Komatsu Bulldozer PC88MR-11 Shop Manual SEN06843-C5 PDF

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Komatsu Bulldozer PC88MR-11 Shop Manual SEN06843-C5 – PDF DOWNLOAD

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Komatsu Bulldozer PC88MR-11 Shop Manual SEN06843-C5 – PDF DOWNLOAD

Language : English
Pages : 2208
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Bulldozer PC88MR-11 Shop Manual SEN06843-C5 – PDF DOWNLOAD

• SERIAL NUMBERS C40001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
FOREWORD, SAFETY, BASIC INFORMATION . 17
HOW TO READ THE SHOP MANUAL . 17
SAFETY NOTICE FOR OPERATION . 19
PRECAUTIONS TO PREVENT FIRE . 27
ACTIONS IF FIRE OCCURS 29
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 30
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 31
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 34
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 41
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 43
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 44
PRACTICAL USE OF KOMTRAX 45
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 46
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 46
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 47
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 48
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 50
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 54
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 55
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 57
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 58
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 60
HOW TO READ ELECTRICAL WIRE CODE 61
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 65
STANDARD TIGHTENING TORQUE TABLE 68
CONVERSION TABLE 75
ABBREVIATION LIST . 80
01 SPECIFICATIONS . 87
CONTENTS 88
SPECIFICATIONS 89
SPECIFICATION DRAWING . 89
SPECIFICATION DRAWING: PC88MR-11 89
WORKING RANGE DRAWINGS 90
WORKING RANGE DRAWINGS: PC88MR-11 . 90
SPECIFICATIONS 91
SPECIFICATIONS: PC88MR-11 . 91
WEIGHT TABLE 95
WEIGHT TABLE: PC88MR-11 . 95
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) . 97
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE . 98
10 STRUCTURE AND FUNCTION . 101
CONTENTS 102
BOOT-UP SYSTEM 105
LAYOUT DRAWING OF BOOT-UP SYSTEM 105
SYSTEM OPERATING LAMP SYSTEM 106
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 106
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 106
BATTERY DISCONNECT SWITCH . 108
FUNCTION OF BATTERY DISCONNECT SWITCH . 108
ENGINE SYSTEM . 109
LAYOUT DRAWING OF ENGINE SYSTEM . 109
ENGINE CONTROL SYSTEM . 111
ENGINE CONTROL SYSTEM DIAGRAM . 111
FUNCTION OF ENGINE CONTROL SYSTEM . 112
AUTO-DECELERATION SYSTEM 114
SYSTEM DIAGRAM OF AUTO-DECELERATION SYSTEM 114
FUNCTION OF AUTO-DECELERATION SYSTEM 114
OPERATION OF AUTO-DECELERATION SYSTEM . 115
ENGINE AUTOMATIC WARM-UP SYSTEM . 116
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 116
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 117
OVERHEAT PREVENTION SYSTEM 118
FUNCTION OF OVERHEAT PREVENTION SYSTEM 118
TURBOCHARGER PROTECTION SYSTEM 119
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 119
AUTOMATIC IDLE STOP SYSTEM 120
AUTOMATIC IDLE STOP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 120
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 120
COMPONENT PARTS OF ENGINE SYSTEM 123
PTO . 123
TURBOCHARGER 124
EGR SYSTEM 126
EGR VALVE . 129
EGR COOLER 131
HIGH EFFICIENCY BREATHER SYSTEM . 132
HIGH EFFICIENCY BREATHER 133
EXHAUST THROTTLE VALVE 135
KDOC 136
COOLING SYSTEM 138
LAYOUT DRAWING OF COOLING SYSTEM 138
SPECIFICATIONS OF COOLING SYSTEM 139
CONTROL SYSTEM 140
LAYOUT DRAWING OF CONTROL SYSTEM 140
MACHINE MONITOR SYSTEM 142
SYSTEM DIAGRAM OF MACHINE MONITOR SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 142
FUNCTION OF MACHINE MONITOR SYSTEM 142
KOMTRAX SYSTEM 144
KOMTRAX SYSTEM DIAGRAM 144
FUNCTION OF KOMTRAX SYSTEM 144
COMPONENT PARTS OF CONTROL SYSTEM . 145
MACHINE MONITOR . 145
GATEWAY FUNCTION CONTROLLER . 157
COMMUNICATION TERMINAL 160
PUMP CONTROLLER . 162
RESISTOR FOR PC-EPC VALVE . 166
CAN TERMINATING RESISTOR 167
ENGINE CONTROLLER . 168
FUEL CONTROL DIAL . 175
HYDRAULIC SYSTEM 176
LAYOUT DRAWING OF HYDRAULIC SYSTEM 176
CLSS 179
STRUCTURE OF CLSS . 179
FUNCTION OF CLSS 180
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 182
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 182
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 183
COMPONENT PARTS OF HYDRAULIC SYSTEM . 186
HYDRAULIC TANK 187
MAIN PUMP . 189
CONTROL VALVE . 203
WORK EQUIPMENT SYSTEM . 267
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 267
PPC LOCK SYSTEM . 269
SYSTEM DIAGRAM OF PPC LOCK SYSTEM . 269
FUNCTION OF PPC LOCK SYSTEM . 269
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 270
SYSTEM DIAGRAM OF LOCK LEVER AUTOMATIC LOCK SYSTEM 270
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 270
OPERATION OF LOCK LEVER AUTOMATIC LOCK SYSTEM . 271
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 272
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 272
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 273
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 274
WORK EQUIPMENT AND SWING PPC VALVE 274
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 279
ATTACHMENT OIL FLOW ADJUSTER EPC VALVE 285
BLADE PPC VALVE . 286
BOOM SWING PPC VALVE 288
SOLENOID VALVE 290
ANTI-DROP VALVE FOR BOOM 293
ANTI-DROP VALVE FOR ARM . 298
MULTI-CONTROL VALVE . 303
PILOT CIRCUIT ACCUMULATOR . 304
ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) . 305
SWING SYSTEM 306
LAYOUT DRAWING OF SWING SYSTEM 306
SWING CONTROL SYSTEM DIAGRAM 308
FUNCTION OF SWING CONTROL SYSTEM 308
COMPONENT PARTS OF SWING SYSTEM . 310
SWING MOTOR . 310
SWING MACHINERY . 319
SWING CIRCLE 321
TRAVEL SYSTEM . 323
LAYOUT DRAWING OF TRAVEL SYSTEM . 323
SYSTEM DIAGRAM OF TRAVEL CONTROL SYSTEM . 325
FUNCTION OF TRAVEL CONTROL SYSTEM . 326
COMPONENT PARTS OF TRAVEL SYSTEM 328
TRAVEL MOTOR 328
TRAVEL PPC VALVE 337
CENTER SWIVEL JOINT . 341
UNDERCARRIAGE AND FRAME . 342
LAYOUT DRAWING OF UNDERCARRIAGE . 342
SPECIFICATIONS OF UNDERCARRIAGE . 342
IDLER CUSHION . 344
STRUCTURE OF IDLER CUSHION 344
SPECIFICATIONS OF IDLER CUSHION . 344
WORK EQUIPMENT 345
STRUCTURE OF WORK EQUIPMENT . 345
FUNCTION OF WORK EQUIPMENT 346
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 347
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 347
BUCKET CLEARANCE ADJUSTMENT SHIM 348
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 348
CAB AND ITS ATTACHMENTS . 349
ROPS CAB 349
STRUCTURE OF ROPS CAB . 349
FUNCTION OF ROPS CAB 349
CAB MOUNT . 350
STRUCTURE OF CAB MOUNT 350
FUNCTION OF CAB MOUNT . 351
TAKE WIRING HARNESS OUT OF CAB 352
20 STANDARD VALUE TABLE . 353
CONTENTS 354
STANDARD VALUE TABLE FOR ENGINE . 355
STANDARD VALUE TABLE FOR ENGINE: PC88MR-11 355
STANDARD VALUE TABLE FOR MACHINE 357
STANDARD VALUE TABLE FOR MACHINE: PC88MR-11 . 357
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE . 369
30 TESTING AND ADJUSTING 375
CONTENTS 376
RELATED INFORMATION ON TESTING AND ADJUSTING 379
TOOLS FOR TESTING AND ADJUSTING . 379
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 384
ENGINE AND COOLING SYSTEM . 386
TEST ENGINE SPEED . 386
TEST ENGINE SPEED . 386
TEST EXHAUST GAS COLOR 390
TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 390
TEST EXHAUST GAS COLOR BY SMOKE METER . 391
TEST AND ADJUST VALVE CLEARANCE . 393
TEST VALVE CLEARANCE 393
ADJUST VALVE CLEARANCE 394
TEST COMPRESSION PRESSURE . 395
TEST COMPRESSION PRESSURE . 395
TEST BLOWBY PRESSURE 398
TEST BLOWBY PRESSURE 398
TEST ENGINE OIL PRESSURE 400
TEST ENGINE OIL PRESSURE 400
VISUAL CHECK INSIDE OF EGR VALVE 402
VISUAL CHECK INSIDE OF EGR VALVE 402
CLEAN INSIDE OF EGR VALVE . 404
CLEAN INSIDE OF EGR VALVE . 404
TEST FUEL PRESSURE 407
TEST FUEL PRESSURE 407
TEST FUEL RETURN RATE AND LEAKAGE . 409
TEST FUEL RETURN RATE AND LEAKAGE . 411
BLEED AIR FROM FUEL SYSTEM 414
BLEED AIR FROM FUEL SYSTEM 414
TEST FUEL SYSTEM FOR LEAKAGE 416
TEST FUEL CIRCUIT FOR LEAKAGE . 416
CYLINDER CUT-OUT MODE OPERATION . 418
NO-INJECTION CRANKING OPERATION . 419
CHECK FAN BELT 420
CHECK FAN BELT 420
TEST AUTO-TENSIONER . 421
TEST AUTO-TENSIONER . 421
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 423
WRITE INJECTOR COMPENSATION VALUE . 423
POWER TRAIN . 429
TEST SWING CIRCLE BEARING CLEARANCE . 429
TEST SWING CIRCLE BEARING CLEARANCE . 429
UNDERCARRIAGE AND FRAME . 430
TEST AND ADJUST TRACK TENSION . 430
TEST TRACK TENSION 430
ADJUST TRACK TENSION 430
HYDRAULIC SYSTEM 432
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 432
RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK 432
RELEASE REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 432
RELEASE REMAINING PRESSURE FROM SWING MOTOR CIRCUIT . 435
RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 435
RELEASE REMAINING PRESSURE FROM SWING CYLINDER CIRCUIT 436
RELEASE REMAINING PRESSURE FROM BLADE CYLINDER 436
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS 437
TEST OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS . 437
ADJUST OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS . 446
ADJUST WORK EQUIPMENT AND TRAVEL RELIEF PRESSURE 446
TEST AND ADJUST OIL PRESSURE IN SWING AND BLADE CIRCUITS 447
TEST SWING AND BLADE RELIEF PRESSURE 447
ADJUST SWING RELIEF PRESSURE 449
ADJUST BLADE LOWER RELIEF PRESSURE 449
ADJUST BLADE RAISE RELIEF PRESSURE 450
TEST OIL PRESSURE OF CONTROL CIRCUIT 451
TEST OIL PRESSURE OF CONTROL CIRCUIT 451
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 453
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 453
TEST SOURCE PRESSURE OF PC-EPC VALVE 455
TEST PC-EPC VALVE OUTPUT PRESSURE . 456
ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 457
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 459
TEST LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 459
TEST LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 461
ADJUST LS VALVE . 464
TEST OUTLET PRESSURE IN SOLENOID VALVE 465
TEST OUTLET PRESSURE IN SOLENOID VALVE 465
OPERATING CONDITION OF SOLENOID VALVE . 467
TEST OUTLET PRESSURE IN PPC VALVE . 468
TEST OUTLET PRESSURE IN PPC VALVE . 468
TEST AND ADJUST TRAVEL DEVIATION 471
TEST TRAVEL DEVIATION . 471
ADJUST TRAVEL DEVIATION . 472
TEST THE PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT 474
TEST PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 474
TEST PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 474
TEST PARTS THAT CAUSE HYDRAULIC DRIFT OF PPC VALVE 475
TEST OIL LEAKAGE 476
TEST OIL LEAKAGE FROM BOOM CYLINDER . 476
TEST OIL LEAKAGE FROM ARM CYLINDER 477
TEST OIL LEAKAGE FROM BUCKET CYLINDER . 477
TEST OIL LEAKAGE FROM BOOM SWING CYLINDER . 478
TEST OIL LEAKAGE FROM BLADE CYLINDER 479
TEST OIL LEAKAGE FROM SWING MOTOR . 480
TEST OIL LEAKAGE FROM TRAVEL MOTOR 481
BLEED AIR FROM HYDRAULIC SYSTEM . 483
BLEED AIR FROM HYDRAULIC CIRCUIT 484
CAB RELATED PARTS . 489
ADJUST MIRRORS 489
ADJUST LEFT FRONT MIRROR 489
ADJUST REAR MIRROR 490
ELECTRICAL SYSTEM . 491
SET AND OPERATE MACHINE MONITOR . 491
OPERATOR MODE . 494
FUNCTION TO SHOW TECHNICIAN IDENTIFICATION STATUS SCREEN 494
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 494
CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 495
CHECK FUNCTION OF SERVICE METER . 495
USAGE LIMITATION AND MAINTENANCE PASSWORD CHANGE FUNCTION . 496
SERVICE MODE 499
OPERATE SERVICE MODE 499
CHECK PRE-DEFINED MONITORING INFORMATION 501
CHECK MONITORING INFORMATION 505
ABNORMALITY RECORD MENU . 514
CHECK MAINTENANCE RECORD 519
MAINTENANCE MODE SETTING 520
SET PHONE NUMBER ENTRY 524
DEFAULT SETTING MENU 526
TESTING MENU 536
ADJUSTMENT MENU . 539
OPERATE NO-INJECTION CRANKING . 553
KOMTRAX SETTINGS MENU . 556
SHOW SERVICE MESSAGE 558
START UP KOMTRAX SYSTEM . 560
ADJUST REARVIEW CAMERA ANGLE 567
ADJUST REARVIEW CAMERA ANGLE 567
ADJUST RIGHTVIEW CAMERA ANGLE . 570
ADJUST RIGHT VIEW CAMERA ANGLE 570
SET REGION OF Bluetooth(R) COMPATIBLE RADIO . 573
SET REGION OF Bluetooth(R) COMPATIBLE RADIO . 573
ENGINE CONTROLLER VOLTAGE CIRCUIT . 575
BATTERY DISCONNECT SWITCH . 576
TEST DIODES . 577
TEST DIODES BY DIGITAL TESTER . 577
TEST DIODES BY ANALOG TESTER 577
Pm-CLINIC . 578
Pm CLINIC SERVICE . 578
Pm CLINIC CHECK SHEET: PC88MR-11 580
40 TROUBLESHOOTING 589
CONTENTS 590
RELATED INFORMATION ON TROUBLESHOOTING 597
GENERAL TROUBLESHOOTING POINTS 597
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 598
CHECKS BEFORE TROUBLESHOOTING . 600
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 602
WALK-AROUND CHECK . 602
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 604
CHECK FUEL LEVEL AND TYPE . 604
CHECK FUEL PREFILTER 605
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 605
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 606
CHECK MAIN FILTER . 608
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 609
CHECK OIL LEVEL IN PTO GEAR CASE 610
CHECK COOLANT LEVEL (EXPANSION TANK) 612
CHECK CLOGGING OF AIR CLEANER . 613
OUTER ELEMENT – CLEAN . 613
ELEMENTS – REPLACE 615
CHECK HYDRAULIC OIL LEVEL . 616
CHECK HYDRAULIC OIL STRAINER 618
CHECK HYDRAULIC FILTER 620
CHECK OIL LEVEL IN SWING MACHINERY CASE . 621
CHECK OIL LEVEL IN FINAL DRIVE CASE . 622
BLEED AIR FROM FUEL SYSTEM 623
BLEED AIR FROM HYDRAULIC SYSTEM . 623
METHOD FOR CHECKING ELECTRIC EQUIPMENT METHOD . 623
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 628
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 628
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 630
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 631
PREPARATION FOR TROUBLESHOOTING OF GATEWAY FUNCTION CONTROLLER 631
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 632
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 636
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 639
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 644
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 646
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE . 649
CONNECTOR LAYOUT 654
CONNECTOR CONTACT IDENTIFICATION 660
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 702
FUSE LOCATION TABLE . 708
FAILURE CODES TABLE . 710
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 718
FAILURE CODE [879AKA] . 718
FAILURE CODE [879AKB] . 719
FAILURE CODE [879BKA] . 720
FAILURE CODE [879BKB] . 722
FAILURE CODE [879CKA] . 724
FAILURE CODE [879CKB] . 725
FAILURE CODE [879DKZ] . 726
FAILURE CODE [879EMC] . 728
FAILURE CODE [879FMC] . 729
FAILURE CODE [879GKX] . 730
FAILURE CODE [989L00] . 732
FAILURE CODE [989M00] . 733
FAILURE CODE [989N00] . 734
FAILURE CODE [A900FR] . 735
FAILURE CODE [A900N6] . 736
FAILURE CODE [A900NY] . 737
FAILURE CODE [AA10NX] . 738
FAILURE CODE [AB00KE] . 740
FAILURE CODE [B@BAZG] . 742
FAILURE CODE [B@BCNS] . 743
FAILURE CODE [B@BCQA] . 744
FAILURE CODE [B@BCZK] . 746
FAILURE CODE [B@HANS] . 748
FAILURE CODE [CA115] 750
FAILURE CODE [CA122] 751
FAILURE CODE [CA123] 753
FAILURE CODE [CA131] 755
FAILURE CODE [CA132] 757
FAILURE CODE [CA144] 759
FAILURE CODE [CA145] 761
FAILURE CODE [CA153] 763
FAILURE CODE [CA154] 766
FAILURE CODE [CA187] 769
FAILURE CODE [CA221] 771
FAILURE CODE [CA222] 773
FAILURE CODE [CA227] 775
FAILURE CODE [CA234] 776
FAILURE CODE [CA238] 777
FAILURE CODE [CA239] 779
FAILURE CODE [CA271] 781
FAILURE CODE [CA272] 783
FAILURE CODE [CA322] 785
FAILURE CODE [CA324] 788
FAILURE CODE [CA331] 791
FAILURE CODE [CA343] 794
FAILURE CODE [CA351] 795
FAILURE CODE [CA352] 796
FAILURE CODE [CA356] 798
FAILURE CODE [CA357] 800
FAILURE CODE [CA386] 803
FAILURE CODE [CA435] 804
FAILURE CODE [CA441] 806
FAILURE CODE [CA442] 808
FAILURE CODE [CA449] 809
FAILURE CODE [CA451] 810
FAILURE CODE [CA452] 812
FAILURE CODE [CA515] 814
FAILURE CODE [CA516] 816
FAILURE CODE [CA553] 818
FAILURE CODE [CA559] 819
FAILURE CODE [CA689] 823
FAILURE CODE [CA691] 825
FAILURE CODE [CA692] 827
FAILURE CODE [CA697] 829
FAILURE CODE [CA698] 830
FAILURE CODE [CA731] 831
FAILURE CODE [CA778] 832
FAILURE CODE [CA1117] . 835
FAILURE CODE [CA1896] . 836
FAILURE CODE [CA1961] . 840
FAILURE CODE [CA2185] . 841
FAILURE CODE [CA2186] . 843
FAILURE CODE [CA2249] . 845
FAILURE CODE [CA2272] . 846
FAILURE CODE [CA2311] . 849
FAILURE CODE [CA2349] . 850
FAILURE CODE [CA2353] . 852
FAILURE CODE [CA2357] . 854
FAILURE CODE [CA2765] . 855
FAILURE CODE [CA2973] . 856
FAILURE CODE [CA3419] . 857
FAILURE CODE [CA3421] . 859
FAILURE CODE [CA3724] . 861
FAILURE CODE [CA4264] . 862
FAILURE CODE [CA4952] . 864
FAILURE CODE [D110KB] . 866
FAILURE CODE [D19JKZ] . 868
FAILURE CODE [D811MC] . 870
FAILURE CODE [D862KA] . 871
FAILURE CODE [D8ALKA] . 872
FAILURE CODE [D8ALKB] . 874
FAILURE CODE [D8AQKR] . 876
FAILURE CODE [D8G1KT] . 881
FAILURE CODE [D8G6KT] . 882
FAILURE CODE [DA20MC] . 883
FAILURE CODE [DA22KK] . 884
FAILURE CODE [DA25KP] . 887
FAILURE CODE [DA29KQ] . 890
FAILURE CODE [DA2LKA] . 892
FAILURE CODE [DA2LKB] . 894
FAILURE CODE [DA2QKR] . 896
FAILURE CODE [DA2RKR] . 902
FAILURE CODE [DAF0MB] . 907
FAILURE CODE [DAF0MC] . 908
FAILURE CODE [DAF8KB] . 909
FAILURE CODE [DAF9KQ] . 911
FAILURE CODE [DAFGMC] . 912
FAILURE CODE [DAFLKA] . 913
FAILURE CODE [DAFLKB] . 915
FAILURE CODE [DAFQKR] . 917
FAILURE CODE [DAZ9KQ] . 923
FAILURE CODE [DAZQKR] . 924
FAILURE CODE [DB2QKR] . 928
FAILURE CODE [DB2RKR] . 934
FAILURE CODE [DDNRKA] . 939
FAILURE CODE [DDNRKY] . 942
FAILURE CODE [DDNS00] . 944
FAILURE CODE [DFB1KZ] . 946
FAILURE CODE [DFB3L8] . 948
FAILURE CODE [DFB5KZ] . 950
FAILURE CODE [DGH2KA] . 952
FAILURE CODE [DGH2KB] . 954
FAILURE CODE [DHA4KA] . 955
FAILURE CODE [DHPAMA] . 957
FAILURE CODE [DHS3MA] . 959
FAILURE CODE [DHS4MA] . 961
FAILURE CODE [DHS5MA] . 963
FAILURE CODE [DHS8MA] . 965
FAILURE CODE [DHS9MA] . 967
FAILURE CODE [DHSAMA] . 969
FAILURE CODE [DHSBMA] . 971
FAILURE CODE [DHSCMA] . 973
FAILURE CODE [DHSDMA] . 975
FAILURE CODE [DHSPMA] . 977
FAILURE CODE [DHSQMA] . 979
FAILURE CODE [DKULKA] . 981
FAILURE CODE [DKULKB] . 983
FAILURE CODE [DKULKY] . 985
FAILURE CODE [DLM5KA] . 987
FAILURE CODE [DLM5MB] . 989
FAILURE CODE [DV20KB] . 991
FAILURE CODE [DW43KA] . 993
FAILURE CODE [DW43KB] . 995
FAILURE CODE [DW43KY] . 997
FAILURE CODE [DW45KA] . 998
FAILURE CODE [DW45KB] .1001
FAILURE CODE [DW45KY] .1004
FAILURE CODE [DW4CKY] .1006
FAILURE CODE [DWA2KA] .1008
FAILURE CODE [DWA2KB] .1010
FAILURE CODE [DWA2KY] .1012
FAILURE CODE [DWJ0KA] .1013
FAILURE CODE [DWJ0KB] .1015
FAILURE CODE [DWJ0KY] .1017
FAILURE CODE [DWN5KA] .1018
FAILURE CODE [DWN5KB] .1020
FAILURE CODE [DWN5KY] .1022
FAILURE CODE [DXA8KA] .1024
FAILURE CODE [DXA8KB] .1026
FAILURE CODE [DXE7KA] .1028
FAILURE CODE [DXE7KB] .1030
FAILURE CODE [DXE7KY] .1032
FAILURE CODE [DXEAKA] .1033
FAILURE CODE [DXEAKB] .1035
FAILURE CODE [DXEAKY] .1037
FAILURE CODE [DY20KA] .1038
FAILURE CODE [DY20MA] .1040
FAILURE CODE [DY2CKB] .1042
FAILURE CODE [DY2DKB] .1044
FAILURE CODE [DY2EKB] .1046
FAILURE CODE [F313KA] .1048
FAILURE CODE [F313KB] .1049
FAILURE CODE [F318KB] .1050
FAILURE CODE [F318KY] .1051
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1052
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1052
MANUAL PREHEATING SYSTEM DOES NOT OPERATE .1058
WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP 1061
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1063
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS IN OPERATION 1066
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS IN OPERATION .1067
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1068
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1069
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1070
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION .1071
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION .1072
FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1073
FUEL GAUGE DOES NOT SHOW CORRECT FUEL LEVEL .1075
COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1076
COOLANT TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE .1077
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1078
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE .1080
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT SHOWN 1081
FUNCTION SWITCH DOES NOT OPERATE 1082
AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER) .1083
AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED 1084
AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION 1085
WORK MODE SELECTOR SCREEN DOES NOT APPEAR WHILE WORK MODE SWITCH IS OPERATED 1086
ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED .1087
TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED 1088
TRAVEL SPEED DOES NOT CHANGE EVEN WHEN YOU CHANGE TRAVEL SPEED 1089
ALARM BUZZER CANNOT BE STOPPED 1090
SERVICE METER IS NOT SHOWN WHILE STARTING SWITCH IS IN OFF POSITION .1091
MACHINE DOES NOT CHANGE TO SERVICE MODE .1092
ALL WORK EQUIPMENT, SWING, TRAVEL DO NOT OPERATE 1093
ALL WORK EQUIPMENT, SWING, TRAVEL CANNOT BE LOCKED 1096
MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED .1098
MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON .1100
WHEN LOCK LEVER AUTOMATIC CANCEL SWITCH IS OPERATED, WORK EQUIPMENT DOES NOT OPERATE 1102
TRAVEL ALARM DOES NOT SOUND .1104
TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS .1106
HORN DOES NOT MAKE SOUND 1107
HORN DOES NOT STOP SOUNDING .1109
WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED 1110
WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED 1111
WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED 1113
BOOM RAISE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1114
BOOM LOWER IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1115
ARM OUT IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .1116
ARM IN IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1117
BUCKET DUMP IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .1118
BUCKET CURL IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .1119
BOOM SWING LEFT IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .1120
BOOM SWING RIGHT IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1121
SWING IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .1122
TRAVEL IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1123
BLADE RAISE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .1124
BLADE LOWER IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .1126
KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY .1128
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1129
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1129
FAILURE MODE AND CAUSE TABLE 1130
ANY WORK EQUIPMENT, SWING OR TRAVEL DOES NOT WORK .1142
ALL WORK EQUIPMENT, SWING, AND TRAVEL SPEED IS LOW OR POWER IS LOW 1143
FINE CONTROL PERFORMANCE OR RESPONSE IS BAD .1145
UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1146
ENGINE SPEED FALLS LARGELY OR ENGINE STOPS 1147
BOOM SPEED OR POWER IS LOW 1149
ARM SPEED OR POWER IS LOW .1153
BUCKET SPEED OR POWER IS LOW 1156
BLADE SPEED OR POWER IS LOW .1159
BOOM SWING SPEED OR POWER IS LOW 1161
WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1164
HYDRAULIC DRIFT OF BOOM IS LARGE 1165
HYDRAULIC DRIFT OF ARM IS LARGE .1166
HYDRAULIC DRIFT OF BUCKET IS LARGE 1167
HYDRAULIC DRIFT OF BLADE IS LARGE .1168
WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 1169
TIME LAG OF WORK EQUIPMENT IS LARGE .1170
ATTACHMENT CIRCUIT CANNOT BE CHANGED 1172
OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 1173
IN COMBINED OPERATION OF WORK EQUIPMENT, WORK EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER 1174
IN COMBINED OPERATION OF WORK EQUIPMENT OR SWING AND TRAVEL, TRAVEL SPEED FALLS LARGELY .1175
IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RAISE SPEED IS LOW 1177
MACHINE DOES NOT TRAVEL STRAIGHT 1178
MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 1181
TRAVEL SPEED IS SLOW 1184
ONE OF TRACKS DOES NOT RUN 1187
TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST .1189
MACHINE DOES NOT SWING TO RIGHT OR LEFT .1190
MACHINE SWINGS ONLY IN ONE DIRECTION 1192
SWING ACCELERATION OR SWING SPEED IS LOW IN TWO DIRECTIONS OF RIGHT AND LEFT 1193
SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION 1194
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (RIGHT AND LEFT) .1195
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (ONLY ONE DIRECTION) .1196
SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWING OPERATION .1197
LARGE UNUSUAL NOISE IS MADE WHEN UPPER STRUCTURE STOPS SWING OPERATION 1198
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 1199
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) .1200
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT ROTATE) .1201
UNUSUAL NOISE IS HEARD FROM AROUND FAN 1202
TROUBLESHOOTING OF ENGINE (S-MODE) 1203
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1203
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1204
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT 1205
FUEL IS INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1206
ENGINE STARTABILITY IS UNSATISFACTORY .1207
ENGINE DOES NOT PICK UP SMOOTHLY 1209
ENGINE STOPS DURING OPERATION .1211
ENGINE RUNNING IS UNSTABLE 1213
OUTPUT IS NOT SUFFICIENT (POWER IS LOW) .1214
EXHAUST IS BLACK 1216
ENGINE OIL CONSUMPTION IS EXCESSIVE .1218
ENGINE OIL BECOMES CONTAMINATED QUICKLY .1219
FUEL CONSUMPTION IS EXCESSIVE .1220
OIL MIXES INTO COOLANT (OR COOLANT SPURTS BACK AND COOLANT LEVEL DOES DOWN) .1221
ENGINE OIL PRESSURE FALLS .1222
FUEL MIXES INTO ENGINE OIL 1223
WATER MIXES INTO ENGINE OIL (MILKY) .1224
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEAT) .1225
THERE IS AN UNUSUAL NOISE .1226
VIBRATION IS EXCESSIVE 1228
AIR CANNOT BE BLED FROM FUEL CIRCUIT 1229
50 DISASSEMBLY AND ASSEMBLY .1231
CONTENTS 1232
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1236
HOW TO READ THIS MANUAL .1236
COATING MATERIALS LIST 1238
SPECIAL TOOLS LIST 1242
SKETCHES OF SPECIAL TOOLS .1259
PREPARATION .1262
DRAIN AND ADD COOLANT .1262
DRAIN COOLANT .1263
ADD COOLANT .1264
DRAIN AND ADD HYDRAULIC OIL .1265
DRAIN HYDRAULIC OIL .1266
ADD HYDRAULIC OIL .1267
DRAIN AND ADD FUEL 1269
DRAIN FUEL 1270
ADD FUEL 1270
COLLECT AND REFILL REFRIGERANT 1272
COLLECT REFRIGERANT .1272
REFILL REFRIGERANT 1273
ENGINE AND COOLING SYSTEM .1274
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .1274
REMOVE SUPPLY PUMP ASSEMBLY .1275
INSTALL SUPPLY PUMP ASSEMBLY 1285
REMOVE AND INSTALL INJECTOR ASSEMBLY 1294
REMOVE INJECTOR ASSEMBLY 1295
INSTALL INJECTOR ASSEMBLY .1299
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .1306
REMOVE CYLINDER HEAD ASSEMBLY .1308
INSTALL CYLINDER HEAD ASSEMBLY 1337
REMOVE AND INSTALL EGR VALVE ASSEMBLY .1377
REMOVE EGR VALVE ASSEMBLY .1378
INSTALL EGR VALVE ASSEMBLY 1379
REMOVE AND INSTALL EGR COOLER ASSEMBLY 1382
REMOVE EGR COOLER ASSEMBLY 1383
INSTALL EGR COOLER ASSEMBLY .1389
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 1395
REMOVE STARTING MOTOR ASSEMBLY 1396
INSTALL STARTING MOTOR ASSEMBLY .1398
REMOVE AND INSTALL FAN BELT .1401
REMOVE FAN BELT .1402
INSTALL FAN BELT 1404
REMOVE AND INSTALL AUTO-TENSIONER .1406
REMOVE AUTO-TENSIONER .1406
INSTALL AUTO-TENSIONER 1407
REMOVE AND INSTALL EXPANSION TANK ASSEMBLY 1408
REMOVE EXPANSION TANK ASSEMBLY 1409
INSTALL EXPANSION TANK ASSEMBLY .1413
REMOVE AND INSTALL RADIATOR ASSEMBLY 1418
REMOVE RADIATOR ASSEMBLY 1419
INSTALL RADIATOR ASSEMBLY .1422
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1425
REMOVE HYDRAULIC OIL COOLER ASSEMBLY 1426
INSTALL HYDRAULIC OIL COOLER ASSEMBLY .1435
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .1444
REMOVE AFTERCOOLER ASSEMBLY .1445
INSTALL AFTERCOOLER ASSEMBLY 1447
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 1450
REMOVE ENGINE AND MAIN PUMP ASSEMBLY 1452
INSTALL ENGINE AND MAIN PUMP ASSEMBLY .1475
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 1500
REMOVE ENGINE FRONT OIL SEAL 1501
INSTALL ENGINE FRONT OIL SEAL .1502
REMOVE AND INSTALL ENGINE REAR OIL SEAL .1505
REMOVE ENGINE REAR OIL SEAL .1506
INSTALL ENGINE REAR OIL SEAL 1508
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .1512
REMOVE FUEL COOLER ASSEMBLY .1513
INSTALL FUEL COOLER ASSEMBLY 1513
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .1515
REMOVE ENGINE HOOD ASSEMBLY .1515
INSTALL ENGINE HOOD ASSEMBLY 1518
REMOVE AND INSTALL KDOC ASSEMBLY 1521
REMOVE KDOC ASSEMBLY 1522
INSTALL KDOC ASSEMBLY .1526
REMOVE AND INSTALL FUEL TANK ASSEMBLY .1531
REMOVE FUEL TANK ASSEMBLY .1532
INSTALL FUEL TANK ASSEMBLY 1537
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .1542
REMOVE AIR CLEANER ASSEMBLY .1543
INSTALL AIR CLEANER ASSEMBLY 1544
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 1547
REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY 1548
INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .1550
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .1552
REMOVE AIR CONDITIONER CONDENSER ASSEMBLY .1553
INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 1555
POWER TRAIN .1557
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1557
REMOVE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1558
INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .1561
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1565
DISASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .1574
ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1594
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .1613
REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY .1614
INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 1619
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .1624
DISASSEMBLE SWING MACHINERY ASSEMBLY 1625
ASSEMBLE SWING MACHINERY ASSEMBLY .1630
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 1636
REMOVE SWING CIRCLE ASSEMBLY 1636
INSTALL SWING CIRCLE ASSEMBLY .1637
UNDERCARRIAGE AND FRAME .1638
SEPARATE AND CONNECT TRACK ASSEMBLY .1638
SEPARATE TRACK ASSEMBLY .1639
INSTALL TRACK ASSEMBLY 1639
REMOVE AND INSTALL SPROCKET .1641
REMOVE SPROCKET .1641
INSTALL SPROCKET 1642
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .1643
REMOVE IDLER AND IDLER CUSHION ASSEMBLY .1643
INSTALL IDLER AND IDLER CUSHION ASSEMBLY 1644
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .1645
DISASSEMBLE IDLER ASSEMBLY 1645
ASSEMBLE IDLER ASSEMBLY .1646
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 1649
DISASSEMBLE IDLER CUSHION ASSEMBLY 1649
ASSEMBLE IDLER CUSHION ASSEMBLY .1650
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 1652
DISASSEMBLE TRACK ROLLER ASSEMBLY .1652
ASSEMBLE TRACK ROLLER ASSEMBLY 1654
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .1657
REMOVE REVOLVING FRAME ASSEMBLY .1658
INSTALL REVOLVING FRAME ASSEMBLY 1664
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .1670
REMOVE COUNTERWEIGHT ASSEMBLY .1671
INSTALL COUNTERWEIGHT ASSEMBLY 1675
HYDRAULIC SYSTEM 1680
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .1680
REMOVE CENTER SWIVEL JOINT ASSEMBLY .1681
INSTALL CENTER SWIVEL JOINT ASSEMBLY 1686
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .1692
DISASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 1692
ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .1693
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 1694
REMOVE HYDRAULIC TANK ASSEMBLY 1695
INSTALL HYDRAULIC TANK ASSEMBLY .1699
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .1703
REMOVE MAIN PUMP ASSEMBLY .1704
INSTALL MAIN PUMP ASSEMBLY 1713
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .1722
REMOVE CONTROL VALVE ASSEMBLY .1724
INSTALL CONTROL VALVE ASSEMBLY 1746
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .1768
ASSEMBLE CONTROL VALVE ASSEMBLY .1768
REPLACE PRESSURE REDUCING VALVE CARTRIDGE ASSEMBLY 1770
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 1773
DISASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY .1773
ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 1774
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 1776
DISASSEMBLE TRAVEL PPC VALVE ASSEMBLY .1776
ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 1777
WORK EQUIPMENT 1779
REMOVE AND INSTALL BLADE ASSEMBLY .1779
REMOVE BLADE ASSEMBLY .1780
INSTALL BLADE ASSEMBLY 1782
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 1785
REMOVE WORK EQUIPMENT ASSEMBLY 1787
INSTALL WORK EQUIPMENT ASSEMBLY .1791
REMOVE AND INSTALL BOOM SWING BRACKET .1796
REMOVE BOOM SWING BRACKET .1797
INSTALL BOOM SWING BRACKET 1800
REMOVE AND INSTALL BOOM ANTI-DROP VALVE ASSEMBLY 1804
REMOVE BOOM ANTI-DROP VALVE ASSEMBLY 1805
INSTALL BOOM ANTI-DROP VALVE ASSEMBLY .1808
REMOVE AND INSTALL ARM ANTI-DROP VALVE ASSEMBLY .1811
REMOVE ARM ANTI-DROP VALVE ASSEMBLY .1812
INSTALL ARM ANTI-DROP VALVE ASSEMBLY 1815
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY .1817
DISASSEMBLE ANTI-DROP VALVE ASSEMBLY 1817
ASSEMBLE ANTI-DROP VALVE ASSEMBLY .1817
DISASSEMBLE AND ASSEMBLE BOOM CYLINDER ASSEMBLY .1818
DISASSEMBLE BOOM CYLINDER ASSEMBLY 1818
ASSEMBLE BOOM CYLINDER ASSEMBLY .1820
DISASSEMBLE AND ASSEMBLE ARM CYLINDER ASSEMBLY 1823
DISASSEMBLE ARM CYLINDER ASSEMBLY .1823
ASSEMBLE ARM CYLINDER ASSEMBLY 1825
DISASSEMBLE AND ASSEMBLE BUCKET CYLINDER ASSEMBLY .1829
DISASSEMBLE BUCKET CYLINDER ASSEMBLY 1829
ASSEMBLE BUCKET CYLINDER ASSEMBLY .1831
DISASSEMBLE AND ASSEMBLE BLADE CYLINDER ASSEMBLY 1834
DISASSEMBLE BLADE CYLINDER ASSEMBLY .1834
ASSEMBLE BLADE CYLINDER ASSEMBLY 1836
DISASSEMBLE AND ASSEMBLE SWING CYLINDER ASSEMBLY 1839
DISASSEMBLE SWING CYLINDER ASSEMBLY .1839
ASSEMBLE SWING CYLINDER ASSEMBLY 1841
CAB RELATED PARTS .1845
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY 1845
REMOVE OPERATOR CAB ASSEMBLY 1846
INSTALL OPERATOR CAB ASSEMBLY .1862
REMOVE AND INSTALL OPERATOR’S CAB DOOR 1877
INSTALL OPERATOR’S CAB DOOR .1878
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .1882
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 1883
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 1884
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 1893
REMOVE FRONT WINDOW ASSEMBLY 1893
INSTALL FRONT WINDOW ASSEMBLY .1895
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .1897
REMOVE FLOOR FRAME ASSEMBLY .1898
INSTALL FLOOR FRAME ASSEMBLY 1907
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 1917
REMOVE AIR CONDITIONER UNIT ASSEMBLY 1918
INSTALL AIR CONDITIONER UNIT ASSEMBLY .1931
REMOVE AND INSTALL OPERATOR’S SEAT 1944
REMOVE OPERATOR’S SEAT 1945
INSTALL OPERATOR’S SEAT .1946
REMOVE AND INSTALL SEATBELT .1949
REMOVE SEATBELT .1950
INSTALL SEATBELT 1950
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .1951
REMOVE FRONT WIPER ASSEMBLY .1952
INSTALL FRONT WIPER ASSEMBLY 1958
ELECTRICAL SYSTEM .1964
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .1964
REMOVE ENGINE CONTROLLER ASSEMBLY .1965
INSTALL ENGINE CONTROLLER ASSEMBLY 1967
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .1970
REMOVE PUMP CONTROLLER ASSEMBLY .1971
INSTALL PUMP CONTROLLER ASSEMBLY 1973
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .1975
REMOVE MACHINE MONITOR ASSEMBLY .1976
INSTALL MACHINE MONITOR ASSEMBLY 1981
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .1986
REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR .1987
INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 1988
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER 1989
REMOVE GATEWAY FUNCTION CONTROLLER 1990
INSTALL GATEWAY FUNCTION CONTROLLER .1992
60 MAINTENANCE STANDARD .1995
CONTENTS 1996
ENGINE AND COOLING SYSTEM .1997
MAINTENANCE STANDARD OF ENGINE MOUNT 1997
MAINTENANCE STANDARD OF PTO .1998
MAINTENANCE STANDARD OF COOLING SYSTEM 1999
POWER TRAIN .2000
MAINTENANCE STANDARD OF SWING CIRCLE 2000
MAINTENANCE STANDARD OF SWING MACHINERY .2002
MAINTENANCE STANDARD OF SPROCKET 2004
UNDERCARRIAGE AND FRAME .2005
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2005
MAINTENANCE STANDARD OF IDLER .2007
MAINTENANCE STANDARD OF TRACK ROLLER 2009
MAINTENANCE STANDARD OF CARRIER ROLLER 2010
MAINTENANCE STANDARD OF TRACK SHOE 2011
MAINTENANCE STANDARD OF TRIPLE SHOE .2014
MAINTENANCE STANDARD FOR RUBBER SHOE 2015
HYDRAULIC SYSTEM 2016
MAINTENANCE STANDARD OF HYDRAULIC TANK 2016
MAINTENANCE STANDARD OF MAIN PUMP .2017
MAINTENANCE STANDARD OF SERVO VALVE OF MAIN PUMP 2019
MAINTENANCE STANDARD OF PC-EPC VALVE 2020
MAINTENANCE STANDARD OF SWING MOTOR .2021
MAINTENANCE STANDARD OF TRAVEL MOTOR 2023
MAINTENANCE STANDARD OF CONTROL VALVE .2024
MAINTENANCE STANDARD OF ANTI-DROP VALVE OF BOOM .2035
MAINTENANCE STANDARD OF ANTI-DROP VALVE OF ARM 2037
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2039
MAINTENANCE STANDARD OF BLADE PPC VALVE .2042
MAINTENANCE STANDARD OF BOOM SWING PPC VALVE 2044
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2046
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2049
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2050
MAINTENANCE STANDARD OF SOLENOID VALVE 2052
MAINTENANCE STANDARD OF ATTACHMENT OIL FLOW ADJUSTER EPC VALVE 2053
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) 2054
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2055
WORK EQUIPMENT 2056
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2056
DIMENSIONS OF ARM .2062
DIMENSIONS OF BUCKET 2064
MAINTENANCE STANDARD OF BOOM CYLINDER .2066
MAINTENANCE STANDARD OF ARM CYLINDER 2067
MAINTENANCE STANDARD OF BUCKET CYLINDER .2068
MAINTENANCE STANDARD OF BOOM SWING CYLINDER .2069
MAINTENANCE STANDARD OF BLADE CYLINDER 2070
80 APPENDIX .2071
CONTENTS 2072
AIR CONDITIONER SYSTEM 2074
PRECAUTIONS FOR REFRIGERANT .2074
AIR CONDITIONER COMPONENT .2075
SPECIFICATIONS OF AIR CONDITIONER .2077
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2078
OUTLINE OF REFRIGERATION CYCLE 2079
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2081
AIR CONDITIONER UNIT 2081
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2081
FUNCTION OF AIR CONDITIONER UNIT 2083
COMPONENT PARTS OF AIR CONDITIONER UNIT .2084
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2085
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2085
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2085
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2086
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2087
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2087
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2087
FUNCTION OF DUAL PRESSURE SWITCH 2088
AIR CONDITIONER CONTROLLER 2089
STRUCTURE OF AIR CONDITIONER CONTROLLER .2089
COMPRESSOR 2090
STRUCTURE OF COMPRESSOR .2090
SPECIFICATIONS OF COMPRESSOR 2090
FUNCTION OF COMPRESSOR 2090
CONDENSER .2091
STRUCTURE OF CONDENSER 2091
SPECIFICATIONS OF CONDENSER .2091
FUNCTION OF CONDENSER .2091
RECEIVER DRIER 2092
STRUCTURE OF RECEIVER DRIER .2092
SPECIFICATIONS OF RECEIVER DRIER 2092
FUNCTION OF RECEIVER DRIER 2092
SENSORS FOR AIR CONDITIONER SYSTEM 2093
STRUCTURE OF SUNLIGHT SENSOR 2093
FUNCTION OF SUNLIGHT SENSOR .2093
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2093
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2093
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2095
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2097
AIR CONDITIONER SYSTEM DIAGRAM 2099
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2100
FUNCTION OF AIR CONDITIONER CONTROLLER 2101
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2102
TESTING AIR LEAKAGE (DUCT) 2108
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2108
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2109
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2110
TEST VENT (MODE) CHANGEOVER .2111
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2111
TESTING FRESH/RECIRC AIR CHANGEOVER .2112
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2112
TEST SUNLIGHT SENSOR 2113
METHOD FOR TESTING SUNLIGHT SENSOR 2113
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2114
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2114
TEST RELAYS .2116
METHOD FOR TESTING RELAYS .2116
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2117
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2118
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2121
FAILURE CODE [879AKA] .2123
FAILURE CODE [879AKB] .2124
FAILURE CODE [879BKA] .2125
FAILURE CODE [879BKB] .2127
FAILURE CODE [879CKA] .2129
FAILURE CODE [879CKB] .2130
FAILURE CODE [879DKZ] .2131
FAILURE CODE [879EMC] .2133
FAILURE CODE [879FMC] .2134
FAILURE CODE [879GKX] .2135
TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2137
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2139
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2142
TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2144
TROUBLESHOOTING USING GAUGE PRESSURE 2146
CONNECTION OF SERVICE TOOL 2149
METHOD FOR CONNECTING SERVICE TOOL 2149
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2151
HANDLE COMPRESSOR OIL .2153
90 CIRCUIT DIAGRAMS .2155
CONTENTS 2156
HOW TO READ THE CODES FOR ELECTRIC CABLE 2157
HYDRAULIC CIRCUIT DIAGRAM .2161
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2161
HYDRAULIC CIRCUIT DIAGRAM .2165
HYDRAULIC CIRCUIT DIAGRAM (AT BOOM RAISE OPERATION) .2167
HYDRAULIC CIRCUIT DIAGRAM (AT LEFT SWING OPERATION) .2169
HYDRAULIC CIRCUIT DIAGRAM (AT BOOM RAISE AND LEFT SWING OPERATION) 2171
ELECTRICAL CIRCUIT DIAGRAM 2173
SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM 2173
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2177
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2179
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2181
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2183
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2185
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2187
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2189
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2191
INDEX 2193

DESCRIPTION:

Komatsu Bulldozer PC88MR-11 Shop Manual SEN06843-C5 – PDF DOWNLOAD

• SERIAL NUMBERS C40001 and up

G.B 27/12/24