Komatsu Hydraulic Excavator PC1250-11,PC1250LC-11,PC1250SP-11 Shop Manual PDF

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Komatsu Hydraulic Excavator PC1250-11,PC1250LC-11,PC1250SP-11 Shop Manual SEN06624-02 – PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC1250-11,PC1250LC-11,PC1250SP-11 Shop Manual SEN06624-02 – PDF DOWNLOAD

Language : English
Pages : 2843
Downloadable : Yes
File Type : PDF

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Komatsu Hydraulic Excavator PC1250-11,PC1250LC-11,PC1250SP-11 Shop Manual SEN06624-02 – PDF DOWNLOAD

• SERIAL NUMBERS
  PC1250- 50001            and up
  PC1250LC- 50001      and up
  PC1250SP- 50001      and up

COVER . 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 22
FOREWORD, SAFETY, BASIC INFORMATION 28
HOW TO READ THE SHOP MANUAL 28
SAFETY NOTICE FOR OPERATION 30
PRECAUTIONS TO PREVENT FIRE 38
ACTIONS IF FIRE OCCURS . 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS . 41
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT . 42
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 45
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 51
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT . 53
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT . 54
PRACTICAL USE OF KOMTRAX . 55
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 57
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 58
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS . 60
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 64
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 65
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE . 70
HOW TO READ ELECTRICAL WIRE CODE . 71
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 75
STANDARD TIGHTENING TORQUE TABLE . 78
CONVERSION TABLE . 85
01 SPECIFICATIONS 91
CONTENTS . 92
ABBREVIATION LIST 93
SPECIFICATIONS . 99
SPECIFICATION DRAWING 99
SPECIFICATION DRAWING: PC1250-11 . 99
SPECIFICATION DRAWING: PC1250SP-11 . 100
SPECIFICATION DRAWING: PC1250LC-11 . 101
WORKING RANGE DRAWINGS . 102
WORKING RANGE: PC1250-11 . 102
WORKING RANGE: PC1250SP-11 . 103
WORKING RANGE: PC1250LC-11 . 104
SPECIFICATIONS . 105
SPECIFICATIONS: PC1250-11 105
SPECIFICATIONS: PC1250SP-11 108
SPECIFICATIONS: PC1250LC-11 111
WEIGHT TABLE . 114
WEIGHT TABLE: PC1250-11 114
WEIGHT TABLE: PC1250SP-11 116
WEIGHT TABLE: PC1250LC-11 118
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) 120
USE OF FUEL, COOLANT AND LUBRICANTS TO ACCORDING TO AMBIENT TEMPERATURE 120
10 STRUCTURE AND FUNCTION 123
CONTENTS . 124
ABBREVIATION LIST 128
BOOT-UP SYSTEM . 134
LAYOUT DRAWING OF BOOT-UP SYSTEM . 134
SYSTEM OPERATING LAMP SYSTEM . 135
SYSTEM OPERATING LAMP SYSTEM DIAGRAM . 135
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM . 135
BATTERY DISCONNECT SWITCH 136
FUNCTION OF BATTERY DISCONNECT SWITCH 136
ENGINE SYSTEM 137
LAYOUT DRAWING OF ENGINE SYSTEM 137
FUNCTION OF ENGINE SYSTEM 139
ENGINE CONTROL SYSTEM 140
ENGINE CONTROL SYSTEM DIAGRAM 140
FUNCTION OF ENGINE CONTROL SYSTEM 140
AUTO-DECELERATION SYSTEM . 143
AUTO-DECELERATION SYSTEM DIAGRAM . 143
FUNCTION OF AUTO-DECELERATION SYSTEM . 143
OPERATION OF AUTO-DECELERATION SYSTEM 144
AUTOMATIC LOW IDLE SYSTEM 145
AUTOMATIC LOW IDLE SYSTEM DIAGRAM 145
FUNCTION OF AUTOMATIC LOW IDLE SYSTEM 145
OPERATION OF AUTOMATIC LOW IDLE SYSTEM . 146
ENGINE AUTOMATIC WARM-UP SYSTEM 147
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 147
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 148
OVERHEAT PREVENTION SYSTEM . 149
OVERHEAT PREVENTION SYSTEM DIAGRAM . 149
FUNCTION OF OVERHEAT PREVENTION SYSTEM . 149
TURBOCHARGER PROTECTION SYSTEM . 150
TURBOCHARGER PROTECTION SYSTEM DIAGRAM . 150
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM . 150
AUTOMATIC IDLE STOP SYSTEM . 151
AUTOMATIC IDLE STOP SYSTEM DIAGRAM . 151
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM . 151
COMPONENT PARTS OF ENGINE SYSTEM . 154
PTO 154
VGT 156
EGR SYSTEM . 160
EGR VALVE 162
EGR COOLER . 164
KCCV SYSTEM 165
KCCV VENTILATOR 167
KDPF . 169
COOLING SYSTEM . 173
LAYOUT DRAWING OF COOLING SYSTEM . 173
SPECIFICATIONS OF COOLING SYSTEM . 174
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 175
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 175
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 176
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 177
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 177
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 177
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN . 179
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN . 179
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN . 179
COMPONENT PARTS OF COOLING SYSTEM 180
COOLING FAN PUMP . 180
COOLING FAN MOTOR 195
CONTROL SYSTEM . 202
LAYOUT DRAWING OF CONTROL SYSTEM . 202
MACHINE MONITOR SYSTEM . 204
MACHINE MONITOR SYSTEM DIAGRAM . 204
KomVision SYSTEM . 205
LAYOUT DRAWING OF KOMVISION SYSTEM . 205
KomVision SYSTEM DIAGRAM . 207
FUNCTION OF KomVision SYSTEM . 208
KOMTRAX Plus SYSTEM 210
KOMTRAX Plus SYSTEM DIAGRAM 210
FUNCTION OF KOMTRAX Plus SYSTEM 211
COMPONENT PARTS OF CONTROL SYSTEM 215
MACHINE MONITOR 215
KomVision CONTROLLER . 230
KomVision CAMERA . 234
KOMTRAX TERMINAL . 235
KOMTRAX Plus CONTROLLER 237
WIRELESS LAN UNIT 242
PUMP CONTROLLER 243
RESISTOR FOR TVC VALVE . 248
CAN TERMINATING RESISTOR . 249
ENGINE CONTROLLER 250
FUEL CONTROL DIAL 264
FUEL FEED PUMP . 265
FUEL FEED PUMP SWITCH 266
HYDRAULIC SYSTEM . 267
LAYOUT DRAWING OF HYDRAULIC SYSTEM . 267
OLSS . 270
STRUCTURE OF OLSS 270
FUNCTION OF OLSS . 271
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 272
ENGINE AND PUMP COMBINED CONTROL SYSTEM 283
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 283
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 285
COMPONENT PARTS OF HYDRAULIC SYSTEM 287
HYDRAULIC TANK . 287
MAIN PUMP 289
CONTROL VALVE 334
VARIABLE BACK PRESSURE VALVE . 357
WORK EQUIPMENT SYSTEM 360
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 360
MACHINE PUSH-UP SYSTEM . 366
MACHINE PUSH-UP SYSTEM DIAGRAM . 366
FUNCTION OF MACHINE PUSH-UP SYSTEM . 367
HEAVY LIFT SYSTEM 368
HEAVY LIFT SYSTEM DIAGRAM 368
FUNCTION OF HEAVY LIFT SYSTEM 370
OPERATION OF HEAVY LIFT SYSTEM . 370
BOOM SHOCKLESS CONTROL SYSTEM 371
BOOM SHOCKLESS CONTROL FUNCTION SYSTEM DIAGRAM . 371
FUNCTION OF BOOM SHOCKLESS CONTROL SYSTEM 371
OPERATION OF BOOM SHOCKLESS CONTROL SYSTEM . 371
PPC LOCK SYSTEM 373
PPC LOCK SYSTEM DIAGRAM 373
FUNCTION OF PPC LOCK SYSTEM 373
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 374
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 374
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 374
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 374
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM . 376
WORK EQUIPMENT AND SWING PPC VALVE . 376
SOLENOID VALVE . 381
PILOT CIRCUIT ACCUMULATOR 384
SWING SYSTEM . 385
LAYOUT DRAWING OF SWING SYSTEM . 385
SWING CONTROL SYSTEM DIAGRAM . 388
FUNCTION OF SWING CONTROL SYSTEM . 389
SWING PRIORITY SYSTEM DIAGRAM 392
FUNCTION OF SWING PRIORITY SYSTEM 394
SWING COMPENSATION SYSTEM DIAGRAM 395
FUNCTION OF SWING COMPENSATION SYSTEM 395
OPERATION OF SWING COMPENSATION SYSTEM . 395
COMPONENT PARTS OF SWING SYSTEM 396
SWING MOTOR 396
SWING MACHINERY 408
SWING CIRCLE . 410
TRAVEL SYSTEM 411
LAYOUT DRAWING OF TRAVEL SYSTEM 411
TRAVEL CONTROL SYSTEM DIAGRAM 415
FUNCTION OF TRAVEL CONTROL SYSTEM 417
COMPONENT PARTS OF TRAVEL SYSTEM . 418
TRAVEL MOTOR . 418
FINAL DRIVE 429
TRAVEL PPC VALVE . 431
CENTER SWIVEL JOINT 435
PNEUMATIC SYSTEM . 437
LAYOUT DRAWING OF PNEUMATIC SYSTEM . 437
PNEUMATIC SYSTEM DIAGRAM . 438
FUNCTION OF PNEUMATIC SYSTEM . 438
COMPONENT PARTS OF PNEUMATIC SYSTEM 439
AIR GOVERNOR . 439
AIR TANK . 440
HORN VALVE . 442
GREASE PUMP 443
LIFTING SYSTEM . 444
HYDRAULICALLY OPERATED STAIRWAY SYSTEM . 444
LAYOUT DRAWING OF HYDRAULICALLY OPERATED STAIRWAY SYSTEM . 444
HYDRAULICALLY OPERATED STAIRWAY SYSTEM DIAGRAM . 445
FUNCTION OF HYDRAULICALLY OPERATED STAIRWAY SYSTEM . 446
COMPONENT PARTS OF LIFTING SYSTEM 447
SWITCH BOX . 447
PROXIMITY SWITCH PART 448
CONTROL VALVE ASSEMBLY . 449
UNDERCARRIAGE AND FRAME 450
LAYOUT DRAWING OF UNDERCARRIAGE 450
SPECIFICATIONS OF UNDERCARRIAGE 451
WORK EQUIPMENT . 452
STRUCTURE OF WORK EQUIPMENT 452
FUNCTION OF WORK EQUIPMENT . 452
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM . 453
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM . 453
BUCKET CLEARANCE ADJUSTMENT SHIM . 453
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM . 453
CAB AND ITS ATTACHMENTS 454
CAB 454
STRUCTURE OF CAB . 454
CAB MOUNT 455
STRUCTURE OF CAB MOUNT . 455
FUNCTION OF CAB MOUNT 455
CAB TIPPING STOPPER 456
STRUCTURE OF CAB TIPPING STOPPER . 456
FUNCTION OF CAB TIPPING STOPPER 456
20 STANDARD VALUE TABLE 457
CONTENTS . 458
ABBREVIATION LIST 459
STANDARD VALUE TABLE FOR ENGINE 465
STANDARD VALUE TABLE FOR ENGINE: PC1250-11 . 465
STANDARD VALUE TABLE FOR ENGINE: PC1250SP-11 . 470
STANDARD VALUE TABLE FOR ENGINE: PC1250LC-11 . 475
STANDARD VALUE TABLE FOR MACHINE . 480
STANDARD VALUE TABLE FOR MACHINE: PC1250-11 480
STANDARD VALUE TABLE FOR MACHINE: PC1250SP-11 494
STANDARD VALUE TABLE FOR MACHINE: PC1250LC-11 508
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 522
30 TESTING AND ADJUSTING . 527
CONTENTS . 528
ABBREVIATION LIST 532
RELATED INFORMATION ON TESTING AND ADJUSTING . 538
TOOLS FOR TESTING AND ADJUSTING 538
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 545
ENGINE AND COOLING SYSTEM 546
TEST ENGINE SPEED 546
METHOD FOR TESTING ENGINE SPEED 546
TEST BOOST PRESSURE 549
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR . 549
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL 550
TEST EXHAUST GAS TEMPERATURE . 551
METHOD FOR TESTING EXHAUST GAS TEMPERATURE . 551
TEST EXHAUST GAS COLOR . 553
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 553
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 554
TEST AND ADJUST VALVE CLEARANCE 557
METHOD FOR TESTING VALVE CLEARANCE . 557
METHOD FOR ADJUSTING VALVE CLEARANCE . 558
TEST COMPRESSION PRESSURE 560
METHOD FOR TESTING COMPRESSION PRESSURE 560
TEST BLOWBY PRESSURE . 564
METHOD FOR TESTING BLOWBY PRESSURE . 564
TEST ENGINE OIL PRESSURE . 566
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 566
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL . 566
TEST EGR VALVE AND VGT OIL PRESSURE 568
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 568
TEST FUEL PRESSURE . 569
METHOD FOR TESTING FUEL PRESSURE . 569
TEST FUEL RETURN RATE AND LEAKAGE 571
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 572
BLEED AIR FROM FUEL SYSTEM . 576
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM . 576
TEST FUEL CIRCUIT FOR LEAKAGE 578
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 578
TEST SUPPLY PUMP . 580
METHOD FOR TESTING SUPPLY PUMP . 580
HANDLE CYLINDER CUT-OUT MODE OPERATION . 583
TEST ALTERNATOR 584
METHOD FOR TESTING ALTERNATOR 584
HANDLE NO-INJECTION CRANKING OPERATION . 585
CLEAN FUEL DOSER . 586
METHOD FOR CLEANING FUEL DOSER . 586
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER . 589
METHOD FOR WRITING INJECTOR COMPENSATION VALUE . 589
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 595
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 595
POWER TRAIN 596
TEST SWING CIRCLE BEARING CLEARANCE 596
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 596
UNDERCARRIAGE AND FRAME 598
TEST SPROCKET WEAR . 598
METHOD FOR TESTING SPROCKET WEAR . 598
TEST AND ADJUST TRACK TENSION 599
METHOD FOR TESTING TRACK TENSION . 599
METHOD FOR ADJUSTING TRACK TENSION . 599
HYDRAULIC SYSTEM . 601
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM . 601
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT . 601
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT . 604
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 604
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 606
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 609
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 616
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 620
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT . 620
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT . 621
TEST AND ADJUST PISTON PUMP CONTROL OIL PRESSURE . 622
METHOD FOR TESTING TVC VALVE OUTLET PRESSURE . 622
METHOD FOR TESTING CO VALVE + NC VALVE OUTLET PRESSURE OF NO. 1 AND NO. 2 PUMPS 623
METHOD FOR TESTING CO VALVE + NC VALVE OUTLET PRESSURE OF NO. 3 PUMP . 624
METHOD FOR TESTING JET SENSOR OUTLET PRESSURE OF 4-SPOOL CONTROL VALVE ON THE RIGHT SIDE . 625
METHOD FOR TESTING JET SENSOR OUTLET PRESSURE OF 4-SPOOL CONTROL VALVE FOR SWING . 626
METHOD FOR ADJUSTING TVC VALVE . 627
METHOD FOR ADJUSTING CO VALVE + NC VALVE OF NO. 1 AND NO. 2 PUMPS 628
METHOD FOR ADJUSTING CO VALVE + NC VALVE OF NO. 3 PUMP . 629
METHOD FOR ADJUSTING JET SENSOR OF 4-SPOOL CONTROL VALVE ON THE RIGHT SIDE AND 5-SPOOL CONTROL VALVE ON THE LEFT SIDE 630
METHOD FOR ADJUSTING JET SENSOR OF 4-SPOOL CONTROL VALVE FOR SWING . 630
TEST SERVO PISTON STROKE . 631
METHOD FOR TESTING SERVO PISTON STROKE . 631
TEST OUTLET PRESSURE OF SOLENOID VALVE . 633
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE . 633
OPERATING CONDITION OF SOLENOID VALVE 635
TEST PPC VALVE OUTLET PRESSURE . 638
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE . 638
TEST SWING PPC SHUTTLE VALVE OUTLET PRESSURE . 640
METHOD FOR TESTING SWING PPC SHUTTLE VALVE OUTLET PRESSURE . 640
ADJUST WORK EQUIPMENT AND SWING PPC VALVES . 642
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES . 642
TEST TRAVEL DEVIATION 643
METHOD FOR TESTING TRAVEL DEVIATION 643
TEST COOLING FAN SPEED . 644
METHOD FOR TESTING COOLING FAN SPEED . 644
TEST AFTERCOOLER FAN SPEED . 645
METHOD FOR TESTING AFTERCOOLER FAN SPEED . 645
TEST OIL PRESSURE IN FAN PUMP CIRCUIT 646
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT 646
TEST AFTERCOOLER FAN PUMP CIRCUIT OIL PRESSURE . 647
METHOD FOR TESTING AFTERCOOLER FAN PUMP CIRCUIT OIL PRESSURE . 647
TEST FAN PUMP EPC ELECTRIC CURRENT . 648
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT . 648
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE . 649
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE . 649
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT . 650
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 650
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER . 650
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 651
TEST OIL LEAKAGE . 652
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 652
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER . 653
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 653
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 654
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR . 654
METHOD FOR TESTING OIL LEAKAGE OF SWIVEL JOINT . 655
BLEED AIR FROM HYDRAULIC CIRCUIT . 658
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT . 659
CAB AND ITS ATTACHMENTS 663
TEST CAB TIPPING STOPPER . 663
METHOD FOR TESTING CAB TIPPING STOPPER . 663
METHOD FOR ADJUSTING MIRRORS . 664
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 664
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 665
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) . 666
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) . 667
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (C) . 668
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (C) . 669
ELECTRICAL SYSTEM 671
SET AND OPERATE MACHINE MONITOR 671
OPERATOR MODE 675
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 675
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN . 675
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 676
CHECKING FUNCTION OF SERVICE METER . 676
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 676
SERVICE MODE . 679
METHOD FOR OPERATING SERVICE MODE 679
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION . 681
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION . 685
ABNORMALITY RECORD MENU 695
METHOD FOR CONFIRMING MAINTENANCE RECORD . 699
METHOD FOR OPERATING MAINTENANCE MODE SETTING 700
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 704
DEFAULT MENU . 706
DIAGNOSTIC TESTS MENU 714
ADJUSTMENT MENU 724
METHOD FOR PERFORMING NO-INJECTION CRANKING 730
KOMTRAX SETTINGS MENU 733
METHOD FOR DISPLAYING SERVICE MESSAGE 735
METHOD FOR HANDLING SNAP SHOT 736
METHOD FOR STARTING UP KOMTRAX TERMINAL 738
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER . 743
METHOD FOR SETTING WITH DEFAULT SETTING OF KOMTRAX Plus CONTROLLER . 743
SETTING DEFAULT OF WIRELESS LAN MODEM 746
METHOD FOR SETTING DEFAULT OF WIRELESS LAN MODEM . 746
METHOD FOR CHECKING OF WIRELESS LAN MODEM COMMUNICATION 747
DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA . 748
METHOD FOR DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA 748
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED 751
METHOD FOR ADJUSTING WHEN KOMTRAX Plus CONTROLLER IS REPLACED 751
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED . 754
METHOD FOR ADJUSTING WHEN WIRELESS LAN MODEM IS REPLACED . 754
ADJUST KomVision CAMERA ANGLE 757
METHOD FOR ADJUSTING KomVision CAMERA ANGLE 758
ADJUST KomVision RELATED ITEMS . 760
SETTING OF KomVision (MAIN SETTING) 761
SETTING OF KomVision (CAMERA SETTING) 763
SETTING OF KomVision (CAMERA CALIBRATION) 764
KomVision screen – Check 12 m visibility . 777
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 780
HANDLE BATTERY DISCONNECT SWITCH . 781
TEST DIODES 782
METHOD FOR TESTING DIODE USING DIGITAL TESTER 782
METHOD FOR TESTING DIODE USING ANALOG TESTER . 782
Pm CLINIC 783
Pm CLINIC SERVICE 783
Pm CLINIC CHECK SHEET: PC1250-11 . 788
Pm CLINIC CHECK SHEET: PC1250SP-11 . 801
Pm CLINIC CHECK SHEET: PC1250LC-11 . 814
PERFORMING QUICK Pm 827
METHOD FOR PERFORMING QUICK Pm . 827
40 TROUBLESHOOTING . 833
CONTENTS . 834
ABBREVIATION LIST 845
RELATED INFORMATION ON TROUBLESHOOTING . 851
GENERAL TROUBLESHOOTING POINTS . 851
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEM . 852
SEQUENCE OF EVENTS IN TROUBLESHOOTING 859
CHECKS BEFORE TROUBLESHOOTING 861
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 863
WALK-AROUND CHECK 863
TESTING IN ACCORDANCE WITH TESTING PROCEDURE . 865
CHECK FUEL LEVEL AND TYPE 865
CHECK IMPURE INGREDIENT IN FUEL 866
CHECK FUEL PREFILTER . 866
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT . 867
FUEL PREFILTER CARTRIDGE – REPLACE . 867
TEST FUEL MAIN FILTER 868
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) . 870
CHECK COOLANT LEVEL (RESERVOIR TANK) . 871
CHECK CLOGGING OF AIR CLEANER 872
OUTER ELEMENT – CLEAN 872
ELEMENTS – REPLACE . 875
CHECK HYDRAULIC OIL LEVEL 875
CHECK HYDRAULIC OIL STRAINER . 877
CHECK HYDRAULIC FILTER . 878
CHECK OIL LEVEL IN SWING MACHINERY CASE 879
CHECK OIL LEVEL IN PTO CASE 881
CHECK PTO LUBRICATION FILTER STRAINER 881
CHECK OIL LEVEL IN FINAL DRIVE CASE 882
BLEED AIR FROM FUEL SYSTEM . 882
BLEED AIR FROM HYDRAULIC SYSTEM 882
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod . 882
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM . 888
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR . 888
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER . 888
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER . 888
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL 889
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX Plus CONTROLLER . 889
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER 889
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK 889
PROCEDURE FOR TESTING AND TROUBLESHOOTING 894
SYMPTOM AND TROUBLESHOOTING NUMBERS 897
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE . 902
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 904
CONNECTORS LIST AND LAYOUT . 907
CONNECTOR CONTACT IDENTIFICATION . 923
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 963
FUSE LOCATION TABLE 969
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 972
PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES [CA1883], [CB1883], [CA3135] AND [CB3135]) 976
FAILURE CODES TABLE 978
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 996
FAILURE CODE [879AKA] 996
FAILURE CODE [879AKB] 997
FAILURE CODE [879BKA] 998
FAILURE CODE [879BKB] 1000
FAILURE CODE [879CKA] 1002
FAILURE CODE [879CKB] 1003
FAILURE CODE [879DKZ] 1004
FAILURE CODE [879EMC] 1006
FAILURE CODE [879FMC] 1007
FAILURE CODE [879GKX] 1008
FAILURE CODE [8800ZG] 1010
FAILURE CODE [989L00] 1011
FAILURE CODE [989M00] 1012
FAILURE CODE [989N00] 1013
FAILURE CODE [A1U0N3] 1014
FAILURE CODE [A1U0N4] 1016
FAILURE CODE [AA10NX] 1018
FAILURE CODE [AB00KE] 1020
FAILURE CODE [AQ00N3] 1022
FAILURE CODE [AQ00N4] 1023
FAILURE CODE [AQ10N3] 1024
FAILURE CODE [B@BAZG] 1025
FAILURE CODE [B@BAZK] 1026
FAILURE CODE [B@BCNS] 1028
FAILURE CODE [B@BCZK] 1029
FAILURE CODE [B@CBNS] 1031
FAILURE CODE [B@HANS] 1033
FAILURE CODE [CA115] .1034
FAILURE CODE [CA122] .1038
FAILURE CODE [CA123] .1040
FAILURE CODE [CA131] .1042
FAILURE CODE [CA132] .1044
FAILURE CODE [CA135] .1046
FAILURE CODE [CA141] .1048
FAILURE CODE [CA144] .1050
FAILURE CODE [CA145] .1052
FAILURE CODE [CA153] .1054
FAILURE CODE [CA154] .1056
FAILURE CODE [CA187] .1058
FAILURE CODE [CA212] .1060
FAILURE CODE [CA213] .1062
FAILURE CODE [CA221] .1064
FAILURE CODE [CA222] .1066
FAILURE CODE [CA227] .1068
FAILURE CODE [CA234] .1070
FAILURE CODE [CA238] .1071
FAILURE CODE [CA239] .1073
FAILURE CODE [CA271] .1075
FAILURE CODE [CA272] .1077
FAILURE CODE [CA273] .1078
FAILURE CODE [CA274] .1080
FAILURE CODE [CA322] .1081
FAILURE CODE [CA323] .1083
FAILURE CODE [CA324] .1085
FAILURE CODE [CA325] .1087
FAILURE CODE [CA331] .1089
FAILURE CODE [CA332] .1091
FAILURE CODE [CA343] .1093
FAILURE CODE [CA351] .1095
FAILURE CODE [CA352] .1097
FAILURE CODE [CA356] .1099
FAILURE CODE [CA357] .1101
FAILURE CODE [CA386] .1103
FAILURE CODE [CA441] .1105
FAILURE CODE [CA442] .1107
FAILURE CODE [CA449] .1109
FAILURE CODE [CA451] .1110
FAILURE CODE [CA452] .1112
FAILURE CODE [CA515] .1114
FAILURE CODE [CA516] .1115
FAILURE CODE [CA553] .1116
FAILURE CODE [CA555] .1117
FAILURE CODE [CA556] .1119
FAILURE CODE [CA559] .1121
FAILURE CODE [CA595] .1126
FAILURE CODE [CA687] .1128
FAILURE CODE [CA689] .1130
FAILURE CODE [CA691] .1132
FAILURE CODE [CA692] .1134
FAILURE CODE [CA697] .1136
FAILURE CODE [CA698] .1137
FAILURE CODE [CA731] .1138
FAILURE CODE [CA778] .1142
FAILURE CODE [CA1117] 1144
FAILURE CODE [CA1135] 1146
FAILURE CODE [CA1257] 1149
FAILURE CODE [CA1664] 1150
FAILURE CODE [CA1691] 1152
FAILURE CODE [CA1695] 1155
FAILURE CODE [CA1696] 1157
FAILURE CODE [CA1843] 1159
FAILURE CODE [CA1844] 1161
FAILURE CODE [CA1879] 1163
FAILURE CODE [CA1881] 1165
FAILURE CODE [CA1883] 1167
FAILURE CODE [CA1921] 1170
FAILURE CODE [CA1922] 1172
FAILURE CODE [CA1923] 1176
FAILURE CODE [CA1924] 1178
FAILURE CODE [CA1925] 1180
FAILURE CODE [CA1927] 1182
FAILURE CODE [CA1928] 1184
FAILURE CODE [CA1942] 1186
FAILURE CODE [CA1963] 1188
FAILURE CODE [CA1977] 1192
FAILURE CODE [CA1993] 1194
FAILURE CODE [CA2185] 1196
FAILURE CODE [CA2186] 1197
FAILURE CODE [CA2249] 1199
FAILURE CODE [CA2265] 1204
FAILURE CODE [CA2266] 1206
FAILURE CODE [CA2271] 1208
FAILURE CODE [CA2272] 1210
FAILURE CODE [CA2349] 1212
FAILURE CODE [CA2353] 1214
FAILURE CODE [CA2357] 1216
FAILURE CODE [CA2381] 1219
FAILURE CODE [CA2382] 1221
FAILURE CODE [CA2383] 1223
FAILURE CODE [CA2386] 1225
FAILURE CODE [CA2387] 1227
FAILURE CODE [CA2555] 1230
FAILURE CODE [CA2556] 1232
FAILURE CODE [CA2637] 1234
FAILURE CODE [CA2639] 1237
FAILURE CODE [CA2732] 1239
FAILURE CODE [CA2733] 1241
FAILURE CODE [CA2741] 1243
FAILURE CODE [CA2765] 1244
FAILURE CODE [CA2777] 1245
FAILURE CODE [CA2878] 1247
FAILURE CODE [CA2881] 1250
FAILURE CODE [CA3133] 1253
FAILURE CODE [CA3134] 1255
FAILURE CODE [CA3135] 1257
FAILURE CODE [CA3167] 1260
FAILURE CODE [CA3251] 1263
FAILURE CODE [CA3253] 1265
FAILURE CODE [CA3254] 1270
FAILURE CODE [CA3255] 1273
FAILURE CODE [CA3256] 1276
FAILURE CODE [CA3311] 1278
FAILURE CODE [CA3312] 1280
FAILURE CODE [CA3313] 1282
FAILURE CODE [CA3314] 1283
FAILURE CODE [CA3315] 1284
FAILURE CODE [CA3316] 1287
FAILURE CODE [CA3317] 1288
FAILURE CODE [CA3318] 1289
FAILURE CODE [CA3319] 1292
FAILURE CODE [CA3321] 1293
FAILURE CODE [CA3322] 1294
FAILURE CODE [CA3419] 1297
FAILURE CODE [CA3421] 1299
FAILURE CODE [CA4151] 1301
FAILURE CODE [CA4158] 1304
FAILURE CODE [CA4161] 1305
FAILURE CODE [CA4162] 1307
FAILURE CODE [CA4163] 1309
FAILURE CODE [CA4259] 1311
FAILURE CODE [CA4952] 1313
FAILURE CODE [CA5383] 1315
FAILURE CODE [CB115] .1316
FAILURE CODE [CB187] .1319
FAILURE CODE [CB227] .1321
FAILURE CODE [CB238] .1322
FAILURE CODE [CB239] .1324
FAILURE CODE [CB271] .1326
FAILURE CODE [CB272] .1328
FAILURE CODE [CB273] .1329
FAILURE CODE [CB274] .1331
FAILURE CODE [CB343] .1332
FAILURE CODE [CB352] .1334
FAILURE CODE [CB386] .1336
FAILURE CODE [CB441] .1338
FAILURE CODE [CB442] .1340
FAILURE CODE [CB689] .1342
FAILURE CODE [CB697] .1344
FAILURE CODE [CB698] .1345
FAILURE CODE [CB731] .1346
FAILURE CODE [CB778] .1350
FAILURE CODE [CB1117] 1352
FAILURE CODE [CB1257] 1354
FAILURE CODE [CB1664] 1355
FAILURE CODE [CB1691] 1357
FAILURE CODE [CB1695] 1360
FAILURE CODE [CB1696] 1362
FAILURE CODE [CB1879] 1364
FAILURE CODE [CB1881] 1366
FAILURE CODE [CB1883] 1368
FAILURE CODE [CB1921] 1371
FAILURE CODE [CB1922] 1373
FAILURE CODE [CB1923] 1377
FAILURE CODE [CB1924] 1379
FAILURE CODE [CB1925] 1381
FAILURE CODE [CB1927] 1383
FAILURE CODE [CB1928] 1385
FAILURE CODE [CB1963] 1387
FAILURE CODE [CB1977] 1391
FAILURE CODE [CB1993] 1393
FAILURE CODE [CB2265] 1395
FAILURE CODE [CB2266] 1397
FAILURE CODE [CB2637] 1399
FAILURE CODE [CB2639] 1402
FAILURE CODE [CB2732] 1404
FAILURE CODE [CB2733] 1406
FAILURE CODE [CB2741] 1408
FAILURE CODE [CB2777] 1410
FAILURE CODE [CB2878] 1412
FAILURE CODE [CB2881] 1415
FAILURE CODE [CB3133] 1418
FAILURE CODE [CB3134] 1420
FAILURE CODE [CB3135] 1422
FAILURE CODE [CB3167] 1425
FAILURE CODE [CB3251] 1428
FAILURE CODE [CB3253] 1430
FAILURE CODE [CB3254] 1435
FAILURE CODE [CB3255] 1438
FAILURE CODE [CB3256] 1441
FAILURE CODE [CB3311] 1443
FAILURE CODE [CB3312] 1445
FAILURE CODE [CB3313] 1447
FAILURE CODE [CB3314] 1448
FAILURE CODE [CB3315] 1449
FAILURE CODE [CB3316] 1452
FAILURE CODE [CB3317] 1453
FAILURE CODE [CB3318] 1454
FAILURE CODE [CB3319] 1457
FAILURE CODE [CB3321] 1458
FAILURE CODE [CB3322] 1459
FAILURE CODE [CB4151] 1462
FAILURE CODE [CB4158] 1465
FAILURE CODE [CB4161] 1466
FAILURE CODE [CB4162] 1468
FAILURE CODE [CB4163] 1470
FAILURE CODE [CB4259] 1472
FAILURE CODE [CB4952] 1474
FAILURE CODE [CB5383] 1476
FAILURE CODE [D110KB] 1477
FAILURE CODE [D163KB] 1479
FAILURE CODE [D195KA] 1481
FAILURE CODE [D195KB] 1483
FAILURE CODE [D19JKZ] 1485
FAILURE CODE [D862KA] 1487
FAILURE CODE [D8AQKR] 1488
FAILURE CODE [DA20MC] 1492
FAILURE CODE [DA22KK] 1493
FAILURE CODE [DA25KP] 1495
FAILURE CODE [DA26KP] 1497
FAILURE CODE [DA29KQ] 1499
FAILURE CODE [DA2LKA] 1501
FAILURE CODE [DA2LKB] 1503
FAILURE CODE [DA2QKR] 1505
FAILURE CODE [DA2RKR] 1510
FAILURE CODE [DAF0KM] 1515
FAILURE CODE [DAF0MB] 1516
FAILURE CODE [DAF0MC] 1517
FAILURE CODE [DAF9KQ] 1518
FAILURE CODE [DAFGMC] 1519
FAILURE CODE [DAFLKA] 1520
FAILURE CODE [DAFLKB] 1523
FAILURE CODE [DAFQKR] 1525
FAILURE CODE [DAZ9KQ] 1530
FAILURE CODE [DAZQKR] 1531
FAILURE CODE [DB2QKR] 1534
FAILURE CODE [DB2RKR] 1541
FAILURE CODE [DBP0KM] 1547
FAILURE CODE [DBP0KT] 1548
FAILURE CODE [DBPQKR] 1549
FAILURE CODE [DBV0MC] 1554
FAILURE CODE [DBV1KK] 1555
FAILURE CODE [DBV5KB] 1557
FAILURE CODE [DBV6KB] 1561
FAILURE CODE [DBVLKA] 1563
FAILURE CODE [DBVLKB] 1565
FAILURE CODE [DBVQKR] 1567
FAILURE CODE [DBVRKR] 1571
FAILURE CODE [DBVVKR] 1575
FAILURE CODE [DBVWKR] 1576
FAILURE CODE [DDNRKA] 1577
FAILURE CODE [DDNRKY] 1579
FAILURE CODE [DDNS00] 1581
FAILURE CODE [DGE5KB] 1583
FAILURE CODE [DGH2KA] 1584
FAILURE CODE [DGH2KB] 1586
FAILURE CODE [DGT3KB] 1588
FAILURE CODE [DGT4KA] 1590
FAILURE CODE [DGT4KB] 1592
FAILURE CODE [DHA4KA] 1594
FAILURE CODE [DHAAMA] 1596
FAILURE CODE [DHABMA] 1597
FAILURE CODE [DHACMA] 1598
FAILURE CODE [DHADMA] 1599
FAILURE CODE [DHPAMA] 1600
FAILURE CODE [DHPAZL] 1602
FAILURE CODE [DHPBMA] 1603
FAILURE CODE [DHPBZL] 1605
FAILURE CODE [DHPGMA] 1606
FAILURE CODE [DHPGZL] 1608
FAILURE CODE [DHPSMA] 1609
FAILURE CODE [DHPTKA] 1611
FAILURE CODE [DHPTKB] 1613
FAILURE CODE [DHS3MA] 1615
FAILURE CODE [DHS4MA] 1618
FAILURE CODE [DHS8MA] 1621
FAILURE CODE [DHS9MA] 1624
FAILURE CODE [DHSAMA] 1627
FAILURE CODE [DHSBMA] 1630
FAILURE CODE [DHSCMA] 1633
FAILURE CODE [DHSDMA] 1636
FAILURE CODE [DHSFMA] 1639
FAILURE CODE [DHSGMA] 1642
FAILURE CODE [DHSHMA] 1645
FAILURE CODE [DHSJMA] 1648
FAILURE CODE [DKR2KA] 1651
FAILURE CODE [DKR2KB] 1653
FAILURE CODE [DKR2NX] 1655
FAILURE CODE [DKR3KA] 1657
FAILURE CODE [DKR3KB] 1659
FAILURE CODE [DKR3NX] 1661
FAILURE CODE [DKULKA] 1663
FAILURE CODE [DKULKB] 1665
FAILURE CODE [DKULKY] 1667
FAILURE CODE [DLM3KA] 1669
FAILURE CODE [DLM3KB] 1671
FAILURE CODE [DLM3MB] 1673
FAILURE CODE [DR10KA] 1674
FAILURE CODE [DUMBKA] 1677
FAILURE CODE [DUMBKB] 1680
FAILURE CODE [DV20KB] 1682
FAILURE CODE [DW41KA] 1684
FAILURE CODE [DW41KB] 1686
FAILURE CODE [DW41KY] 1687
FAILURE CODE [DW43KA] 1688
FAILURE CODE [DW43KB] 1690
FAILURE CODE [DW43KY] 1691
FAILURE CODE [DW45KA] 1692
FAILURE CODE [DW45KB] 1695
FAILURE CODE [DW45KY] 1698
FAILURE CODE [DW48KA] 1700
FAILURE CODE [DW48KB] 1702
FAILURE CODE [DW48KY] 1704
FAILURE CODE [DW4CKY] 1705
FAILURE CODE [DW7BKA] 1707
FAILURE CODE [DW7BKB] 1709
FAILURE CODE [DW7BKY] 1711
FAILURE CODE [DW91KA] 1712
FAILURE CODE [DW91KB] 1714
FAILURE CODE [DW91KY] 1715
FAILURE CODE [DWA5KA] 1716
FAILURE CODE [DWA5KB] 1718
FAILURE CODE [DWA5KY] 1720
FAILURE CODE [DWK0KA] 1722
FAILURE CODE [DWK0KB] 1724
FAILURE CODE [DWK0KY] 1726
FAILURE CODE [DWK2KA] 1727
FAILURE CODE [DWK2KB] 1729
FAILURE CODE [DWK2KY] 1731
FAILURE CODE [DWK8KA] 1732
FAILURE CODE [DWK8KB] 1734
FAILURE CODE [DWK8KY] 1736
FAILURE CODE [DX16KA] 1737
FAILURE CODE [DX16KB] 1739
FAILURE CODE [DXA0KA] 1741
FAILURE CODE [DXA0KB] 1744
FAILURE CODE [DXAXKA] 1746
FAILURE CODE [DXAXKB] 1748
FAILURE CODE [DY20KA] 1750
FAILURE CODE [DY20KA] 1752
FAILURE CODE [DY20MA] 1755
FAILURE CODE [DY20MA] 1757
FAILURE CODE [DY2CKB] 1760
FAILURE CODE [DY2DKB] 1762
FAILURE CODE [DY2DKB] 1764
FAILURE CODE [DY2EKB] 1767
FAILURE CODE [DY2EKB] 1769
FAILURE CODE [DY2FMA] 1772
FAILURE CODE [DY2GKM] 1774
FAILURE CODE [F@BYNR] 1776
FAILURE CODE [F@BYNS] 1777
FAILURE CODE [J100KA] 1778
FAILURE CODE [J100KB] 1780
FAILURE CODE [J100L6] 1782
FAILURE CODE [J190KA] 1783
FAILURE CODE [J190KB] 1785
FAILURE CODE [J190L6] 1787
FAILURE CODE [LA10ZL] 1788
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1789
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1789
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK .1796
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1799
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1801
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1803
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW .1806
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW .1807
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1808
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1809
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1810
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1811
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1812
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1813
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1814
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1815
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1816
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 1818
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1819
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE .1820
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1821
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 1823
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 1824
E-23 FUNCTION SWITCH DOES NOT OPERATE 1825
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 1826
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF .1827
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER .1828
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 1829
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED .1830
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 1831
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE .1832
E-31 ALARM BUZZER CANNOT BE CANCELED .1833
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 1834
E-33 SERVICE MODE CANNOT BE SELECTED .1835
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE .1836
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 1839
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 1841
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 1844
E-38 ALARM DOES NOT SOUND DURING TRAVEL 1846
E-39 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED .1848
E-40 HORN DOES NOT SOUND .1849
E-41 HORN DOES NOT STOP SOUNDING .1851
E-42 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 1852
E-43 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED (SINGLE WIPER SPECIFICATION) .1853
E-44 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED (DOUBLE WIPER SPECIFICATION) .1855
E-45 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE .1857
E-46 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1858
E-47 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1859
E-48 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1860
E-49 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1861
E-50 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1862
E-51 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1863
E-52 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1864
E-53 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1865
E-54 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1866
E-55 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED .1867
E-56 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE .1869
E-57 STEP LIGHT DOES NOT LIGHT UP 1870
E-58 STEP LIGHT DOES NOT GO OUT 1873
E-59 BOOM SHOCKLESS FUNCTION CANNOT BE CANCELED 1875
E-60 BOOM SHOCKLESS FUNCTION DOES NOT WORK .1877
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1878
H-1 ALL WORK EQUIPMENT, TRAVEL, SWING SPEED OR POWER IS LOW 1878
H-2 ENGINE SPEED DROPS SIGNIFICANTLY OR ENGINE STALLS 1880
H-3 ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK 1881
H-4 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT PUMP .1883
H-5 BOOM SPEED OR POWER IS LOW IN NORMAL MODE 1884
H-6 BOOM RAISE SPEED OR POWER IS LOW IN HEAVY LIFT MODE 1885
H-7 BOOM LOWER SPEED OR POWER IS LOW IN MACHINE PUSH UP MODE .1886
H-8 ARM SPEED OR POWER IS LOW 1887
H-9 BUCKET SPEED OR POWER IS LOW .1888
H-10 BOOM DOES NOT OPERATE .1889
H-11 ARM DOES NOT OPERATE 1890
H-12 BUCKET DOES NOT OPERATE .1891
H-13 HYDRAULIC DRIFT OF BOOM IS LARGE 1892
H-14 HYDRAULIC DRIFT OF ARM IS LARGE .1893
H-15 HYDRAULIC DRIFT OF BUCKET IS LARGE 1894
H-16 TIME LAG OF BOOM IS LARGE .1895
H-17 TIME LAG OF ARM IS LARGE 1896
H-18 TIME LAG OF BUCKET IS LARGE .1897
H-19 BOOM SHOCKLESS FUNCTION DOES NOT WORK OR CANNOT BE RELEASED .1898
H-20 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS (IT TURNS IN THE SAME DIRECTION WHEN TRAVELING FORWARD AND REVERSE) 1899
H-21 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS (IT TURNS IN THE DIFFERENT DIRECTIONS WHEN TRAVELING FORWARD AND REVERSE) 1901
H-22 ONLY WHEN OPERATING THE TRAVEL LEVER FULLY, TRAVEL DEVIATION IS LARGE AT START OF TRAVELING .1902
H-23 REGARDLESS OF THE STROKE OF THE TRAVEL LEVER, TRAVEL DEVIATION IS LARGE AT START OF TRAVELING .1903
H-24 TRAVEL DEVIATION IS LARGE AT COMBINED OPERATION .1904
H-25 TRAVEL SPEED OR POWER IS LOW 1905
H-26 ONLY THE ONE SIDE TRACK CAN OPERATE (MACHINE DOES NOT TRAVEL EITHER FORWARD OR REVERSE) .1906
H-27 ONLY THE ONE SIDE TRACK CAN OPERATE (MACHINE CAN TRAVEL ONLY FORWARD OR REVERSE) 1907
H-28 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST .1908
H-29 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT .1909
H-30 SWINGS ONLY IN ONE DIRECTION 1910
H-31 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 1911
H-32 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION .1912
H-33 IN COMBINED OPERATION OF WORK EQUIPMENT, SWING SPEED OR POWER IS LOW 1913
H-34 WHILE COMBINED OPERATION WITH BOOM IN SWING PRIORITY MODE, SWING SPEED IS LOW OR SWING ACCELERATION PERFORMANCE IS POOR .1914
H-35 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) .1915
H-36 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) .1916
H-37 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING (BOTH RIGHT AND LEFT) 1917
H-38 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 1918
H-39 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING (BOTH RIGHT AND LEFT) 1919
H-40 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING IN ONLY ONE DIRECTION 1920
H-41 SWING DRIFT ON A SLOPE IS LARGE .1921
H-42 FAN SPEED IS ABNORMAL (SUCH AS EXCESSIVE NOISE OR VIBRATION OF FAN, OR OVERHEATING) .1922
TROUBLESHOOTING OF ENGINE (S-MODE) .1923
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1923
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION .1924
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .1925
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) .1926
S-4 ENGINE STARTABILITY IS POOR 1927
S-5 ENGINE DOES NOT PICK UP SMOOTHLY .1929
S-6 ENGINE STOPS DURING OPERATION 1931
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE .1933
S-8 ENGINE LACKS POWER .1934
S-9 KDPF GETS CLOGGED IN A SHORT TIME 1936
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE .1938
S-11 OIL BECOMES CONTAMINATED QUICKLY 1939
S-12 FUEL CONSUMPTION IS EXCESSIVE .1940
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .1941
S-14 OIL PRESSURE DROPS 1942
S-15 FUEL MIXES INTO ENGINE OIL 1944
S-16 WATER MIXES INTO ENGINE OIL (MILKY) .1945
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 1946
S-18 UNUSUAL NOISE IS HEARD 1948
S-19 VIBRATION IS EXCESSIVE 1949
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 1950
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 1951
S-22 ACTIVE REGENERATION TAKES TIME 1952
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION .1953
50 DISASSEMBLY AND ASSEMBLY 1955
CONTENTS .1956
ABBREVIATION LIST 1961
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1967
HOW TO READ THIS MANUAL 1967
COATING MATERIALS LIST .1969
SPECIAL TOOLS LIST .1973
SKETCHES OF SPECIAL TOOLS 1983
ENGINE AND COOLING SYSTEM 1990
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1990
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY .1990
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY .2002
REMOVE AND INSTALL INJECTOR ASSEMBLY .2016
METHOD FOR REMOVING INJECTOR ASSEMBLY 2017
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2027
REMOVE AND INSTALL FUEL DOSER ASSEMBLY .2040
METHOD FOR REMOVING FUEL DOSER ASSEMBLY 2040
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY 2043
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2046
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY .2047
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY .2086
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2137
METHOD FOR REMOVING EGR VALVE ASSEMBLY .2137
METHOD FOR INSTALLING EGR VALVE ASSEMBLY .2141
REMOVE AND INSTALL EGR COOLER ASSEMBLY .2145
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2145
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2151
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY .2160
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2160
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2161
REMOVE AND INSTALL ALTERNATOR BELT .2162
METHOD FOR REMOVING ALTERNATOR BELT 2162
METHOD FOR INSTALLING ALTERNATOR BELT 2163
REMOVE AND INSTALL RADIATOR ASSEMBLY .2165
METHOD FOR REMOVING RADIATOR ASSEMBLY 2165
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2169
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY .2174
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2174
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2179
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2185
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY .2185
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY .2191
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 2197
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY .2197
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY .2210
REMOVE AND INSTALL ENGINE PTO AND HYDRAULIC ASSEMBLY .2222
METHOD FOR REMOVING ENGINE PTO AND HYDRAULIC ASSEMBLY 2222
METHOD FOR INSTALLING ENGINE PTO AND HYDRAULIC ASSEMBLY 2238
REMOVE AND INSTALL ENGINE FRONT OIL SEAL .2254
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2254
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2257
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2261
METHOD FOR REMOVING ENGINE REAR OIL SEAL .2261
METHOD FOR INSTALLING ENGINE REAR OIL SEAL .2262
REMOVE AND INSTALL FUEL COOLER ASSEMBLY 2266
METHOD FOR REMOVING FUEL COOLER ASSEMBLY .2266
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY .2267
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2269
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY .2269
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY .2275
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2282
METHOD FOR REMOVING FUEL TANK ASSEMBLY .2282
METHOD FOR INSTALLING FUEL TANK ASSEMBLY .2287
REMOVE AND INSTALL KDPF ASSEMBLY .2292
METHOD FOR REMOVING KDPF ASSEMBLY 2292
METHOD FOR INSTALLING KDPF ASSEMBLY 2298
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2305
METHOD FOR DISASSEMBLING KDPF ASSEMBLY .2306
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2311
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY .2319
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 2319
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 2323
REMOVE AND INSTALL KCCV ASSEMBLY .2327
METHOD FOR REMOVING KCCV ASSEMBLY 2327
METHOD FOR INSTALLING KCCV ASSEMBLY 2329
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2331
METHOD FOR REMOVING AIR CLEANER ASSEMBLY .2331
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY .2331
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .2333
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2333
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2334
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2336
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY .2336
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY .2337
POWER TRAIN 2340
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY 2340
METHOD FOR DISASSEMBLING PTO ASSEMBLY 2340
METHOD FOR ASSEMBLING PTO ASSEMBLY .2342
REMOVE AND INSTALL PTO ASSEMBLY 2346
METHOD FOR REMOVING PTO ASSEMBLY .2346
METHOD FOR INSTALLING PTO ASSEMBLY .2348
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2351
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2351
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2352
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2353
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2353
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY .2357
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2366
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY .2366
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY .2368
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2371
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 2371
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY .2375
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY .2381
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 2381
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 2382
UNDERCARRIAGE AND FRAME 2383
REMOVE AND INSTALL IDLER ASSEMBLY 2383
METHOD FOR REMOVING IDLER ASSEMBLY .2383
METHOD FOR INSTALLING IDLER ASSEMBLY .2384
DISASSEMBLE AND ASSEMBLE RECOIL SPRING .2385
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING 2385
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY .2386
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY .2387
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY 2387
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY 2388
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY .2390
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY 2390
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY 2391
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD 2392
METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD 2394
METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD .2395
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2398
METHOD FOR SEPARATING TRACK ASSEMBLY .2398
METHOD FOR INSTALLING TRACK ASSEMBLY .2400
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2401
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2401
METHOD FOR ASSEMBLING IDLER ASSEMBLY .2403
DISASSEMBLE AND ASSEMBLE AIDLER ADJUSTMENT CYLINDER ASSEMBLY .2406
METHOD FOR DISASSEMBLING AIDLER ADJUSTMENT CYLINDER ASSEMBLY .2406
METHOD FOR ASSEMBLING AIDLER ADJUSTMENT CYLINDER ASSEMBLY 2407
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY .2408
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY .2408
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2409
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 2412
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY .2412
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2413
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2415
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY .2415
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY .2416
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2418
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY .2418
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY .2420
HYDRAULIC SYSTEM .2422
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2422
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY .2422
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY .2423
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2425
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2426
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2427
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY .2428
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2428
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2432
REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY .2437
METHOD FOR REMOVING HYDRAULIC PUMP ASSEMBLY 2437
METHOD FOR INSTALLING HYDRAULIC PUMP ASSEMBLY 2450
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2461
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY .2461
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY .2466
REMOVE AND INSTALL SWING MOTOR ASSEMBLY 2473
METHOD FOR REMOVING SWING MOTOR ASSEMBLY .2473
METHOD FOR INSTALLING SWING MOTOR ASSEMBLY .2474
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY .2476
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2476
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2477
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY .2479
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2479
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2480
DISASSEMBLE AND ASSEMBLE GREASE GUN ASSEMBLY .2482
METHOD FOR DISASSEMBLING GREASE GUN ASSEMBLY .2482
METHOD FOR ASSEMBLING GREASE GUN ASSEMBLY 2482
WORK EQUIPMENT .2483
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY 2483
METHOD FOR REMOVING BUCKET CYLINDER ASSEMBLY .2483
METHOD FOR INSTALLING BUCKET CYLINDER ASSEMBLY .2484
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY .2486
METHOD FOR REMOVING ARM CYLINDER ASSEMBLY 2486
METHOD FOR INSTALLING ARM CYLINDER ASSEMBLY 2488
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY 2490
METHOD FOR REMOVING BOOM CYLINDER ASSEMBLY .2490
METHOD FOR INSTALLING BOOM CYLINDER ASSEMBLY .2491
REMOVE AND INSTALL BUCKET ASSEMBLY .2493
METHOD FOR REMOVING BUCKET ASSEMBLY 2494
METHOD FOR INSTALLING BUCKET ASSEMBLY 2495
REMOVE AND INSTALL ARM ASSEMBLY 2497
METHOD FOR REMOVING ARM ASSEMBLY .2497
METHOD FOR INSTALLING ARM ASSEMBLY .2498
REMOVE AND INSTALL BOOM ASSEMBLY .2500
METHOD FOR REMOVING BOOM ASSEMBLY 2500
METHOD FOR INSTALLING BOOM ASSEMBLY 2502
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2504
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2505
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2507
CAB AND ITS ATTACHMENTS 2512
REMOVE AND INSTALL TOP GUARD ASSEMBLY 2512
METHOD FOR REMOVING TOP GUARD ASSEMBLY .2512
METHOD FOR INSTALLING TOP GUARD ASSEMBLY .2514
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY .2516
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY 2516
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY 2524
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 2533
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) .2535
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) .2535
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY .2545
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 2545
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 2548
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 2554
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY .2554
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY .2560
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .2567
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2567
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2572
REMOVE AND INSTALL OPERATOR’S SEAT .2577
METHOD FOR REMOVING OPERATOR’S SEAT 2577
METHOD FOR INSTALLING OPERATOR’S SEAT 2579
REMOVE AND INSTALL SEAT BELT .2582
METHOD FOR REMOVING SEAT BELT 2582
METHOD FOR INSTALLING SEAT BELT 2582
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 2584
METHOD FOR REMOVING FRONT WIPER ASSEMBLY .2584
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY .2589
ELECTRICAL SYSTEM 2598
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2598
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY .2598
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY .2600
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 2603
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY .2603
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY .2605
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY .2608
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY 2608
METHOD FOR INSTALLING KomVision CONTROLLER .2609
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2610
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY .2610
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY .2612
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2616
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR .2616
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR .2617
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2618
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR .2618
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR .2619
REMOVE AND INSTALL KomVision CAMERA 2621
METHOD FOR REMOVING KomVision CAMERA .2621
METHOD FOR INSTALLING KomVision CAMERA .2622
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY .2624
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2624
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2625
REMOVE AND INSTALL KOMTRAX Plus CONTROLLER ASSEMBLY 2628
METHOD FOR REMOVING KOMTRAX Plus CONTROLLER ASSEMBLY .2628
METHOD FOR INSTALLING KOMTRAX Plus CONTROLLER ASSEMBLY .2629
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY 2630
METHOD FOR REMOVING WIRELESS LAN UNIT ASSEMBLY .2630
METHOD FOR NSTALLING WIRELESS LAN UNIT ASSEMBLY 2631
60 MAINTENANCE STANDARD 2635
CONTENTS .2636
ABBREVIATION LIST 2637
ENGINE AND COOLING SYSTEM 2643
MAINTENANCE STANDARD OF ENGINE MOUNT .2643
MAINTENANCE STANDARD FOR PTO .2645
MAINTENANCE STANDARD OF COOLING SYSTEM .2646
MAINTENANCE STANDARD OF COOLING FAN PUMP .2648
MAINTENANCE STANDARD OF EPC VALVE OF COOLING FAN PUMP 2650
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2651
POWER TRAIN 2653
MAINTENANCE STANDARD OF SWING CIRCLE .2653
MAINTENANCE STANDARD OF SWING MACHINERY 2654
MAINTENANCE STANDARD OF FINAL DRIVE 2656
MAINTENANCE STANDARD OF SPROCKET .2658
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 2659
UNDERCARRIAGE AND FRAME 2661
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2661
MAINTENANCE STANDARD OF IDLER 2663
MAINTENANCE STANDARD OF TRACK ROLLER .2665
MAINTENANCE STANDARD OF CARRIER ROLLER .2666
MAINTENANCE STANDARD OF TRACK SHOE .2667
MAINTENANCE STANDARD OF DOUBLE SHOE 2670
HYDRAULIC SYSTEM .2671
MAINTENANCE STANDARD OF MAIN PUMP 2671
MAINTENANCE STANDARD OF SWING MOTOR 2674
MAINTENANCE STANDARD OF CONTROL VALVE 2677
MAINTENANCE STANDARD OF STRAIGHT TRAVEL VALVE OF CONTROL VALVE .2686
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE VALVE .2687
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE .2688
MAINTENANCE STANDARD OF TRAVEL PPC VALVE .2691
MAINTENANCE STANDARD OF SOLENOID VALVE .2693
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 2694
WORK EQUIPMENT .2695
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE .2695
DIMENSION OF ARM .2698
DIMENSIONS OF BUCKET .2700
MAINTENANCE STANDARD OF BOOM CYLINDER 2702
MAINTENANCE STANDARD OF ARM CYLINDER .2703
MAINTENANCE STANDARD OF BUCKET CYLINDER 2704
80 APPENDIX 2705
CONTENTS .2706
ABBREVIATION LIST 2708
AIR CONDITIONER SYSTEM .2714
PRECAUTIONS FOR REFRIGERANT 2714
AIR CONDITIONER COMPONENT 2715
SPECIFICATIONS OF AIR CONDITIONER 2717
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2718
OUTLINE OF REFRIGERATION CYCLE .2719
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2721
AIR CONDITIONER UNIT .2721
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2721
FUNCTION OF AIR CONDITIONER UNIT .2723
COMPONENT PARTS OF AIR CONDITIONER UNIT 2725
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT .2726
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2726
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2726
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 2726
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2727
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2727
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2727
FUNCTION OF DUAL PRESSURE SWITCH .2728
AIR CONDITIONER CONTROLLER .2729
STRUCTURE OF AIR CONDITIONER CONTROLLER 2729
COMPRESSOR .2730
STRUCTURE OF COMPRESSOR 2730
SPECIFICATIONS OF COMPRESSOR .2730
FUNCTION OF COMPRESSOR .2730
CONDENSER 2731
STRUCTURE OF CONDENSER .2731
SPECIFICATIONS OF CONDENSER 2731
FUNCTION OF CONDENSER 2731
RECEIVER DRIER .2732
STRUCTURE OF RECEIVER DRIER 2732
SPECIFICATIONS OF RECEIVER DRIER .2732
FUNCTION OF RECEIVER DRIER .2732
SENSORS FOR AIR CONDITIONER SYSTEM .2733
STRUCTURE OF SUNLIGHT SENSOR .2733
FUNCTION OF SUNLIGHT SENSOR 2733
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 2733
FUNCTION OF AMBIENT TEMPERATURE SENSOR .2733
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2735
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2737
AIR CONDITIONER SYSTEM DIAGRAM .2739
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .2740
FUNCTION OF AIR CONDITIONER CONTROLLER .2741
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2742
TESTING AIR LEAKAGE (DUCT) .2746
METHOD FOR TESTING AIR LEAKAGE (DUCT) 2746
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2748
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR .2749
TEST VENT (MODE) CHANGEOVER 2750
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2750
TESTING FRESH/RECIRC AIR CHANGEOVER 2752
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .2752
TEST SUNLIGHT SENSOR .2753
METHOD FOR TESTING SUNLIGHT SENSOR .2753
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2754
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2754
TEST RELAYS 2755
METHOD FOR TESTING RELAYS 2755
AIR CONDITIONER TROUBLESHOOTING CHART 1 2756
AIR CONDITIONER TROUBLESHOOTING CHART 2 2757
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE .2760
FAILURE CODE [879AKA] 2762
FAILURE CODE [879AKB] 2763
FAILURE CODE [879BKA] 2764
FAILURE CODE [879BKB] 2766
FAILURE CODE [879CKA] 2768
FAILURE CODE [879CKB] 2769
FAILURE CODE [879DKZ] 2770
FAILURE CODE [879EMC] 2772
FAILURE CODE [879FMC] 2773
FAILURE CODE [879GKX] 2774
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) .2776
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2778
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) .2781
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 2783
TROUBLESHOOTING USING GAUGE PRESSURE .2785
CONNECTION OF SERVICE TOOL .2788
METHOD FOR CONNECTING SERVICE TOOL .2788
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2790
HANDLE COMPRESSOR OIL 2792
90 CIRCUIT DIAGRAMS 2795
CONTENTS .2796
ABBREVIATION LIST 2797
HYDRAULIC CIRCUIT DIAGRAM 2803
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2803
HYDRAULIC CIRCUIT DIAGRAM 2807
ELECTRICAL CIRCUIT DIAGRAM .2808
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM .2808
ELECTRICAL CIRCUIT DIAGRAM (1/14) 2812
ELECTRICAL CIRCUIT DIAGRAM (2/14) 2813
ELECTRICAL CIRCUIT DIAGRAM (3/14) 2814
ELECTRICAL CIRCUIT DIAGRAM (4/14) 2815
ELECTRICAL CIRCUIT DIAGRAM (5/14) 2816
ELECTRICAL CIRCUIT DIAGRAM (6/14) 2817
ELECTRICAL CIRCUIT DIAGRAM (7/14) 2818
ELECTRICAL CIRCUIT DIAGRAM (8/14) 2819
ELECTRICAL CIRCUIT DIAGRAM (9/14) 2820
ELECTRICAL CIRCUIT DIAGRAM (10/14) .2821
ELECTRICAL CIRCUIT DIAGRAM (11/14) .2822
ELECTRICAL CIRCUIT DIAGRAM (12/14) .2823
ELECTRICAL CIRCUIT DIAGRAM (13/14) .2824
ELECTRICAL CIRCUIT DIAGRAM (14/14) .2825
INDEX .2826

DESCRIPTION:

Komatsu Hydraulic Excavator PC1250-11,PC1250LC-11,PC1250SP-11 Shop Manual SEN06624-02 – PDF DOWNLOAD

• SERIAL NUMBERS
  PC1250- 50001            and up
  PC1250LC- 50001      and up
  PC1250SP- 50001      and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
REMARK
• 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.
• The materials and specifications are subject to change without notice.
• 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.
• 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.

G.B 27/12/24