832
Pm CLINIC CHECK SHEET 833
40 TROUBLESHOOTING 847
CONTENTS 848
ABBREVIATION LIST 860
RELATED INFORMATION ON TROUBLESHOOTING 866
GENERAL TROUBLESHOOTING POINTS 866
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 868
SEQUENCE OF EVENTS IN TROUBLESHOOTING 880
CHECKS BEFORE TROUBLESHOOTING 882
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 884
WALK-AROUND CHECK 884
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 886
CHECK FUEL LEVEL AND TYPE 886
CHECK IMPURE INGREDIENT IN FUEL 887
CHECK FUEL PREFILTER 887
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 887
FUEL PREFILTER CARTRIDGE – REPLACE 888
CHECK MAIN FILTER 889
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 890
CHECK COOLANT LEVEL (RESERVOIR TANK) 892
CHECK CLOGGING OF AIR CLEANER 892
OUTER ELEMENT – CLEAN 893
ELEMENTS – REPLACE 895
CHECK HYDRAULIC OIL LEVEL 896
CHECK HYDRAULIC OIL STRAINER 896
CHECK HYDRAULIC FILTER 897
CHECK OIL LEVEL IN SWING MACHINERY CASE 898
CHECK OIL LEVEL IN DAMPER CASE 899
CHECK OIL LEVEL IN FINAL DRIVE CASE 899
BLEED AIR FROM FUEL SYSTEM 900
BLEED AIR FROM HYDRAULIC SYSTEM 900
ELECTRICAL EQUIPMENT – CHECK METHOD 900
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 906
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM 919
PROCEDURE FOR TESTING AND TROUBLESHOOTING 930
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 933
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 937
CONNECTOR LIST AND LAYOUT 939
CONNECTOR CONTACT IDENTIFICATION 952
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 992
FUSE LOCATION TABLE 998
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)1001
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])1005
FAILURE CODE TABLE1007
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1027
FAILURE CODE [879AKA]1027
FAILURE CODE [879AKB]1028
FAILURE CODE [879BKA]1029
FAILURE CODE [879BKB]1031
FAILURE CODE [879CKA]1033
FAILURE CODE [879CKB]1034
FAILURE CODE [879DKZ]1035
FAILURE CODE [879EMC]1037
FAILURE CODE [879FMC]1038
FAILURE CODE [879GKX]1039
FAILURE CODE [989L00]1041
FAILURE CODE [989M00]1042
FAILURE CODE [989N00]1043
FAILURE CODE [A1U0N3]1044
FAILURE CODE [A1U0N4]1046
FAILURE CODE [A900FR]1048
FAILURE CODE [A900N6]1049
FAILURE CODE [A900NY]1050
FAILURE CODE [AA10NX]1051
FAILURE CODE [AB00KE]1053
FAILURE CODE [AQ10N3]1056
FAILURE CODE [AS00N3]1058
FAILURE CODE [AS00R2]1060
FAILURE CODE [AS00R3]1061
FAILURE CODE [AS00R4]1062
FAILURE CODE [AS00R5]1063
FAILURE CODE [AS00R6]1064
FAILURE CODE [AS00ZK]1065
FAILURE CODE [AS10KM]1066
FAILURE CODE [AS10NR]1067
FAILURE CODE [AS10NT]1068
FAILURE CODE [B@BAZG]1069
FAILURE CODE [B@BAZK]1070
FAILURE CODE [B@BCNS]1072
FAILURE CODE [B@BCQA]1073
FAILURE CODE [B@BCZK]1075
FAILURE CODE [B@HANS]1077
FAILURE CODE [CA115]1078
FAILURE CODE [CA122]1079
FAILURE CODE [CA123]1081
FAILURE CODE [CA131]1083
FAILURE CODE [CA132]1085
FAILURE CODE [CA135]1087
FAILURE CODE [CA141]1089
FAILURE CODE [CA144]1091
FAILURE CODE [CA145]1093
FAILURE CODE [CA153]1095
FAILURE CODE [CA154]1098
FAILURE CODE [CA187]1101
FAILURE CODE [CA221]1103
FAILURE CODE [CA222]1105
FAILURE CODE [CA227]1107
FAILURE CODE [CA234]1108
FAILURE CODE [CA238]1109
FAILURE CODE [CA239]1111
FAILURE CODE [CA249]1113
FAILURE CODE [CA256]1115
FAILURE CODE [CA271]1117
FAILURE CODE [CA272]1119
FAILURE CODE [CA273]1120
FAILURE CODE [CA274]1122
FAILURE CODE [CA322]1123
FAILURE CODE [CA323]1125
FAILURE CODE [CA324]1127
FAILURE CODE [CA325]1129
FAILURE CODE [CA331]1131
FAILURE CODE [CA332]1133
FAILURE CODE [CA343]1135
FAILURE CODE [CA351]1136
FAILURE CODE [CA352]1137
FAILURE CODE [CA356]1140
FAILURE CODE [CA357]1142
FAILURE CODE [CA386]1144
FAILURE CODE [CA441]1145
FAILURE CODE [CA442]1147
FAILURE CODE [CA449]1148
FAILURE CODE [CA451]1149
FAILURE CODE [CA452]1151
FAILURE CODE [CA515]1153
FAILURE CODE [CA516]1155
FAILURE CODE [CA553]1157
FAILURE CODE [CA555]1158
FAILURE CODE [CA556]1159
FAILURE CODE [CA559]1160
FAILURE CODE [CA595]1165
FAILURE CODE [CA687]1166
FAILURE CODE [CA689]1168
FAILURE CODE [CA691]1170
FAILURE CODE [CA692]1172
FAILURE CODE [CA697]1174
FAILURE CODE [CA698]1175
FAILURE CODE [CA731]1176
FAILURE CODE [CA778]1177
FAILURE CODE [CA1117]1180
FAILURE CODE [CA1664]1181
FAILURE CODE [CA1669]1184
FAILURE CODE [CA1673]1185
FAILURE CODE [CA1677]1186
FAILURE CODE [CA1678]1187
FAILURE CODE [CA1682]1188
FAILURE CODE [CA1683]1190
FAILURE CODE [CA1684]1192
FAILURE CODE [CA1686]1194
FAILURE CODE [CA1691]1195
FAILURE CODE [CA1694]1198
FAILURE CODE [CA1695]1200
FAILURE CODE [CA1696]1201
FAILURE CODE [CA1712]1203
FAILURE CODE [CA1713]1206
FAILURE CODE [CA1714]1208
FAILURE CODE [CA1715]1209
FAILURE CODE [CA1776]1210
FAILURE CODE [CA1777]1213
FAILURE CODE [CA1843]1216
FAILURE CODE [CA1844]1218
FAILURE CODE [CA1879]1221
FAILURE CODE [CA1881]1224
FAILURE CODE [CA1883]1226
FAILURE CODE [CA1885]1229
FAILURE CODE [CA1887]1231
FAILURE CODE [CA1921]1233
FAILURE CODE [CA1922]1236
FAILURE CODE [CA1923]1241
FAILURE CODE [CA1924]1243
FAILURE CODE [CA1925]1245
FAILURE CODE [CA1927]1247
FAILURE CODE [CA1928]1249
FAILURE CODE [CA1942]1251
FAILURE CODE [CA1963]1252
FAILURE CODE [CA1977]1255
FAILURE CODE [CA1993]1258
FAILURE CODE [CA2185]1261
FAILURE CODE [CA2186]1263
FAILURE CODE [CA2249]1265
FAILURE CODE [CA2265]1266
FAILURE CODE [CA2266]1268
FAILURE CODE [CA2271]1270
FAILURE CODE [CA2272]1272
FAILURE CODE [CA2349]1274
FAILURE CODE [CA2353]1276
FAILURE CODE [CA2357]1278
FAILURE CODE [CA2381]1279
FAILURE CODE [CA2382]1281
FAILURE CODE [CA2383]1283
FAILURE CODE [CA2386]1285
FAILURE CODE [CA2387]1287
FAILURE CODE [CA2555]1288
FAILURE CODE [CA2556]1291
FAILURE CODE [CA2637]1293
FAILURE CODE [CA2639]1295
FAILURE CODE [CA2732]1298
FAILURE CODE [CA2733]1300
FAILURE CODE [CA2741]1302
FAILURE CODE [CA2765]1303
FAILURE CODE [CA2771]1304
FAILURE CODE [CA2777]1310
FAILURE CODE [CA2878]1313
FAILURE CODE [CA2881]1316
FAILURE CODE [CA2976]1319
FAILURE CODE [CA3133]1321
FAILURE CODE [CA3134]1323
FAILURE CODE [CA3135]1325
FAILURE CODE [CA3142]1328
FAILURE CODE [CA3143]1329
FAILURE CODE [CA3144]1330
FAILURE CODE [CA3146]1332
FAILURE CODE [CA3147]1333
FAILURE CODE [CA3148]1334
FAILURE CODE [CA3151]1336
FAILURE CODE [CA3165]1342
FAILURE CODE [CA3167]1344
FAILURE CODE [CA3229]1347
FAILURE CODE [CA3231]1349
FAILURE CODE [CA3232]1351
FAILURE CODE [CA3235]1355
FAILURE CODE [CA3239]1357
FAILURE CODE [CA3241]1360
FAILURE CODE [CA3242]1363
FAILURE CODE [CA3251]1366
FAILURE CODE [CA3253]1368
FAILURE CODE [CA3254]1371
FAILURE CODE [CA3255]1374
FAILURE CODE [CA3256]1378
FAILURE CODE [CA3311]1380
FAILURE CODE [CA3312]1382
FAILURE CODE [CA3313]1385
FAILURE CODE [CA3314]1386
FAILURE CODE [CA3315]1387
FAILURE CODE [CA3316]1390
FAILURE CODE [CA3317]1391
FAILURE CODE [CA3318]1392
FAILURE CODE [CA3319]1394
FAILURE CODE [CA3321]1395
FAILURE CODE [CA3322]1397
FAILURE CODE [CA3419]1400
FAILURE CODE [CA3421]1402
FAILURE CODE [CA3497]1404
FAILURE CODE [CA3498]1405
FAILURE CODE [CA3543]1406
FAILURE CODE [CA3545]1413
FAILURE CODE [CA3547]1415
FAILURE CODE [CA3558]1416
FAILURE CODE [CA3559]1418
FAILURE CODE [CA3562]1420
FAILURE CODE [CA3563]1422
FAILURE CODE [CA3567]1425
FAILURE CODE [CA3568]1428
FAILURE CODE [CA3571]1432
FAILURE CODE [CA3572]1434
FAILURE CODE [CA3574]1436
FAILURE CODE [CA3575]1438
FAILURE CODE [CA3577]1440
FAILURE CODE [CA3578]1442
FAILURE CODE [CA3582]1444
FAILURE CODE [CA3583]1450
FAILURE CODE [CA3596]1452
FAILURE CODE [CA3649]1454
FAILURE CODE [CA3681]1456
FAILURE CODE [CA3682]1461
FAILURE CODE [CA3713]1467
FAILURE CODE [CA3717]1470
FAILURE CODE [CA3718]1471
FAILURE CODE [CA3725]1472
FAILURE CODE [CA3748]1475
FAILURE CODE [CA3751]1477
FAILURE CODE [CA3755]1479
FAILURE CODE [CA3866]1481
FAILURE CODE [CA3867]1485
FAILURE CODE [CA3868]1488
FAILURE CODE [CA3899]1492
FAILURE CODE [CA3911]1494
FAILURE CODE [CA3912]1498
FAILURE CODE [CA3932]1500
FAILURE CODE [CA3933]1502
FAILURE CODE [CA3934]1504
FAILURE CODE [CA3935]1507
FAILURE CODE [CA3936]1509
FAILURE CODE [CA4151]1511
FAILURE CODE [CA4152]1515
FAILURE CODE [CA4155]1519
FAILURE CODE [CA4156]1521
FAILURE CODE [CA4157]1524
FAILURE CODE [CA4158]1526
FAILURE CODE [CA4159]1527
FAILURE CODE [CA4161]1528
FAILURE CODE [CA4162]1531
FAILURE CODE [CA4163]1534
FAILURE CODE [CA4164]1536
FAILURE CODE [CA4165]1538
FAILURE CODE [CA4166]1540
FAILURE CODE [CA4168]1542
FAILURE CODE [CA4169]1545
FAILURE CODE [CA4171]1547
FAILURE CODE [CA4249]1550
FAILURE CODE [CA4251]1552
FAILURE CODE [CA4259]1554
FAILURE CODE [CA4261]1556
FAILURE CODE [CA4277]1559
FAILURE CODE [CA4281]1563
FAILURE CODE [CA4459]1566
FAILURE CODE [CA4461]1569
FAILURE CODE [CA4658]1572
FAILURE CODE [CA4731]1576
FAILURE CODE [CA4732]1577
FAILURE CODE [CA4739]1578
FAILURE CODE [CA4768]1579
FAILURE CODE [CA4769]1581
FAILURE CODE [CA4842]1584
FAILURE CODE [CA4952]1588
FAILURE CODE [CA5115]1590
FAILURE CODE [CA5179]1593
FAILURE CODE [CA5181]1595
FAILURE CODE [CA5383]1597
FAILURE CODE [D110KB]1599
FAILURE CODE [D19JKZ]1601
FAILURE CODE [D811MC]1604
FAILURE CODE [D862KA]1605
FAILURE CODE [D8ALKA]1607
FAILURE CODE [D8ALKB]1610
FAILURE CODE [D8AQKR]1612
FAILURE CODE [D8G1KT]1619
FAILURE CODE [D8G6KT]1620
FAILURE CODE [DA20MC]1621
FAILURE CODE [DA22KK]1622
FAILURE CODE [DA25KP]1625
FAILURE CODE [DA29KQ]1628
FAILURE CODE [DA2LKA]1630
FAILURE CODE [DA2LKB]1633
FAILURE CODE [DA2QKR]1635
FAILURE CODE [DA2RKR]1644
FAILURE CODE [DAF0KM]1645
FAILURE CODE [DAF0MB]1646
FAILURE CODE [DAF0MC]1647
FAILURE CODE [DAF8KB]1648
FAILURE CODE [DAF9KQ]1650
FAILURE CODE [DAFGMC]1651
FAILURE CODE [DAFLKA]1652
FAILURE CODE [DAFLKB]1655
FAILURE CODE [DAFQKR]1657
FAILURE CODE [DAZ9KQ]1665
FAILURE CODE [DAZQKR]1666
FAILURE CODE [DB2QKR]1673
FAILURE CODE [DB2RKR]1681
FAILURE CODE [DBP0KM]1685
FAILURE CODE [DBP0KT]1686
FAILURE CODE [DBP5KB]1687
FAILURE CODE [DBP5KY]1690
FAILURE CODE [DBPQKR]1693
FAILURE CODE [DDNRKA]1701
FAILURE CODE [DDNRKY]1703
FAILURE CODE [DDNS00]1705
FAILURE CODE [DFB6KZ]1707
FAILURE CODE [DGH2KA]1709
FAILURE CODE [DGH2KB]1711
FAILURE CODE [DHA4KA]1713
FAILURE CODE [DHAAMA]1715
FAILURE CODE [DHACMA]1717
FAILURE CODE [DHPAMA]1719
FAILURE CODE [DHPBMA]1722
FAILURE CODE [DHS3MA]1725
FAILURE CODE [DHS4MA]1728
FAILURE CODE [DHS8MA]1731
FAILURE CODE [DHS9MA]1734
FAILURE CODE [DHSAMA]1737
FAILURE CODE [DHSBMA]1740
FAILURE CODE [DHSCMA]1743
FAILURE CODE [DHSDMA]1746
FAILURE CODE [DHSFMA]1749
FAILURE CODE [DHSGMA]1752
FAILURE CODE [DHSHMA]1755
FAILURE CODE [DHSJMA]1758
FAILURE CODE [DHZAMA]1761
FAILURE CODE [DHZCL8]1765
FAILURE CODE [DKR0MA]1766
FAILURE CODE [DKR1MA]1769
FAILURE CODE [DKULKA]1772
FAILURE CODE [DKULKB]1774
FAILURE CODE [DKULKY]1776
FAILURE CODE [DLM3KA]1778
FAILURE CODE [DLM3KB]1780
FAILURE CODE [DLM3MB]1782
FAILURE CODE [DR10KA]1783
FAILURE CODE [DR12KA]1786
FAILURE CODE [DR20KA]1788
FAILURE CODE [DR21KX]1790
FAILURE CODE [DR30KA]1792
FAILURE CODE [DR31KX]1794
FAILURE CODE [DR40KA]1796
FAILURE CODE [DUMBKA]1798
FAILURE CODE [DUMBKB]1801
FAILURE CODE [DV00KA]1803
FAILURE CODE [DV00KB]1804
FAILURE CODE [DV20KB]1805
FAILURE CODE [DW43KA]1807
FAILURE CODE [DW43KB]1809
FAILURE CODE [DW43KY]1811
FAILURE CODE [DW45KA]1813
FAILURE CODE [DW45KB]1816
FAILURE CODE [DW45KY]1819
FAILURE CODE [DW4CKY]1821
FAILURE CODE [DW7BKA]1822
FAILURE CODE [DW7BKB]1824
FAILURE CODE [DW7BKY]1826
FAILURE CODE [DW91KA]1827
FAILURE CODE [DW91KB]1829
FAILURE CODE [DW91KY]1831
FAILURE CODE [DWA2KA]1833
FAILURE CODE [DWA2KB]1835
FAILURE CODE [DWA2KY]1837
FAILURE CODE [DWK0KA]1839
FAILURE CODE [DWK0KB]1841
FAILURE CODE [DWK0KY]1843
FAILURE CODE [DWK2KA]1845
FAILURE CODE [DWK2KB]1847
FAILURE CODE [DWK2KY]1849
FAILURE CODE [DWK8KA]1851
FAILURE CODE [DWK8KB]1853
FAILURE CODE [DWK8KY]1855
FAILURE CODE [DWPUKA]1857
FAILURE CODE [DWPUKB]1859
FAILURE CODE [DWPUKY]1861
FAILURE CODE [DX16KA]1863
FAILURE CODE [DX16KB]1865
FAILURE CODE [DXA8KA]1867
FAILURE CODE [DXA8KB]1869
FAILURE CODE [DXA9KA]1871
FAILURE CODE [DXA9KB]1873
FAILURE CODE [DXE0KA]1875
FAILURE CODE [DXE0KB]1877
FAILURE CODE [DXE4KA]1879
FAILURE CODE [DXE4KB]1881
FAILURE CODE [DXE4KY]1883
FAILURE CODE [DXE5KA]1885
FAILURE CODE [DXE5KB]1887
FAILURE CODE [DXE6KA]1889
FAILURE CODE [DXE6KB]1891
FAILURE CODE [DXE7KA]1893
FAILURE CODE [DXE7KB]1895
FAILURE CODE [DXE7KY]1897
FAILURE CODE [DXE8KA]1899
FAILURE CODE [DXE8KB]1901
FAILURE CODE [DXE8KY]1903
FAILURE CODE [DXE9KA]1905
FAILURE CODE [DXE9KB]1907
FAILURE CODE [DXE9KY]1909
FAILURE CODE [DXEAKA]1911
FAILURE CODE [DXEAKB]1913
FAILURE CODE [DXEAKY]1915
FAILURE CODE [DXEKKY]1917
FAILURE CODE [DY20KA]1919
FAILURE CODE [DY20MA]1921
FAILURE CODE [DY2CKB]1923
FAILURE CODE [DY2DKB]1926
FAILURE CODE [DY2EKB]1928
FAILURE CODE [F311KA]1930
FAILURE CODE [F311KB]1932
FAILURE CODE [F312KA]1934
FAILURE CODE [F312KB]1936
FAILURE CODE [F313KA]1938
FAILURE CODE [F313KB]1940
FAILURE CODE [F314KA]1943
FAILURE CODE [F314KB]1945
FAILURE CODE [F315KB]1947
FAILURE CODE [F315KY]1949
FAILURE CODE [F316KB]1951
FAILURE CODE [F316KY]1953
FAILURE CODE [F318KB]1955
FAILURE CODE [F318KY]1958
FAILURE CODE [F31AKB]1960
FAILURE CODE [F31AKY]1962
FAILURE CODE [F31BKB]1964
FAILURE CODE [F31BKY]1966
FAILURE CODE [F31CKB]1968
FAILURE CODE [F31CKY]1970
FAILURE CODE [F31DKB]1972
FAILURE CODE [F31DKY]1974
FAILURE CODE [F31EKB]1976
FAILURE CODE [F31EKY]1978
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1980
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1980
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1986
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1989
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1991
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING1993
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW1996
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW1997
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1998
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1999
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING2000
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2001
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2002
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2003
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2004
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2005
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM2006
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL2008
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM2009
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE2010
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM2011
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE2013
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED2014
E-23 FUNCTION SWITCH DOES NOT OPERATE2015
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)2016
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF2017
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER2018
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED2019
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED2020
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE2021
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE2022
E-31 ALARM BUZZER CANNOT BE CANCELED2024
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION2025
E-33 SERVICE MODE CANNOT BE SELECTED2026
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE2027
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK2029
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING2030
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE2033
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR2035
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED2038
E-40 ALARM DOES NOT SOUND DURING TRAVEL2039
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED2041
E-42 HORN DOES NOT SOUND2042
E-43 HORN DOES NOT STOP SOUNDING2046
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF2048
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE2049
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE2051
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2052
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2053
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2054
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2055
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2056
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2057
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2058
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2059
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2060
E-56 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED2062
E-57 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY2063
E-58 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED2064
E-59 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE2066
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)2067
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)2067
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS2068
FAILURE MODE AND CAUSE TABLE2070
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK2078
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER2079
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR2081
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP2082
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS2083
H-6 SPEED OR POWER OF BOOM IS LOW2085
H-7 ARM SPEED OR POWER IS LOW2091
H-8 BUCKET SPEED OR POWER IS LOW2096
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION2099
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE2100
H-11 HYDRAULIC DRIFT OF ARM IS LARGE2102
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE2104
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES2105
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE2106
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE2107
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE2108
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED2109
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED2110
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER2111
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY2112
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW2113
H-22 MACHINE DOES NOT TRAVEL STRAIGHT2114
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW2116
H-24 TRAVEL SPEED IS LOW2119
H-25 ONE OF TRACKS DOES NOT RUN2121
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST2122
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT2123
H-28 SWINGS ONLY IN ONE DIRECTION2124
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)2125
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION2126
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)2127
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)2128
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING2129
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING2130
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)2131
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)2132
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)2133
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN2135
TROUBLESHOOTING OF ENGINE (S-MODE)2136
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2136
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2137
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2138
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2139
S-4 ENGINE STARTABILITY IS POOR2140
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2142
S-6 ENGINE STOPS DURING OPERATION2144
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2146
S-8 ENGINE LACKS POWER2147
S-9 KDPF GETS CLOGGED IN A SHORT TIME2149
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2151
S-11 OIL BECOMES CONTAMINATED QUICKLY2152
S-12 FUEL CONSUMPTION IS EXCESSIVE2153
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2154
S-14 OIL PRESSURE DROPS2155
S-15 FUEL MIXES INTO ENGINE OIL2157
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2158
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2159
S-18 UNUSUAL NOISE IS HEARD2161
S-19 VIBRATION IS EXCESSIVE2162
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2163
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2164
S-22 ACTIVE REGENERATION TAKES TIME2166
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2168
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE2169
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)2171
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2172
50 DISASSEMBLY AND ASSEMBLY2173
CONTENTS2174
ABBREVIATION LIST2179
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2185
HOW TO READ THIS MANUAL2185
COATING MATERIALS LIST2186
SPECIAL TOOLS LIST2191
SKETCHES OF SPECIAL TOOLS2203
ENGINE AND COOLING SYSTEM2209
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2209
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2209
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2215
REMOVE AND INSTALL INJECTOR ASSEMBLY2224
METHOD FOR REMOVING INJECTOR ASSEMBLY2224
METHOD FOR INSTALLING INJECTOR ASSEMBLY2230
REMOVE AND INSTALL FUEL DOSER ASSEMBLY2240
METHOD FOR REMOVING FUEL DOSER2240
METHOD FOR INSTALLING FUEL DOSER2241
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2243
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2244
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2253
REMOVE AND INSTALL EGR VALVE ASSEMBLY2266
METHOD FOR REMOVING EGR VALVE ASSEMBLY2266
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2268
REMOVE AND INSTALL EGR COOLER ASSEMBLY2270
METHOD FOR REMOVING EGR COOLER ASSEMBLY2270
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2274
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2280
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY2280
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY2281
REMOVE AND INSTALL ALTERNATOR BELT2283
METHOD FOR REMOVING ALTERNATOR BELT2283
METHOD FOR INSTALLING ALTERNATOR BELT2286
REMOVE AND INSTALL RADIATOR ASSEMBLY2291
METHOD FOR REMOVING RADIATOR ASSEMBLY2291
METHOD FOR INSTALLING RADIATOR ASSEMBLY2293
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2296
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2296
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2300
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2305
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2305
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2307
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2309
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2309
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2311
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY2315
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY2316
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY2334
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2353
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2354
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2356
REMOVE AND INSTALL ENGINE REAR OIL SEAL2360
METHOD FOR REMOVING ENGINE REAR OIL SEAL2361
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2364
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2370
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2370
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2378
REMOVE AND INSTALL FUEL TANK ASSEMBLY2389
METHOD FOR REMOVING FUEL TANK ASSEMBLY2389
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2393
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2397
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2397
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2403
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2408
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2408
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2415
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2421
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2421
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2421
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER2428
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER2428
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER2430
REMOVE AND INSTALL KDPF ASSEMBLY2433
REMOVE KDPF ASSEMBLY2433
INSTALL KDPF ASSEMBLY2438
DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY2442
DISASSEMBLE KDPF ASSEMBLY2443
ASSEMBLE KDPF ASSEMBLY2445
REMOVE AND INSTALL SCR ASSEMBLY2450
REMOVE SCR ASSEMBLY2450
INSTALL SCR ASSEMBLY2453
REMOVE AND INSTALL KDPF AND SCR ASSEMBLY2457
REMOVE KDPF AND SCR ASSEMBLY2457
INSTALL KDPF AND SCR ASSEMBLY2462
REMOVE AND INSTALL BRACKET FOR KDPF AND SCR ASSEMBLY2467
REMOVE BRACKET FOR KDPF AND SCR ASSEMBLY2467
INSTAL BRACKET FOR KDPF AND SCR ASSEMBLY2472
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY2481
REMOVE BELLOWS PIPE ASSEMBLY2481
INSTALL BELLOWS PIPE ASSEMBLY2483
REMOVE AND INSTALL KCCV ASSEMBLY2487
METHOD FOR REMOVING KCCV ASSEMBLY2487
METHOD FOR INSTALLING KCCV ASSEMBLY2488
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2492
REMOVE AdBlue/DEF MIXING TUBE2492
INSTALL AdBlue/DEF MIXING TUBE2497
REMOVE AND INSTALL AdBlue/DEF INJECTOR2503
METHOD FOR REMOVING AdBlue/DEF INJECTOR2503
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2507
REMOVE AND INSTALL AdBlue/DEF PUMP2512
REMOVE AdBlue/DEF PUMP2512
INSTALL AdBlue/DEF PUMP2514
REMOVE AND INSTALL AdBlue/DEF HOSE2516
REMOVE AdBlue/DEF HOSE2516
INSTALL AdBlue/DEF HOSE2521
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2529
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2529
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2530
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2533
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2533
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2536
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2540
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2540
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2541
POWER TRAIN2543
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2543
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2543
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2544
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY2545
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY2545
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY2550
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY2556
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY2556
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY2557
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY2559
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY2560
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY2563
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY2569
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY2569
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY2569
UNDERCARRIAGE AND FRAME2571
SEPARATION AND CONNECTION OF TRACK ASSEMBLY2571
METHOD FOR SEPARATING TRACK ASSEMBLY2571
METHOD FOR INSTALLING TRACK ASSEMBLY2573
REMOVE AND INSTALL SPROCKET2576
METHOD FOR REMOVING SPROCKET2576
METHOD FOR INSTALLING SPROCKET2576
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY2578
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY2578
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY2579
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2581
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2581
METHOD FOR ASSEMBLING IDLER ASSEMBLY2583
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY2588
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY2589
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY2591
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2594
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2595
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2596
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY2600
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY2600
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY2602
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY2606
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY2606
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY2608
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2611
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2611
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2612
HYDRAULIC SYSTEM2615
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY2615
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY2615
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY2617
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2619
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2620
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2621
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2622
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2622
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2627
REMOVE AND INSTALL MAIN PUMP ASSEMBLY2633
REMOVE MAIN PUMP ASSEMBLY2633
INSTALL MAIN PUMP ASSEMBLY2636
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2642
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2642
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2647
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY2653
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING2654
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY2655
REMOVE AND INSTALL ATT BYPASS SOLENOID2660
REMOVE ATT BYPASS SOLENOID2660
INSTALL ATT BYPASS SOLENOID2663
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2665
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2665
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2666
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2668
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY2668
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY2669
WORK EQUIPMENT2671
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2671
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2672
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2675
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2679
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2679
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2682
CAB AND ITS ATTACHMENTS2686
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2686
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2686
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2693
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS)2700
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2702
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2702
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY2712
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY2712
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY2715
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY2721
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY2721
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY2728
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2736
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2736
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2742
REMOVE AND INSTALL OPERATOR’S SEAT2749
METHOD FOR REMOVING OPERATOR’S SEAT2749
METHOD FOR INSTALLING OPERATOR’S SEAT2751
REMOVE AND INSTALL SEAT BELT2754
METHOD FOR REMOVING SEAT BELT2754
METHOD FOR INSTALLING SEAT BELT2755
REMOVE AND INSTALL FRONT WIPER ASSEMBLY2756
METHOD FOR REMOVING FRONT WIPER ASSEMBLY2756
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY2761
ELECTRICAL SYSTEM2770
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2770
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2770
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2771
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY2773
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY2773
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY2776
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY2781
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY2781
METHOD FOR INSTALLING KomVision CONTROLLER ASSEMBLY2782
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2783
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2783
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY2786
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR2790
REMOVE PUMP SWASH PLATE SENSOR2790
INSTALL PUMP SWASH PLATE SENSOR2791
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2792
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR2792
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR2793
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2795
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR2795
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR2796
REMOVE AND INSTALL SCR TEMPERATURE SENSOR2798
REMOVE SCR TEMPERATURE SENSOR2798
INSTALL SCR TEMPERATURE SENSOR2799
REMOVE AND INSTALL KomVision CAMERA2801
METHOD FOR REMOVING KomVision CAMERA2801
METHOD FOR INSTALLING KomVision CAMERA2802
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY2804
METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY2804
METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY2809
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS2814
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS2814
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS2822
REMOVE AND INSTALL COMMUNICATION TERMINAL2831
METHOD FOR REMOVING COMMUNICATION TERMINAL2831
METHOD FOR INSTALLING COMMUNICATION TERMINAL2833
60 MAINTENANCE STANDARD2837
CONTENTS2838
ABBREVIATION LIST2839
ENGINE AND COOLING SYSTEM2845
MAINTENANCE STANDARD OF ENGINE MOUNT2845
MAINTENANCE STANDARD OF COOLING SYSTEM2846
MAINTENANCE STANDARD OF COOLING FAN PUMP2847
MAINTENANCE STANDARD OF SERVO VALVE2848
MAINTENANCE STANDARD OF COOLING FAN MOTOR2849
POWER TRAIN2850
MAINTENANCE STANDARD OF SWING CIRCLE2850
MAINTENANCE STANDARD OF SWING MACHINERY2851
MAINTENANCE STANDARD OF FINAL DRIVE2853
MAINTENANCE STANDARD OF SPROCKET2855
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING2856
UNDERCARRIAGE AND FRAME2858
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION2858
MAINTENANCE STANDARD OF IDLER2860
MAINTENANCE STANDARD OF TRACK ROLLER2862
MAINTENANCE STANDARD OF CARRIER ROLLER2864
MAINTENANCE STANDARD OF TRACK SHOE2865
MAINTENANCE STANDARD OF TRIPLE SHOE2868
HYDRAULIC SYSTEM2869
MAINTENANCE STANDARD OF MAIN PUMP2869
MAINTENANCE STANDARD OF SWING MOTOR2871
MAINTENANCE STANDARD OF TRAVEL MOTOR2874
MAINTENANCE STANDARD OF CONTROL VALVE2877
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE2888
MAINTENANCE STANDARD OF TRAVEL PPC VALVE2891
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)2894
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE2896
MAINTENANCE STANDARD OF SOLENOID VALVE2897
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE2898
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT2899
WORK EQUIPMENT2900
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE2900
DIMENSION OF ARM2905
DIMENSIONS OF BUCKET2907
MAINTENANCE STANDARD OF BOOM CYLINDER2909
MAINTENANCE STANDARD OF ARM CYLINDER2910
MAINTENANCE STANDARD OF BUCKET CYLINDER2911
80 APPENDIX2913
CONTENTS2914
ABBREVIATION LIST2916
AIR CONDITIONER SYSTEM2922
PRECAUTIONS FOR REFRIGERANT2922
AIR CONDITIONER COMPONENT2923
SPECIFICATIONS OF AIR CONDITIONER2925
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2926
OUTLINE OF REFRIGERATION CYCLE2927
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2929
AIR CONDITIONER UNIT2929
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2929
FUNCTION OF AIR CONDITIONER UNIT2931
COMPONENT PARTS OF AIR CONDITIONER UNIT2933
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2934
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2934
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT2934
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT2934
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2935
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2935
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2935
FUNCTION OF DUAL PRESSURE SWITCH2936
AIR CONDITIONER CONTROLLER2937
STRUCTURE OF AIR CONDITIONER CONTROLLER2937
COMPRESSOR2938
STRUCTURE OF COMPRESSOR2938
SPECIFICATIONS OF COMPRESSOR2938
FUNCTION OF COMPRESSOR2938
CONDENSER2939
STRUCTURE OF CONDENSER2939
SPECIFICATIONS OF CONDENSER2939
FUNCTION OF CONDENSER2939
RECEIVER DRIER2940
STRUCTURE OF RECEIVER DRIER2940
SPECIFICATIONS OF RECEIVER DRIER2940
FUNCTION OF RECEIVER DRIER2940
SENSORS FOR AIR CONDITIONER SYSTEM2941
STRUCTURE OF SUNLIGHT SENSOR2941
FUNCTION OF SUNLIGHT SENSOR2941
STRUCTURE OF AMBIENT TEMPERATURE SENSOR2941
FUNCTION OF AMBIENT TEMPERATURE SENSOR2941
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2943
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER2945
AIR CONDITIONER SYSTEM DIAGRAM2947
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER2948
FUNCTION OF AIR CONDITIONER CONTROLLER2949
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2950
TESTING AIR LEAKAGE (DUCT)2954
METHOD FOR TESTING AIR LEAKAGE (DUCT)2954
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION2956
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR2957
TEST VENT (MODE) CHANGEOVER2958
METHOD FOR TESTING VENT (MODE) CHANGEOVER2958
TESTING FRESH/RECIRC AIR CHANGEOVER2960
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER2960
TEST SUNLIGHT SENSOR2961
METHOD FOR TESTING SUNLIGHT SENSOR2961
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT2962
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT2962
TEST RELAYS2964
METHOD FOR TESTING RELAYS2964
AIR CONDITIONER TROUBLESHOOTING CHART 12965
AIR CONDITIONER TROUBLESHOOTING CHART 22967
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2970
FAILURE CODE [879AKA]2972
FAILURE CODE [879AKB]2973
FAILURE CODE [879BKA]2974
FAILURE CODE [879BKB]2976
FAILURE CODE [879CKA]2978
FAILURE CODE [879CKB]2979
FAILURE CODE [879DKZ]2980
FAILURE CODE [879EMC]2982
FAILURE CODE [879FMC]2983
FAILURE CODE [879GKX]2984
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)2986
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)2987
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)2988
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER2989
TROUBLESHOOTING USING GAUGE PRESSURE2990
CONNECTION OF SERVICE TOOL2993
METHOD FOR CONNECTING SERVICE TOOL2993
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS2995
HANDLE COMPRESSOR OIL2997
90 CIRCUIT DIAGRAMS2999
CONTENTS3000
ABBREVIATION LIST3001
HYDRAULIC CIRCUIT DIAGRAM3007
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM3007
HYDRAULIC CIRCUIT DIAGRAM (1/2)3011
HYDRAULIC CIRCUIT DIAGRAM (2/2)3013
ELECTRICAL CIRCUIT DIAGRAM3015
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM3015
ELECTRICAL CIRCUIT DIAGRAM (1/11)3019
ELECTRICAL CIRCUIT DIAGRAM (2/11)3021
ELECTRICAL CIRCUIT DIAGRAM (3/11)3023
ELECTRICAL CIRCUIT DIAGRAM (4/11)3025
ELECTRICAL CIRCUIT DIAGRAM (5/11)3027
ELECTRICAL CIRCUIT DIAGRAM (6/11)3029
ELECTRICAL CIRCUIT DIAGRAM (7/11)3031
ELECTRICAL CIRCUIT DIAGRAM (8/11)3033
ELECTRICAL CIRCUIT DIAGRAM (9/11)3035
ELECTRICAL CIRCUIT DIAGRAM (10/11)3037
ELECTRICAL CIRCUIT DIAGRAM (11/11)3039
INDEX3041

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24