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Komatsu PC45MR-5M0 PC55MR-5M0 Hydraulic Excavator Shop Manual PDF
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Komatsu PC45MR-5M0 PC55MR-5M0 Hydraulic Excavator Shop Manual WENBM00100 – PDF DOWNLOADย
SERIAL NUMBERS
PC45MR-5M0 F50001 and up
PC55MR-5M0 F60001 and up
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Description
Komatsu PC45MR-5M0 PC55MR-5M0 Hydraulic Excavator Shop Manual WENBM00100 – PDF DOWNLOAD
FILE DETAILS:
Komatsu PC45MR-5M0 PC55MR-5M0 Hydraulic Excavator Shop Manual WENBM00100 – PDF DOWNLOADย
Language : English
Pages : 1118
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:
Komatsu PC45MR-5M0 PC55MR-5M0 Hydraulic Excavator Shop Manual WENBM00100 – PDF DOWNLOADย
SERIAL NUMBERS
PC45MR-5M0 F50001 and up
PC55MR-5M0 F60001 and up
FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE SHOP MANUAL:
โข Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
โข The materials and specifications are subject to change without notice.
โข Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
โข Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual:
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
HOW TO READ THE SHOP MANUAL:
โข Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
โข The materials and specifications are subject to change without notice.
โข Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
โข Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual:
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
TABLE OF CONTENTS:
Komatsu PC45MR-5M0 PC55MR-5M0 Hydraulic Excavator Shop Manual WENBM00100 – PDF DOWNLOADย
SERIAL NUMBERS
PC45MR-5M0 F50001 and up
PC55MR-5M0 F60001 and up
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 13
FOREWORD, SAFETY, BASIC INFORMATION 19
HOW TO READ THE SHOP MANUAL 19
SAFETY NOTICE FOR OPERATION 21
PRECAUTIONS TO PREVENT FIRE 29
ACTIONS IF FIRE OCCURS 31
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 32
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 33
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 36
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 43
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 45
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 46
PRACTICAL USE OF KOMTRAX 47
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 48
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 48
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 49
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 50
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 52
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 56
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 57
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 60
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 62
HOW TO READ ELECTRICAL WIRE CODE 63
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 67
STANDARD TIGHTENING TORQUE TABLE 70
CONVERSION TABLE 77
01 SPECIFICATIONS 83
CONTENTS 84
ABBREVIATION LIST 85
SPECIFICATIONS 91
SPECIFICATION DRAWING 91
SPECIFICATION DRAWING: PC45MR-5M0 91
SPECIFICATION DRAWING: PC55MR-5M0 92
WORKING RANGE DRAWINGS 94
WORKING RANGE: PC45MR-5M0 94
WORKING RANGE: PC55MR-5M0 95
SPECIFICATIONS 96
SPECIFICATIONS: PC45MR-5M0 96
SPECIFICATIONS: PC55MR-5M0 99
WEIGHT TABLE 103
WEIGHT TABLE: PC45MR-5M0 103
WEIGHT TABLE: PC55MR-5M0 104
TABLE OF FUEL, COOLANT, AND LUBRICANTS 106
10 STRUCTURE AND FUNCTION 107
CONTENTS 108
ABBREVIATION LIST 110
BOOT-UP SYSTEM 116
LAYOUT DRAWING OF BOOT-UP SYSTEM 116
SYSTEM OPERATING LAMP SYSTEM 118
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 118
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 118
BATTERY DISCONNECT SWITCH 120
FUNCTION OF BATTERY DISCONNECT SWITCH 120
ENGINE SYSTEM 121
LAYOUT DRAWING OF ENGINE SYSTEM 121
ENGINE CONTROL SYSTEM 122
ENGINE CONTROL SYSTEM DIAGRAM 122
FUNCTION OF ENGINE CONTROL SYSTEM 123
AUTO-DECELERATION SYSTEM 126
AUTO-DECELERATION SYSTEM DIAGRAM 126
FUNCTION OF AUTO-DECELERATION SYSTEM 126
OPERATION OF AUTO-DECELERATION SYSTEM 127
OVERHEAT PREVENTION SYSTEM 128
OVERHEAT PREVENTION SYSTEM DIAGRAM 128
FUNCTION OF OVERHEAT PREVENTION SYSTEM 128
AUTOMATIC IDLE STOP SYSTEM 130
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 130
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 130
COMPONENT PARTS OF ENGINE SYSTEM 132
PTO 132
COOLING SYSTEM 133
LAYOUT DRAWING OF COOLING SYSTEM 133
SPECIFICATIONS OF COOLING SYSTEM 134
CONTROL SYSTEM 135
LAYOUT DRAWING OF CONTROL SYSTEM 135
MACHINE MONITOR SYSTEM 136
MACHINE MONITOR SYSTEM DIAGRAM 136
KOMTRAX SYSTEM 137
KOMTRAX SYSTEM DIAGRAM 137
FUNCTION OF KOMTRAX SYSTEM 137
COMPONENT PARTS OF CONTROL SYSTEM 138
MACHINE MONITOR 138
KOMTRAX TERMINAL 145
MACHINE CONTROLLER 147
RESISTOR FOR PC-EPC VALVE 151
FUEL CONTROL DIAL 151
HYDRAULIC SYSTEM 153
LAYOUT DRAWING OF HYDRAULIC SYSTEM 153
CLSS 155
STRUCTURE OF CLSS 155
FUNCTION OF CLSS 156
ENGINE AND PUMP COMBINED CONTROL SYSTEM 158
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 158
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 159
COMPONENT PARTS OF HYDRAULIC SYSTEM 161
HYDRAULIC TANK 161
MAIN PUMP 165
CONTROL VALVE 176
WORK EQUIPMENT SYSTEM 221
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 221
STRUCTURE OF VALVE CONTROL 225
PPC LOCK SYSTEM 227
PPC LOCK SYSTEM DIAGRAM 227
FUNCTION OF PPC LOCK SYSTEM 228
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 229
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 229
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 229
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 230
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 230
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 231
HYDRAULIC QUICK COUPLER WORKING SYSTEM 232
QUICK COUPLER WORKING SYSTEM DIAGRAM 232
FUNCTION OF QUICK COUPLER WORKING SYSTEM 232
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 234
WORK EQUIPMENT AND SWING PPC VALVE 234
239
BLADE PPC VALVE 241
BOOM SWING PPC VALVE 242
BIPARTITE SOLENOID VALVE 244
QUICK COUPLER SOLENOID VALVE 247
PILOT CIRCUIT ACCUMULATOR 248
SWING SYSTEM 249
LAYOUT DRAWING OF SWING SYSTEM 249
COMPONENT PARTS OF SWING SYSTEM 250
SWING MOTOR 250
SWING MACHINERY 257
SWING CIRCLE 258
TRAVEL SYSTEM 259
LAYOUT DRAWING OF TRAVEL SYSTEM 259
TRAVEL CONTROL SYSTEM DIAGRAM 261
FUNCTION OF TRAVEL CONTROL SYSTEM 261
COMPONENT PARTS OF TRAVEL SYSTEM 263
TRAVEL MOTOR 263
TRAVEL PPC VALVE 270
CENTER SWIVEL JOINT 273
UNDERCARRIAGE AND FRAME 274
LAYOUT DRAWING OF UNDERCARRIAGE 274
SPECIFICATIONS OF UNDERCARRIAGE 274
IDLER CUSHION 275
STRUCTURE OF IDLER CUSHION 275
SPECIFICATIONS OF IDLER CUSHION 275
WORK EQUIPMENT 276
STRUCTURE OF WORK EQUIPMENT 276
FUNCTION OF WORK EQUIPMENT 277
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 278
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 278
CAB AND ITS ATTACHMENTS 279
ROPS CAB 279
STRUCTURE OF ROPS CAB 279
FUNCTION OF ROPS CAB 279
TILT TYPE FLOOR 280
STRUCTURE OF TILT TYPE FLOOR 280
FUNCTION OF TILT TYPE FLOOR 280
20 STANDARD VALUE TABLE 281
CONTENTS 282
ABBREVIATION LIST 283
STANDARD VALUE TABLE FOR ENGINE 289
STANDARD VALUE TABLE FOR ENGINE: PC45MR-5M0 289
STANDARD VALUE TABLE FOR ENGINE: PC55MR-5M0 291
STANDARD VALUE TABLE FOR MACHINE 293
STANDARD VALUE TABLE FOR MACHINE: PC45MR-5M0 293
STANDARD VALUE TABLE FOR MACHINE: PC55MR-5M0 305
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 317
30 TESTING AND ADJUSTING 323
CONTENTS 324
ABBREVIATION LIST 327
RELATED INFORMATION ON TESTING AND ADJUSTING 333
TOOLS FOR TESTING AND ADJUSTING 333
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 336
ENGINE AND COOLING SYSTEM 338
TEST ENGINE SPEED 338
TEST EXHAUST GAS COLOR 339
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 339
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 340
TEST AND ADJUST VALVE CLEARANCE 341
METHOD FOR TESTING VALVE CLEARANCE 341
METHOD FOR ADJUSTING VALVE CLEARANCE 342
TEST COMPRESSION PRESSURE 343
METHOD FOR TESTING COMPRESSION PRESSURE 343
TEST ENGINE OIL PRESSURE 345
METHOD FOR TESTING ENGINE OIL PRESSURE 345
BLEED AIR FROM FUEL SYSTEM 347
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 347
TEST FUEL CIRCUIT FOR LEAKAGE 348
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 348
TEST AND ADJUST ALTERNATOR BELT TENSION 349
METHOD FOR TESTING ALTERNATOR BELT TENSION 349
METHOD FOR ADJUSTING ALTERNATOR BELT TENSION 349
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 350
METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 350
POWER TRAIN 352
TEST SWING CIRCLE BEARING CLEARANCE 352
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 352
UNDERCARRIAGE AND FRAME 353
TEST AND ADJUST TRACK TENSION 353
METHOD FOR TESTING TRACK TENSION 353
METHOD FOR ADJUSTING TRACK TENSION 353
HYDRAULIC SYSTEM 355
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 355
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 355
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 355
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 359
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 360
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS 361
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS 361
368
TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE 370
METHOD FOR TESTING SWING AND BLADE CIRCUIT OIL PRESSURE 370
METHOD FOR ADJUSTING SWING AND BLADE CIRCUIT OIL PRESSURE 374
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 376
376
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 378
ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 380
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 380
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 382
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 382
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL 383
METHOD FOR ADJUSTING LS VALVE 385
TEST OUTLET PRESSURE OF SOLENOID VALVE 386
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY MACHINE MONITOR 386
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY TESTING TOOL 388
OPERATING CONDITION OF SOLENOID VALVE 389
TEST PPC VALVE OUTLET PRESSURE 390
METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY MACHINE MONITOR 390
METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL 393
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 396
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 396
TEST SWING PARKING BRAKE RELEASE PRESSURE 397
METHOD FOR TESTING SWING PARKING BRAKE RELEASE PRESSURE WITH MACHINE MONITOR 397
METHOD FOR TESTING SWING PARKING BRAKE RELEASE PRESSURE BY TESTING TOOL 397
TEST AND ADJUST TRAVEL DEVIATION 399
METHOD FOR ADJUSTING TRAVEL DEVIATION 399
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 401
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 401
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 401
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 402
TEST OIL LEAKAGE 403
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 403
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 403
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 404
METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER 404
BLEED AIR FROM HYDRAULIC CIRCUIT 406
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 407
PRESSURIZE HYDRAULIC TANK 409
METHOD FOR PRESSURIZING HYDRAULIC TANK 409
CAB AND ITS ATTACHMENTS 410
METHOD FOR OPENING AND CLOSING FLOOR UNIT 410
METHOD FOR OPENING FLOOR UNIT 411
METHOD FOR CLOSING FLOOR UNIT 413
ELECTRICAL SYSTEM 416
SET AND OPERATE MACHINE MONITOR 416
OPERATOR MODE 418
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 418
CHECKING FUNCTION OF SERVICE METER 418
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 419
SERVICE MODE 421
METHOD FOR OPERATING SERVICE MODE 421
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 423
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 425
ABNORMALITY RECORD MENU 430
METHOD FOR CONFIRMING MAINTENANCE RECORD 434
METHOD FOR OPERATING MAINTENANCE MODE SETTING 435
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 439
DEFAULT MENU 440
ADJUSTMENT MENU 446
METHOD FOR OPERATING BATTERY DISCONNECT SWITCH SETTING 454
KOMTRAX SETTINGS MENU 455
METHOD FOR DISPLAYING SERVICE MESSAGE 457
METHOD FOR STARTING UP KOMTRAX TERMINAL 459
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 464
TEST DIODES 465
METHOD FOR TESTING DIODE USING DIGITAL TESTER 465
METHOD FOR TESTING DIODE USING ANALOG TESTER 465
40 TROUBLESHOOTING 467
CONTENTS 468
ABBREVIATION LIST 472
RELATED INFORMATION ON TROUBLESHOOTING 478
GENERAL TROUBLESHOOTING POINTS 478
SEQUENCE OF EVENTS IN TROUBLESHOOTING 479
CHECKS BEFORE TROUBLESHOOTING 481
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 483
WALK-AROUND CHECK 483
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 484
CHECK FUEL LEVEL AND TYPE 484
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT / CLEANING ELEMENT 485
CHECK MAIN FILTER 487
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 489
CHECK COOLANT LEVEL (RESERVOIR TANK) 491
CHECK CLOGGING OF AIR CLEANER 492
CLEAN OUTER ELEMENT (SINGLE ELEMENT) 492
CLEAN OUTER ELEMENT (DOUBLE ELEMENT) 495
REPLACE SINGLE ELEMENT 498
REPLACE DOUBLE ELEMENT 500
CHECK HYDRAULIC OIL LEVEL 502
CHECK HYDRAULIC OIL STRAINER 505
CHECK HYDRAULIC FILTER 506
CHECK OIL LEVEL IN FINAL DRIVE CASE 508
BLEED AIR FROM FUEL SYSTEM 508
BLEED AIR FROM HYDRAULIC SYSTEM 509
PROCEDURE FOR TESTING AND TROUBLESHOOTING 510
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 513
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 517
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 519
FUSE LOCATION TABLE 525
FAILURE CODES TABLE 527
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 533
FAILURE CODE [6AZ0ZG] 533
FAILURE CODE [989L00] 535
FAILURE CODE [989M00] 536
FAILURE CODE [989N00] 537
FAILURE CODE [B@BCNS] 538
FAILURE CODE [D19JKZ] 539
FAILURE CODE [D811MC] 542
FAILURE CODE [D862KA] 543
FAILURE CODE [D8ALKA] 544
FAILURE CODE [D8ALKB] 546
FAILURE CODE [D8AQKR] 548
FAILURE CODE [DAF0KT] 550
FAILURE CODE [DAF0MB] 551
FAILURE CODE [DAF0MC] 552
FAILURE CODE [DAF3KK] 553
FAILURE CODE [DAF9KQ] 555
FAILURE CODE [DAFGMC] 556
FAILURE CODE [DAFLKA] 557
FAILURE CODE [DAFLKB] 559
FAILURE CODE [DAFQKR] 561
FAILURE CODE [DB2QKR] 562
FAILURE CODE [DBH0MC] 566
FAILURE CODE [DBH2KK] 567
FAILURE CODE [DBH5KP] 570
FAILURE CODE [DBH9KQ] 573
FAILURE CODE [DBHLKA] 576
FAILURE CODE [DBHLKB] 578
FAILURE CODE [DBHQKR] 580
FAILURE CODE [DDNRKA] 585
FAILURE CODE [DDNRKY] 587
FAILURE CODE [DDNS00] 589
FAILURE CODE [DDWLKA] 591
FAILURE CODE [DDWLKB] 593
FAILURE CODE [DFB1KZ] 595
FAILURE CODE [DFB2KZ] 597
FAILURE CODE [DFB3L8] 599
FAILURE CODE [DFB4L8] 602
FAILURE CODE [DFB5KZ] 605
FAILURE CODE [DFB6KZ] 607
FAILURE CODE [DHS1MA] 609
FAILURE CODE [DHS5MA] 611
FAILURE CODE [DHX1MA] 613
FAILURE CODE [DKULKA] 615
FAILURE CODE [DKULKB] 617
FAILURE CODE [DKULKY] 619
FAILURE CODE [DV00KB] 621
FAILURE CODE [DV20KB] 622
FAILURE CODE [DV20KB] 624
FAILURE CODE [DV50KB] 626
FAILURE CODE [DV50KY] 628
FAILURE CODE [DW43KA] 630
FAILURE CODE [DW43KB] 632
FAILURE CODE [DW43KY] 634
FAILURE CODE [DW4CKY] 635
FAILURE CODE [DXA8KA] 637
FAILURE CODE [DXA8KB] 640
FAILURE CODE [DXE7KA] 642
FAILURE CODE [DXE7KB] 644
FAILURE CODE [DXE7KY] 646
FAILURE CODE [DXE8KA] 648
FAILURE CODE [DXE8KB] 650
FAILURE CODE [DXE8KY] 652
FAILURE CODE [DXE9KA] 654
FAILURE CODE [DXE9KB] 656
FAILURE CODE [DXE9KY] 658
FAILURE CODE [DXEAKA] 660
FAILURE CODE [DXEAKB] 662
FAILURE CODE [DXEAKY] 664
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 666
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 666
E-2 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM) 673
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 675
E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 677
E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 680
E-6 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 681
E-7 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 682
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 683
E-9 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 684
E-10 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 685
E-11 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 687
E-12 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 688
E-13 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 689
E-14 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 690
E-15 FUNCTION SWITCH DOES NOT OPERATE 691
E-16 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 692
E-17 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 693
E-18 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 694
E-19 ALARM BUZZER DOES NOT SOUND 696
E-20 ALARM BUZZER CANNOT BE CANCELED 697
E-21 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 698
E-22 SERVICE MODE CANNOT BE SELECTED 699
E-23 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 700
E-24 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 702
E-25 ALARM DOES NOT SOUND DURING TRAVEL 704
E-26 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 706
E-27 HORN DOES NOT SOUND 707
E-28 HORN DOES NOT STOP SOUNDING 710
E-29 NONE OF WORKING LAMP, TRAVEL LAMP, OR ADDITIONAL LAMP DOES NOT LIGHT UP 712
E-30 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 716
E-31 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 718
E-32 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 720
E-33 Swing or Arm IN IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 721
E-34 Work equipment IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 722
E-35 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 724
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 725
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 725
H-1 ALL WORK EQUIPMENT, TRAVEL, SWING OR BLADE DO NOT OPERATE 726
H-2 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE 727
H-3 TRAVEL OR BLADE DOES NOT OPERATE 728
H-4 SWING OR BLADE DOES NOT OPERATE 729
H-5 ALL WORK EQUIPMENT, TRAVEL, SWING AND BLADE SPEED OR POWER IS LOW 730
H-6 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW 731
H-7 TRAVEL AND BLADE SPEED OR POWER IS LOW 732
H-8 SWING AND BLADE SPEED OR POWER IS LOW 733
H-9 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 734
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 735
H-11 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 736
H-12 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 738
H-13 ALL WORK EQUIPMENTS AND BLADE SPEED OR POWER IS LOW 739
H-14 BLADE DOES NOT OPERATE 740
H-15 ALL WORK EQUIPMENTS DO NOT OPERATE 741
H-16 ALL WORK EQUIPMENTS OR BLADE DO NOT OPERATE 742
H-17 SPEED OR POWER OF BOOM IS LOW 743
H-18 ARM SPEED OR POWER IS LOW 745
H-19 BUCKET SPEED OR POWER IS LOW 746
H-20 BLADE SPEED OR POWER IS LOW 747
H-21 BOOM SWING SPEED OR POWER IS LOW 749
H-22 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 750
H-23 HYDRAULIC DRIFT OF BOOM IS LARGE 751
H-24 HYDRAULIC DRIFT OF ARM IS LARGE 752
H-25 HYDRAULIC DRIFT OF BUCKET IS LARGE 753
H-26 HYDRAULIC DRIFT OF BLADE IS LARGE 754
H-27 TIME LAG OF WORK EQUIPMENT IS LARGE 756
H-28 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 757
H-29 MACHINE DOES NOT TRAVEL STRAIGHT 758
H-30 MACHINE DOES NOT MOVE OFF STRAIGHT 760
H-31 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 761
H-32 TRAVEL SPEED IS LOW 763
H-33 BOTH SIDES OF CRAWLERS DO NOT MOVE 765
H-34 ONE OF TRACKS DOES NOT RUN 766
H-35 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 768
H-36 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 769
H-37 SWINGS ONLY IN ONE DIRECTION 771
H-38 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 773
H-39 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 775
H-40 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 776
H-41 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 777
H-42 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 778
H-43 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 779
H-44 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 780
H-45 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 781
TROUBLESHOOTING OF ENGINE (S-MODE) 782
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 782
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 783
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 784
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 785
S-4 ENGINE STARTABILITY IS POOR 786
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 788
S-6 ENGINE STOPS DURING OPERATION 789
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 790
S-8 ENGINE LACKS POWER 791
S-9 ENGINE OIL CONSUMPTION IS EXCESSIVE 793
S-10 OIL BECOMES CONTAMINATED QUICKLY 794
S-11 FUEL CONSUMPTION IS EXCESSIVE 795
S-12 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 796
S-13 OIL PRESSURE DROPS 797
S-14 FUEL MIXES INTO ENGINE OIL 798
S-15 WATER MIXES INTO ENGINE OIL (MILKY) 799
S-16 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 800
S-17 UNUSUAL NOISE IS HEARD 801
S-18 VIBRATION IS EXCESSIVE 802
S-19 AIR CANNOT BE BLED FROM FUEL CIRCUIT 803
50 DISASSEMBLY AND ASSEMBLY 805
CONTENTS 806
ABBREVIATION LIST 808
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 814
HOW TO READ THIS MANUAL 814
COATING MATERIALS LIST 816
SPECIAL TOOLS LIST 820
SKETCHES OF SPECIAL TOOLS 825
ENGINE AND COOLING SYSTEM 826
REMOVE AND INSTALL STARTER ASSEMBLY 826
METHOD FOR REMOVING STARTER ASSEMBLY 826
METHOD FOR INSTALLING STARTER ASSEMBLY 826
REMOVE AND INSTALL RADIATOR ASSEMBLY 828
METHOD FOR REMOVING RADIATOR ASSEMBLY 828
METHOD FOR INSTALLING RADIATOR ASSEMBLY 831
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 835
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 835
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 838
REMOVE AND INSTALL FUEL TANK ASSEMBLY 842
METHOD FOR REMOVING FUEL TANK ASSEMBLY 842
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 844
POWER TRAIN 847
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 847
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 847
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 849
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 851
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 851
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 852
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 853
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 853
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 856
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 860
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 860
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 860
UNDERCARRIAGE AND FRAME 862
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 862
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING 862
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 863
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 865
METHOD FOR SEPARATING TRACK ASSEMBLY 865
METHOD FOR INSTALLING TRACK ASSEMBLY 865
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 867
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 867
METHOD FOR ASSEMBLING IDLER ASSEMBLY 868
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 870
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 870
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 871
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 873
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 873
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 874
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 876
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 876
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 877
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 879
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 879
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 882
HYDRAULIC SYSTEM 886
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 886
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 886
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 887
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 890
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 891
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 892
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 893
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 893
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 896
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 899
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 899
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 900
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 902
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 902
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 903
WORK EQUIPMENT 905
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 905
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 905
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 906
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 909
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 910
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 913
CAB AND ITS ATTACHMENTS 918
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 918
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 918
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 921
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 925
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 926
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 927
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 935
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 935
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 936
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 938
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 938
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 942
REMOVE AND INSTALL OPERATOR’S SEAT 946
METHOD FOR REMOVING OPERATOR’S SEAT 946
METHOD FOR INSTALLING OPERATOR’S SEAT 946
REMOVE AND INSTALL SEAT BELT 948
METHOD FOR REMOVING SEAT BELT 948
METHOD FOR INSTALLING SEAT BELT 948
ELECTRICAL SYSTEM 949
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 949
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 949
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 950
REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY 951
METHOD FOR REMOVING MACHINE CONTROLLER ASSEMBLY 951
METHOD FOR INSTALLING MACHINE CONTROLLER ASSEMBLY 952
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 954
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 954
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 955
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 957
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 957
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 957
60 MAINTENANCE STANDARD 959
CONTENTS 960
ABBREVIATION LIST 961
ENGINE AND COOLING SYSTEM 967
MAINTENANCE STANDARD FOR PTO 967
MAINTENANCE STANDARD OF COOLING SYSTEM 968
POWER TRAIN 969
MAINTENANCE STANDARD OF SWING CIRCLE 969
MAINTENANCE STANDARD OF SWING MACHINERY 970
MAINTENANCE STANDARD OF SPROCKET 972
UNDERCARRIAGE AND FRAME 973
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 973
MAINTENANCE STANDARD OF IDLER 974
MAINTENANCE STANDARD OF TRACK ROLLER 976
MAINTENANCE STANDARD OF CARRIER ROLLER 977
MAINTENANCE STANDARD OF TRACK SHOE 978
MAINTENANCE STANDARD OF TRIPLE SHOE 980
MAINTENANCE STANDARD OF ROAD LINER 981
MAINTENANCE STANDARD FOR RUBBER SHOE 982
HYDRAULIC SYSTEM 983
MAINTENANCE STANDARD OF HYDRAULIC TANK 983
MAINTENANCE STANDARD OF MAIN PUMP 984
MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE 985
MAINTENANCE STANDARD OF PC-EPC VALVE 986
MAINTENANCE STANDARD OF SWING MOTOR 987
MAINTENANCE STANDARD OF TRAVEL MOTOR 989
MAINTENANCE STANDARD OF CONTROL VALVE 990
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 1000
MAINTENANCE STANDARD OF BLADE PPC VALVE 1003
MAINTENANCE STANDARD OF BOOM SWING PPC VALVE 1005
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 1007
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 1010
WORK EQUIPMENT 1011
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 1011
DIMENSION OF ARM 1017
DIMENSIONS OF BUCKET 1021
MAINTENANCE STANDARD OF BOOM CYLINDER 1023
MAINTENANCE STANDARD OF ARM CYLINDER 1024
MAINTENANCE STANDARD OF BUCKET CYLINDER 1026
MAINTENANCE STANDARD OF BLADE CYLINDER 1028
MAINTENANCE STANDARD OF BOOM SWING CYLINDER 1029
80 APPENDIX 1031
CONTENTS 1032
ABBREVIATION LIST 1033
AIR CONDITIONER SYSTEM 1039
PRECAUTIONS FOR REFRIGERANT 1039
AIR CONDITIONER COMPONENT 1040
SPECIFICATIONS OF AIR CONDITIONER 1041
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 1042
OUTLINE OF REFRIGERATION CYCLE 1043
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 1045
AIR CONDITIONER UNIT 1045
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 1045
COMPRESSOR 1047
STRUCTURE OF COMPRESSOR 1047
SPECIFICATIONS OF COMPRESSOR 1047
FUNCTION OF COMPRESSOR 1047
CONDENSER 1049
STRUCTURE OF CONDENSER 1049
SPECIFICATIONS OF CONDENSER 1049
FUNCTION OF CONDENSER 1049
RECEIVER DRIER 1050
STRUCTURE OF RECEIVER DRIER 1050
SPECIFICATIONS OF RECEIVER DRIER 1050
FUNCTION OF RECEIVER DRIER 1050
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1051
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 1053
A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 1056
A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION 1060
A-4 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (ELECTRICAL SYSTEM) 1063
A-5 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (MECHANICAL SYSTEMS) 1067
A-6 TROUBLESHOOTING FOR HOT WATER CIRCUIT SYSTEM 1068
A-7 UNUSUAL NOISE IS HEARD FROM AIR CONDITINOER RELATED PARTS 1069
A-8 WATER LEAKS FROM AIR CONDITINOER RELATED PARTS 1070
A-9 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 1071
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 1072
HANDLE COMPRESSOR OIL 1074
90 CIRCUIT DIAGRAMS 1075
CONTENTS 1076
ABBREVIATION LIST 1077
HYDRAULIC CIRCUIT DIAGRAM 1083
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 1083
HYDRAULIC CIRCUIT DIAGRAM (1/2) 1087
HYDRAULIC CIRCUIT DIAGRAM (2/2) 1089
ELECTRICAL CIRCUIT DIAGRAM 1091
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 1091
ELECTRICAL CIRCUIT DIAGRAM (1/6) 1095
ELECTRICAL CIRCUIT DIAGRAM (2/6) 1097
ELECTRICAL CIRCUIT DIAGRAM (3/6) 1099
ELECTRICAL CIRCUIT DIAGRAM (4/6) 1101
ELECTRICAL CIRCUIT DIAGRAM (5/6) 1103
ELECTRICAL CIRCUIT DIAGRAM (6/6) 1105
INDEX 1107
INDEX 4
ABBREVIATION LIST 13
FOREWORD, SAFETY, BASIC INFORMATION 19
HOW TO READ THE SHOP MANUAL 19
SAFETY NOTICE FOR OPERATION 21
PRECAUTIONS TO PREVENT FIRE 29
ACTIONS IF FIRE OCCURS 31
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 32
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 33
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 36
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 43
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 45
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 46
PRACTICAL USE OF KOMTRAX 47
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 48
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 48
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 49
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 50
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 52
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 56
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 57
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 60
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 62
HOW TO READ ELECTRICAL WIRE CODE 63
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 67
STANDARD TIGHTENING TORQUE TABLE 70
CONVERSION TABLE 77
01 SPECIFICATIONS 83
CONTENTS 84
ABBREVIATION LIST 85
SPECIFICATIONS 91
SPECIFICATION DRAWING 91
SPECIFICATION DRAWING: PC45MR-5M0 91
SPECIFICATION DRAWING: PC55MR-5M0 92
WORKING RANGE DRAWINGS 94
WORKING RANGE: PC45MR-5M0 94
WORKING RANGE: PC55MR-5M0 95
SPECIFICATIONS 96
SPECIFICATIONS: PC45MR-5M0 96
SPECIFICATIONS: PC55MR-5M0 99
WEIGHT TABLE 103
WEIGHT TABLE: PC45MR-5M0 103
WEIGHT TABLE: PC55MR-5M0 104
TABLE OF FUEL, COOLANT, AND LUBRICANTS 106
10 STRUCTURE AND FUNCTION 107
CONTENTS 108
ABBREVIATION LIST 110
BOOT-UP SYSTEM 116
LAYOUT DRAWING OF BOOT-UP SYSTEM 116
SYSTEM OPERATING LAMP SYSTEM 118
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 118
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 118
BATTERY DISCONNECT SWITCH 120
FUNCTION OF BATTERY DISCONNECT SWITCH 120
ENGINE SYSTEM 121
LAYOUT DRAWING OF ENGINE SYSTEM 121
ENGINE CONTROL SYSTEM 122
ENGINE CONTROL SYSTEM DIAGRAM 122
FUNCTION OF ENGINE CONTROL SYSTEM 123
AUTO-DECELERATION SYSTEM 126
AUTO-DECELERATION SYSTEM DIAGRAM 126
FUNCTION OF AUTO-DECELERATION SYSTEM 126
OPERATION OF AUTO-DECELERATION SYSTEM 127
OVERHEAT PREVENTION SYSTEM 128
OVERHEAT PREVENTION SYSTEM DIAGRAM 128
FUNCTION OF OVERHEAT PREVENTION SYSTEM 128
AUTOMATIC IDLE STOP SYSTEM 130
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 130
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 130
COMPONENT PARTS OF ENGINE SYSTEM 132
PTO 132
COOLING SYSTEM 133
LAYOUT DRAWING OF COOLING SYSTEM 133
SPECIFICATIONS OF COOLING SYSTEM 134
CONTROL SYSTEM 135
LAYOUT DRAWING OF CONTROL SYSTEM 135
MACHINE MONITOR SYSTEM 136
MACHINE MONITOR SYSTEM DIAGRAM 136
KOMTRAX SYSTEM 137
KOMTRAX SYSTEM DIAGRAM 137
FUNCTION OF KOMTRAX SYSTEM 137
COMPONENT PARTS OF CONTROL SYSTEM 138
MACHINE MONITOR 138
KOMTRAX TERMINAL 145
MACHINE CONTROLLER 147
RESISTOR FOR PC-EPC VALVE 151
FUEL CONTROL DIAL 151
HYDRAULIC SYSTEM 153
LAYOUT DRAWING OF HYDRAULIC SYSTEM 153
CLSS 155
STRUCTURE OF CLSS 155
FUNCTION OF CLSS 156
ENGINE AND PUMP COMBINED CONTROL SYSTEM 158
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 158
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 159
COMPONENT PARTS OF HYDRAULIC SYSTEM 161
HYDRAULIC TANK 161
MAIN PUMP 165
CONTROL VALVE 176
WORK EQUIPMENT SYSTEM 221
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 221
STRUCTURE OF VALVE CONTROL 225
PPC LOCK SYSTEM 227
PPC LOCK SYSTEM DIAGRAM 227
FUNCTION OF PPC LOCK SYSTEM 228
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 229
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 229
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 229
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 230
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 230
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 231
HYDRAULIC QUICK COUPLER WORKING SYSTEM 232
QUICK COUPLER WORKING SYSTEM DIAGRAM 232
FUNCTION OF QUICK COUPLER WORKING SYSTEM 232
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 234
WORK EQUIPMENT AND SWING PPC VALVE 234
239
BLADE PPC VALVE 241
BOOM SWING PPC VALVE 242
BIPARTITE SOLENOID VALVE 244
QUICK COUPLER SOLENOID VALVE 247
PILOT CIRCUIT ACCUMULATOR 248
SWING SYSTEM 249
LAYOUT DRAWING OF SWING SYSTEM 249
COMPONENT PARTS OF SWING SYSTEM 250
SWING MOTOR 250
SWING MACHINERY 257
SWING CIRCLE 258
TRAVEL SYSTEM 259
LAYOUT DRAWING OF TRAVEL SYSTEM 259
TRAVEL CONTROL SYSTEM DIAGRAM 261
FUNCTION OF TRAVEL CONTROL SYSTEM 261
COMPONENT PARTS OF TRAVEL SYSTEM 263
TRAVEL MOTOR 263
TRAVEL PPC VALVE 270
CENTER SWIVEL JOINT 273
UNDERCARRIAGE AND FRAME 274
LAYOUT DRAWING OF UNDERCARRIAGE 274
SPECIFICATIONS OF UNDERCARRIAGE 274
IDLER CUSHION 275
STRUCTURE OF IDLER CUSHION 275
SPECIFICATIONS OF IDLER CUSHION 275
WORK EQUIPMENT 276
STRUCTURE OF WORK EQUIPMENT 276
FUNCTION OF WORK EQUIPMENT 277
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 278
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 278
CAB AND ITS ATTACHMENTS 279
ROPS CAB 279
STRUCTURE OF ROPS CAB 279
FUNCTION OF ROPS CAB 279
TILT TYPE FLOOR 280
STRUCTURE OF TILT TYPE FLOOR 280
FUNCTION OF TILT TYPE FLOOR 280
20 STANDARD VALUE TABLE 281
CONTENTS 282
ABBREVIATION LIST 283
STANDARD VALUE TABLE FOR ENGINE 289
STANDARD VALUE TABLE FOR ENGINE: PC45MR-5M0 289
STANDARD VALUE TABLE FOR ENGINE: PC55MR-5M0 291
STANDARD VALUE TABLE FOR MACHINE 293
STANDARD VALUE TABLE FOR MACHINE: PC45MR-5M0 293
STANDARD VALUE TABLE FOR MACHINE: PC55MR-5M0 305
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 317
30 TESTING AND ADJUSTING 323
CONTENTS 324
ABBREVIATION LIST 327
RELATED INFORMATION ON TESTING AND ADJUSTING 333
TOOLS FOR TESTING AND ADJUSTING 333
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 336
ENGINE AND COOLING SYSTEM 338
TEST ENGINE SPEED 338
TEST EXHAUST GAS COLOR 339
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 339
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 340
TEST AND ADJUST VALVE CLEARANCE 341
METHOD FOR TESTING VALVE CLEARANCE 341
METHOD FOR ADJUSTING VALVE CLEARANCE 342
TEST COMPRESSION PRESSURE 343
METHOD FOR TESTING COMPRESSION PRESSURE 343
TEST ENGINE OIL PRESSURE 345
METHOD FOR TESTING ENGINE OIL PRESSURE 345
BLEED AIR FROM FUEL SYSTEM 347
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 347
TEST FUEL CIRCUIT FOR LEAKAGE 348
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 348
TEST AND ADJUST ALTERNATOR BELT TENSION 349
METHOD FOR TESTING ALTERNATOR BELT TENSION 349
METHOD FOR ADJUSTING ALTERNATOR BELT TENSION 349
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 350
METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 350
POWER TRAIN 352
TEST SWING CIRCLE BEARING CLEARANCE 352
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 352
UNDERCARRIAGE AND FRAME 353
TEST AND ADJUST TRACK TENSION 353
METHOD FOR TESTING TRACK TENSION 353
METHOD FOR ADJUSTING TRACK TENSION 353
HYDRAULIC SYSTEM 355
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 355
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 355
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 355
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 359
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 360
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS 361
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS 361
368
TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE 370
METHOD FOR TESTING SWING AND BLADE CIRCUIT OIL PRESSURE 370
METHOD FOR ADJUSTING SWING AND BLADE CIRCUIT OIL PRESSURE 374
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 376
376
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 378
ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 380
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 380
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 382
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 382
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL 383
METHOD FOR ADJUSTING LS VALVE 385
TEST OUTLET PRESSURE OF SOLENOID VALVE 386
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY MACHINE MONITOR 386
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY TESTING TOOL 388
OPERATING CONDITION OF SOLENOID VALVE 389
TEST PPC VALVE OUTLET PRESSURE 390
METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY MACHINE MONITOR 390
METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL 393
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 396
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 396
TEST SWING PARKING BRAKE RELEASE PRESSURE 397
METHOD FOR TESTING SWING PARKING BRAKE RELEASE PRESSURE WITH MACHINE MONITOR 397
METHOD FOR TESTING SWING PARKING BRAKE RELEASE PRESSURE BY TESTING TOOL 397
TEST AND ADJUST TRAVEL DEVIATION 399
METHOD FOR ADJUSTING TRAVEL DEVIATION 399
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 401
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 401
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 401
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 402
TEST OIL LEAKAGE 403
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 403
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 403
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 404
METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER 404
BLEED AIR FROM HYDRAULIC CIRCUIT 406
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 407
PRESSURIZE HYDRAULIC TANK 409
METHOD FOR PRESSURIZING HYDRAULIC TANK 409
CAB AND ITS ATTACHMENTS 410
METHOD FOR OPENING AND CLOSING FLOOR UNIT 410
METHOD FOR OPENING FLOOR UNIT 411
METHOD FOR CLOSING FLOOR UNIT 413
ELECTRICAL SYSTEM 416
SET AND OPERATE MACHINE MONITOR 416
OPERATOR MODE 418
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 418
CHECKING FUNCTION OF SERVICE METER 418
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 419
SERVICE MODE 421
METHOD FOR OPERATING SERVICE MODE 421
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 423
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 425
ABNORMALITY RECORD MENU 430
METHOD FOR CONFIRMING MAINTENANCE RECORD 434
METHOD FOR OPERATING MAINTENANCE MODE SETTING 435
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 439
DEFAULT MENU 440
ADJUSTMENT MENU 446
METHOD FOR OPERATING BATTERY DISCONNECT SWITCH SETTING 454
KOMTRAX SETTINGS MENU 455
METHOD FOR DISPLAYING SERVICE MESSAGE 457
METHOD FOR STARTING UP KOMTRAX TERMINAL 459
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 464
TEST DIODES 465
METHOD FOR TESTING DIODE USING DIGITAL TESTER 465
METHOD FOR TESTING DIODE USING ANALOG TESTER 465
40 TROUBLESHOOTING 467
CONTENTS 468
ABBREVIATION LIST 472
RELATED INFORMATION ON TROUBLESHOOTING 478
GENERAL TROUBLESHOOTING POINTS 478
SEQUENCE OF EVENTS IN TROUBLESHOOTING 479
CHECKS BEFORE TROUBLESHOOTING 481
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 483
WALK-AROUND CHECK 483
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 484
CHECK FUEL LEVEL AND TYPE 484
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT / CLEANING ELEMENT 485
CHECK MAIN FILTER 487
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 489
CHECK COOLANT LEVEL (RESERVOIR TANK) 491
CHECK CLOGGING OF AIR CLEANER 492
CLEAN OUTER ELEMENT (SINGLE ELEMENT) 492
CLEAN OUTER ELEMENT (DOUBLE ELEMENT) 495
REPLACE SINGLE ELEMENT 498
REPLACE DOUBLE ELEMENT 500
CHECK HYDRAULIC OIL LEVEL 502
CHECK HYDRAULIC OIL STRAINER 505
CHECK HYDRAULIC FILTER 506
CHECK OIL LEVEL IN FINAL DRIVE CASE 508
BLEED AIR FROM FUEL SYSTEM 508
BLEED AIR FROM HYDRAULIC SYSTEM 509
PROCEDURE FOR TESTING AND TROUBLESHOOTING 510
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 513
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 517
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 519
FUSE LOCATION TABLE 525
FAILURE CODES TABLE 527
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 533
FAILURE CODE [6AZ0ZG] 533
FAILURE CODE [989L00] 535
FAILURE CODE [989M00] 536
FAILURE CODE [989N00] 537
FAILURE CODE [B@BCNS] 538
FAILURE CODE [D19JKZ] 539
FAILURE CODE [D811MC] 542
FAILURE CODE [D862KA] 543
FAILURE CODE [D8ALKA] 544
FAILURE CODE [D8ALKB] 546
FAILURE CODE [D8AQKR] 548
FAILURE CODE [DAF0KT] 550
FAILURE CODE [DAF0MB] 551
FAILURE CODE [DAF0MC] 552
FAILURE CODE [DAF3KK] 553
FAILURE CODE [DAF9KQ] 555
FAILURE CODE [DAFGMC] 556
FAILURE CODE [DAFLKA] 557
FAILURE CODE [DAFLKB] 559
FAILURE CODE [DAFQKR] 561
FAILURE CODE [DB2QKR] 562
FAILURE CODE [DBH0MC] 566
FAILURE CODE [DBH2KK] 567
FAILURE CODE [DBH5KP] 570
FAILURE CODE [DBH9KQ] 573
FAILURE CODE [DBHLKA] 576
FAILURE CODE [DBHLKB] 578
FAILURE CODE [DBHQKR] 580
FAILURE CODE [DDNRKA] 585
FAILURE CODE [DDNRKY] 587
FAILURE CODE [DDNS00] 589
FAILURE CODE [DDWLKA] 591
FAILURE CODE [DDWLKB] 593
FAILURE CODE [DFB1KZ] 595
FAILURE CODE [DFB2KZ] 597
FAILURE CODE [DFB3L8] 599
FAILURE CODE [DFB4L8] 602
FAILURE CODE [DFB5KZ] 605
FAILURE CODE [DFB6KZ] 607
FAILURE CODE [DHS1MA] 609
FAILURE CODE [DHS5MA] 611
FAILURE CODE [DHX1MA] 613
FAILURE CODE [DKULKA] 615
FAILURE CODE [DKULKB] 617
FAILURE CODE [DKULKY] 619
FAILURE CODE [DV00KB] 621
FAILURE CODE [DV20KB] 622
FAILURE CODE [DV20KB] 624
FAILURE CODE [DV50KB] 626
FAILURE CODE [DV50KY] 628
FAILURE CODE [DW43KA] 630
FAILURE CODE [DW43KB] 632
FAILURE CODE [DW43KY] 634
FAILURE CODE [DW4CKY] 635
FAILURE CODE [DXA8KA] 637
FAILURE CODE [DXA8KB] 640
FAILURE CODE [DXE7KA] 642
FAILURE CODE [DXE7KB] 644
FAILURE CODE [DXE7KY] 646
FAILURE CODE [DXE8KA] 648
FAILURE CODE [DXE8KB] 650
FAILURE CODE [DXE8KY] 652
FAILURE CODE [DXE9KA] 654
FAILURE CODE [DXE9KB] 656
FAILURE CODE [DXE9KY] 658
FAILURE CODE [DXEAKA] 660
FAILURE CODE [DXEAKB] 662
FAILURE CODE [DXEAKY] 664
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 666
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 666
E-2 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM) 673
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 675
E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 677
E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 680
E-6 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 681
E-7 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 682
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 683
E-9 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 684
E-10 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 685
E-11 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 687
E-12 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 688
E-13 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 689
E-14 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 690
E-15 FUNCTION SWITCH DOES NOT OPERATE 691
E-16 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 692
E-17 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 693
E-18 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 694
E-19 ALARM BUZZER DOES NOT SOUND 696
E-20 ALARM BUZZER CANNOT BE CANCELED 697
E-21 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 698
E-22 SERVICE MODE CANNOT BE SELECTED 699
E-23 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 700
E-24 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 702
E-25 ALARM DOES NOT SOUND DURING TRAVEL 704
E-26 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 706
E-27 HORN DOES NOT SOUND 707
E-28 HORN DOES NOT STOP SOUNDING 710
E-29 NONE OF WORKING LAMP, TRAVEL LAMP, OR ADDITIONAL LAMP DOES NOT LIGHT UP 712
E-30 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 716
E-31 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 718
E-32 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 720
E-33 Swing or Arm IN IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 721
E-34 Work equipment IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 722
E-35 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 724
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 725
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 725
H-1 ALL WORK EQUIPMENT, TRAVEL, SWING OR BLADE DO NOT OPERATE 726
H-2 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE 727
H-3 TRAVEL OR BLADE DOES NOT OPERATE 728
H-4 SWING OR BLADE DOES NOT OPERATE 729
H-5 ALL WORK EQUIPMENT, TRAVEL, SWING AND BLADE SPEED OR POWER IS LOW 730
H-6 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW 731
H-7 TRAVEL AND BLADE SPEED OR POWER IS LOW 732
H-8 SWING AND BLADE SPEED OR POWER IS LOW 733
H-9 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 734
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 735
H-11 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 736
H-12 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 738
H-13 ALL WORK EQUIPMENTS AND BLADE SPEED OR POWER IS LOW 739
H-14 BLADE DOES NOT OPERATE 740
H-15 ALL WORK EQUIPMENTS DO NOT OPERATE 741
H-16 ALL WORK EQUIPMENTS OR BLADE DO NOT OPERATE 742
H-17 SPEED OR POWER OF BOOM IS LOW 743
H-18 ARM SPEED OR POWER IS LOW 745
H-19 BUCKET SPEED OR POWER IS LOW 746
H-20 BLADE SPEED OR POWER IS LOW 747
H-21 BOOM SWING SPEED OR POWER IS LOW 749
H-22 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 750
H-23 HYDRAULIC DRIFT OF BOOM IS LARGE 751
H-24 HYDRAULIC DRIFT OF ARM IS LARGE 752
H-25 HYDRAULIC DRIFT OF BUCKET IS LARGE 753
H-26 HYDRAULIC DRIFT OF BLADE IS LARGE 754
H-27 TIME LAG OF WORK EQUIPMENT IS LARGE 756
H-28 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 757
H-29 MACHINE DOES NOT TRAVEL STRAIGHT 758
H-30 MACHINE DOES NOT MOVE OFF STRAIGHT 760
H-31 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 761
H-32 TRAVEL SPEED IS LOW 763
H-33 BOTH SIDES OF CRAWLERS DO NOT MOVE 765
H-34 ONE OF TRACKS DOES NOT RUN 766
H-35 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 768
H-36 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 769
H-37 SWINGS ONLY IN ONE DIRECTION 771
H-38 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 773
H-39 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 775
H-40 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 776
H-41 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 777
H-42 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 778
H-43 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 779
H-44 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 780
H-45 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 781
TROUBLESHOOTING OF ENGINE (S-MODE) 782
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 782
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 783
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 784
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 785
S-4 ENGINE STARTABILITY IS POOR 786
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 788
S-6 ENGINE STOPS DURING OPERATION 789
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 790
S-8 ENGINE LACKS POWER 791
S-9 ENGINE OIL CONSUMPTION IS EXCESSIVE 793
S-10 OIL BECOMES CONTAMINATED QUICKLY 794
S-11 FUEL CONSUMPTION IS EXCESSIVE 795
S-12 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 796
S-13 OIL PRESSURE DROPS 797
S-14 FUEL MIXES INTO ENGINE OIL 798
S-15 WATER MIXES INTO ENGINE OIL (MILKY) 799
S-16 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 800
S-17 UNUSUAL NOISE IS HEARD 801
S-18 VIBRATION IS EXCESSIVE 802
S-19 AIR CANNOT BE BLED FROM FUEL CIRCUIT 803
50 DISASSEMBLY AND ASSEMBLY 805
CONTENTS 806
ABBREVIATION LIST 808
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 814
HOW TO READ THIS MANUAL 814
COATING MATERIALS LIST 816
SPECIAL TOOLS LIST 820
SKETCHES OF SPECIAL TOOLS 825
ENGINE AND COOLING SYSTEM 826
REMOVE AND INSTALL STARTER ASSEMBLY 826
METHOD FOR REMOVING STARTER ASSEMBLY 826
METHOD FOR INSTALLING STARTER ASSEMBLY 826
REMOVE AND INSTALL RADIATOR ASSEMBLY 828
METHOD FOR REMOVING RADIATOR ASSEMBLY 828
METHOD FOR INSTALLING RADIATOR ASSEMBLY 831
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 835
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 835
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 838
REMOVE AND INSTALL FUEL TANK ASSEMBLY 842
METHOD FOR REMOVING FUEL TANK ASSEMBLY 842
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 844
POWER TRAIN 847
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 847
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 847
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 849
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 851
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 851
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 852
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 853
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 853
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 856
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 860
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 860
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 860
UNDERCARRIAGE AND FRAME 862
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 862
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING 862
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 863
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 865
METHOD FOR SEPARATING TRACK ASSEMBLY 865
METHOD FOR INSTALLING TRACK ASSEMBLY 865
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 867
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 867
METHOD FOR ASSEMBLING IDLER ASSEMBLY 868
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 870
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 870
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 871
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 873
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 873
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 874
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 876
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 876
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 877
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 879
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 879
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 882
HYDRAULIC SYSTEM 886
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 886
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 886
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 887
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 890
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 891
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 892
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 893
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 893
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 896
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 899
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 899
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 900
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 902
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 902
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 903
WORK EQUIPMENT 905
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 905
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 905
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 906
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 909
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 910
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 913
CAB AND ITS ATTACHMENTS 918
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 918
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 918
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 921
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 925
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 926
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 927
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 935
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 935
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 936
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 938
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 938
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 942
REMOVE AND INSTALL OPERATOR’S SEAT 946
METHOD FOR REMOVING OPERATOR’S SEAT 946
METHOD FOR INSTALLING OPERATOR’S SEAT 946
REMOVE AND INSTALL SEAT BELT 948
METHOD FOR REMOVING SEAT BELT 948
METHOD FOR INSTALLING SEAT BELT 948
ELECTRICAL SYSTEM 949
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 949
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 949
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 950
REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY 951
METHOD FOR REMOVING MACHINE CONTROLLER ASSEMBLY 951
METHOD FOR INSTALLING MACHINE CONTROLLER ASSEMBLY 952
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 954
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 954
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 955
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 957
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 957
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 957
60 MAINTENANCE STANDARD 959
CONTENTS 960
ABBREVIATION LIST 961
ENGINE AND COOLING SYSTEM 967
MAINTENANCE STANDARD FOR PTO 967
MAINTENANCE STANDARD OF COOLING SYSTEM 968
POWER TRAIN 969
MAINTENANCE STANDARD OF SWING CIRCLE 969
MAINTENANCE STANDARD OF SWING MACHINERY 970
MAINTENANCE STANDARD OF SPROCKET 972
UNDERCARRIAGE AND FRAME 973
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 973
MAINTENANCE STANDARD OF IDLER 974
MAINTENANCE STANDARD OF TRACK ROLLER 976
MAINTENANCE STANDARD OF CARRIER ROLLER 977
MAINTENANCE STANDARD OF TRACK SHOE 978
MAINTENANCE STANDARD OF TRIPLE SHOE 980
MAINTENANCE STANDARD OF ROAD LINER 981
MAINTENANCE STANDARD FOR RUBBER SHOE 982
HYDRAULIC SYSTEM 983
MAINTENANCE STANDARD OF HYDRAULIC TANK 983
MAINTENANCE STANDARD OF MAIN PUMP 984
MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE 985
MAINTENANCE STANDARD OF PC-EPC VALVE 986
MAINTENANCE STANDARD OF SWING MOTOR 987
MAINTENANCE STANDARD OF TRAVEL MOTOR 989
MAINTENANCE STANDARD OF CONTROL VALVE 990
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 1000
MAINTENANCE STANDARD OF BLADE PPC VALVE 1003
MAINTENANCE STANDARD OF BOOM SWING PPC VALVE 1005
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 1007
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 1010
WORK EQUIPMENT 1011
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 1011
DIMENSION OF ARM 1017
DIMENSIONS OF BUCKET 1021
MAINTENANCE STANDARD OF BOOM CYLINDER 1023
MAINTENANCE STANDARD OF ARM CYLINDER 1024
MAINTENANCE STANDARD OF BUCKET CYLINDER 1026
MAINTENANCE STANDARD OF BLADE CYLINDER 1028
MAINTENANCE STANDARD OF BOOM SWING CYLINDER 1029
80 APPENDIX 1031
CONTENTS 1032
ABBREVIATION LIST 1033
AIR CONDITIONER SYSTEM 1039
PRECAUTIONS FOR REFRIGERANT 1039
AIR CONDITIONER COMPONENT 1040
SPECIFICATIONS OF AIR CONDITIONER 1041
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 1042
OUTLINE OF REFRIGERATION CYCLE 1043
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 1045
AIR CONDITIONER UNIT 1045
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 1045
COMPRESSOR 1047
STRUCTURE OF COMPRESSOR 1047
SPECIFICATIONS OF COMPRESSOR 1047
FUNCTION OF COMPRESSOR 1047
CONDENSER 1049
STRUCTURE OF CONDENSER 1049
SPECIFICATIONS OF CONDENSER 1049
FUNCTION OF CONDENSER 1049
RECEIVER DRIER 1050
STRUCTURE OF RECEIVER DRIER 1050
SPECIFICATIONS OF RECEIVER DRIER 1050
FUNCTION OF RECEIVER DRIER 1050
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1051
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 1053
A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 1056
A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION 1060
A-4 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (ELECTRICAL SYSTEM) 1063
A-5 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (MECHANICAL SYSTEMS) 1067
A-6 TROUBLESHOOTING FOR HOT WATER CIRCUIT SYSTEM 1068
A-7 UNUSUAL NOISE IS HEARD FROM AIR CONDITINOER RELATED PARTS 1069
A-8 WATER LEAKS FROM AIR CONDITINOER RELATED PARTS 1070
A-9 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 1071
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 1072
HANDLE COMPRESSOR OIL 1074
90 CIRCUIT DIAGRAMS 1075
CONTENTS 1076
ABBREVIATION LIST 1077
HYDRAULIC CIRCUIT DIAGRAM 1083
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 1083
HYDRAULIC CIRCUIT DIAGRAM (1/2) 1087
HYDRAULIC CIRCUIT DIAGRAM (2/2) 1089
ELECTRICAL CIRCUIT DIAGRAM 1091
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 1091
ELECTRICAL CIRCUIT DIAGRAM (1/6) 1095
ELECTRICAL CIRCUIT DIAGRAM (2/6) 1097
ELECTRICAL CIRCUIT DIAGRAM (3/6) 1099
ELECTRICAL CIRCUIT DIAGRAM (4/6) 1101
ELECTRICAL CIRCUIT DIAGRAM (5/6) 1103
ELECTRICAL CIRCUIT DIAGRAM (6/6) 1105
INDEX 1107
S.V 12/12/24ย ย
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Komatsu Pw95-1 Hydraulic Excavator Service Repair Workshop Manual Download Sn 0000007
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