Komatsu Hydraulic Excavator PC210-10M0 PC210LC-10M0 Shop Manual SEN06701-00

Description

Komatsu Hydraulic Excavator PC210-10M0 PC210LC-10M0 Shop Manual SEN06701-00- PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC210-10M0 PC210LC-10M0 Shop Manual SEN06701-00- PDF DOWNLOAD

Language : English
Pages :2500
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Excavator PC210-10M0 PC210LC-10M0 Shop Manual SEN06701-00- PDF DOWNLOAD

SERIAL NUMBERS PC210- 600001
PC210LC- 600001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• 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.

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC210-10M0 PC210LC-10M0 Shop Manual SEN06701-00- PDF DOWNLOAD

SERIAL NUMBERS PC210- 600001
PC210LC- 600001 and up

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 16
FOREWORD, SAFETY, BASIC INFORMATION 21
HOW TO READ THE SHOP MANUAL 21
SAFETY NOTICE FOR OPERATION 23
PRECAUTIONS TO PREVENT FIRE 31
ACTIONS IF FIRE OCCURS 32
PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS 33
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 34
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS 37
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT 44
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 46
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 47
PRACTICAL USE OF KOMTRAX 48
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 49
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 49
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 50
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 51
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 53
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 57
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 58
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 60
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 61
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 63
HOW TO READ ELECTRICAL WIRE CODE 64
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 68
STANDARD TIGHTENING TORQUE TABLE 71
CONVERSION TABLE 78
01 SPECIFICATION 83
CONTENTS 84
ABBREVIATION LIST 85
SPECIFICATION 90
SPECIFICATION DRAWING 90
SPECIFICATION DRAWING: PC210-10M0 90
SPECIFICATION DRAWING: PC210LC-10M0 91
WORKING RANGE DRAWINGS 93
WORKING RANGE DRAWINGS: PC210-10M0 93
WORKING RANGE DRAWINGS: PC210LC-10M0 94
SPECIFICATION 96
SPECIFICATION: PC210-10M0 96
SPECIFICATIONS: PC210LC-10M0 98
WEIGHT TABLE 102
WEIGHT TABLE: PC210-10M0 102
WEIGHT TABLE: PC210LC-10M0 103
FUEL, COOLANT AND LUBRICANT TO MEET AMBIENT TEMPERATURE 105
10 STRUCTURE AND FUNCTION 107
CONTENTS 108
ABBREVIATION LIST 111
BOOT-UP SYSTEM 116
LAYOUT DRAWING OF BOOT-UP SYSTEM 116
SYSTEM OPERATING LAMP SYSTEM 117
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 117
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 117
OPERATION OF SYSTEM OPERATING LAMP 117
BATTERY DISCONNECT SWITCH 118
FUNCTION OF BATTERY DISCONNECT SWITCH 118
OPERATION OF BATTERY DISCONNECT SWITCH 118
ENGINE SYSTEM 119
LAYOUT DRAWING OF ENGINE SYSTEM 119
ENGINE CONTROL SYSTEM 120
ENGINE CONTROL SYSTEM DRAWING 120
OPERATION OF ENGINE CONTROL SYSTEM 120
AUTO-DECELERATION SYSTEM 122
AUTO-DECELERATION SYSTEM DRAWING 122
FUNCTION OF AUTO-DECELERATION SYSTEM 122
OPERATION OF AUTO-DECELERATION SYSTEM 123
ENGINE AUTOMATIC WARM-UP SYSTEM 124
ENGINE AUTOMATIC WARM-UP SYSTEM DRAWING 124
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 125
OPERATION OF ENGINE AUTOMATIC WARM-UP SYSTEM 125
OVERHEAT PREVENTION SYSTEM 126
OVERHEAT PREVENTION SYSTEM DRAWING 126
FUNCTION OF OVERHEAT PREVENTION SYSTEM 127
OPERATION OF OVERHEAT PREVENTION SYSTEM 127
TURBOCHARGER PROTECTION SYSTEM 129
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 129
COOLING SYSTEM 130
LAYOUT DRAWING OF COOLING SYSTEM 130
SPECIFICATIONS OF COOLING SYSTEM 131
CONTROL SYSTEM 132
LAYOUT DRAWING OF CONTROL SYSTEM PARTS 132
MACHINE MONITOR SYSTEM 134
MACHINE MONITOR SYSTEM DIAGRAM 134
FUNCTION OF MACHINE MONITOR SYSTEM 134
KOMTRAX SYSTEM 136
KOMTRAX SYSTEM DIAGRAM 136
FUNCTION OF KOMTRAX SYSTEM 136
CONTROL SYSTEM 137
MACHINE MONITOR 137
KOMTRAX TERMINAL 148
PUMP CONTROLLER 151
RESISTOR FOR PC-EPC VALVE 155
CAN TERMINATING RESISTOR 155
ENGINE CONTROLLER 156
FUEL CONTROL DIAL 160
HYDRAULIC SYSTEM 161
LAYOUT DRAWING OF HYDRAULIC SYSTEM 161
CLSS 164
CLSS SYSTEM DIAGRAM 164
FUNCTION OF CLSS 165
PRESSURE COMPENSATION CONTROL 182
ENGINE AND PUMP COMBINED CONTROL SYSTEM 183
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 183
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 184
PUMP AND VALVE CONTROL SYSTEM 188
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 188
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 189
COMPONENT PARTS OF HYDRAULIC SYSTEM 191
HYDRAULIC TANK 191
MAIN PUMP 193
CONTROL VALVE 213
WORK EQUIPMENT SYSTEM 259
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 259
ONE-TOUCH POWER MAXIMIZING SYSTEM 263
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 263
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 264
PPC LOCK SYSTEM 265
PPC LOCK SYSTEM DIAGRAM 265
FUNCTION OF PPC LOCK SYSTEM 266
ATTACHMENT OIL FLOW ADJUSTER SYSTEM 267
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 267
FUNCTION OF ATTACHMENT OIL FLOW ADJUSTER SYSTEM 268
WORK EQUIPMENT SYSTEM 269
WORK EQUIPMENT AND SWING PPC VALVE 269
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 273
2ND-LINE ATTACHMENT PPC VALVE 278
SOLENOID VALVE 282
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 284
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 286
PILOT CIRCUIT ACCUMULATOR 289
ATTACHMENT CIRCUIT ACCUMULATOR 289
SWING SYSTEM 292
LAYOUT DRAWING OF SWING SYSTEM 292
SWING CONTROL SYSTEM DIAGRAM 294
FUNCTION OF SWING CONTROL SYSTEM 294
SWING SYSTEM 298
SWING MOTOR 298
SWING MACHINERY 307
SWING CIRCLE 309
TRAVEL SYSTEM 310
LAYOUT DRAWING OF TRAVEL SYSTEM 310
TRAVEL CONTROL SYSTEM DIAGRAM 312
FUNCTION OF TRAVEL CONTROL SYSTEM 313
TRAVEL SYSTEM 314
TRAVEL MOTOR 314
FINAL DRIVE 325
TRAVEL PPC VALVE 326
CENTER SWIVEL JOINT 331
FUNCTION OF SWING CIRCLE 333
UNDERCARRIAGE AND FRAME 334
LAYOUT DRAWING OF UNDERCARRIAG 334
SPECIFICATIONS OF UNDERCARRIAGE 334
WORK EQUIPMENT 336
STRUCTURE OF WORK EQUIPMENT 336
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 337
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 337
BUCKET CLEARANCE ADJUSTMENT SHIM 338
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 338
CAB RELATED PARTS 339
ROPS CAB 339
STRUCTURE OF ROPS CAB 339
FUNCTION OF ROPS CAB 339
CAB MOUNT 340
STRUCTURE OF CAB MOUNT 340
FUNCTION OF CAB MOUNT 341
CAB TIPPING STOPPER 342
STRUCTURE OF CAB TIPPING STOPPER 342
FUNCTION OF CAB TIPPING STOPPER 342
20 STANDARD VALUE TABLE 343
CONTENTS 344
ABBREVIATION LIST 345
STANDARD VALUE TABLE FOR ENGINE 350
STANDARD VALUE TABLE FOR ENGINE: PC210-10M0 350
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0 354
STANDARD VALUE TABLE FOR ENGINE: PC210LC-10M0 368
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0 372
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE 386
30 TESTING AND ADJUSTING 389
CONTENTS 390
ABBREVIATION LIST 393
RELATED INFORMATION ON TESTING AND ADJUSTING 398
TOOLS FOR TESTING AND ADJUSTING 398
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 403
ENGINE AND COOLING SYSTEM 405
TEST ENGINE SPEED 405
TEST ENGINE HIGH IDLE SPEED 405
Test engine low idle speed 405
TEST ENGINE SPEED AT 2 PUMPS RELIEF 405
Test engine speed at 2 pumps relief and one-touch power maximizing 406
TEST ENGINE SPEED WITH AUTO-DECELERATION 406
Test boost pressure 408
TEST BOOST PRESSURE ON MACHINE MONITOR 408
TEST BOOST PRESSURE BY TESTING TOOL 409
TEST EXHAUST GAS COLOR 411
Test exhaust gas color by handy smoke checker 411
TEST EXHAUST GAS COLOR BY SMOKE METER 412
Test and adjust valve clearance 414
TEST VALVE CLEARANCE 414
Adjust valve clearance 415
TEST COMPRESSION PRESSURE 417
TEST COMPRESSION PRESSURE 417
TEST BLOWBY PRESSURE 420
TEST BLOWBY PRESSURE ON MACHINE MONITOR (MACHINE WITH BLOWBY PRESSURE SENSOR (OPT)) 420
Test blowby pressure (machine without blowby pressure sensor) 421
TEST ENGINE OIL PRESSURE 423
TEST ENGINE OIL PRESSURE 423
Test fuel pressure 425
TEST FUEL PRESSURE 426
Test fuel discharged volume, return rate, and leakage 432
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 433
BLEED AIR FROM FUEL SYSTEM 438
Bleed air from fuel system 438
Test fuel system for leakage 440
Test fuel circuit for leakage 440
CYLINDER CUT-OUT MODE OPERATION 442
NO-INJECTION CRANKING OPERATION 443
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 444
CHECK AIR CONDITIONER COMPRESSOR BELT 444
ADJUST AIR CONDITIONER COMPRESSOR BELT 444
POWER TRAIN 446
Test swing circle bearing clearance 446
Test swing circle bearing clearance 446
UNDERCARRIAGE AND FRAME 447
Test and adjust track shoe tension 447
Test track shoe tension 447
Adjust track shoe tension 447
HYDRAULIC SYSTEM 449
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 449
RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK 449
Release remaining pressure in hydraulic cylinder circuit 449
Release remaining pressure for machines without anti-drop valve 449
Release remaining pressure for machines with boom anti-drop valve 449
Release remaining pressure from swing motor circuit 451
RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 451
Test and adjust oil pressure in work equipment, swing, and travel circuits 452
Test oil pressure in work equipment, swing, and travel circuits 452
Adjust oil pressure in work equipment, swing, and travel circuits 459
TEST OIL PRESSURE OF CONTROL CIRCUIT 462
Test oil pressure of control circuit 462
Test and adjust oil pressure in pump PC control circuit 464
Test PC valve outlet pressure (servo piston inlet pressure) 464
TEST PC-EPC VALVE OUTLET PRESSURE 465
Adjust oil pressure in pump PC control circuit 467
Test and adjust oil pressure in pump LS control circuit 468
Test LS differential pressure with machine monitor 468
Test LS differential pressure by testing tool 470
Test LS valve outlet pressure (servo piston inlet pressure) 472
Test LS-EPC valve outlet pressure 473
Adjust LS valve 474
Test outlet pressure of solenoid valve 476
Test outlet pressure of solenoid valve 476
OPERATING CONDITION OF SOLENOID VALVE 478
Test PPC valve outlet pressure 480
Test outlet pressure of PPC valve with machine monitor 480
TEST OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL 481
Adjust play of work equipment and swing PPC valve 483
Adjust play of work equipment and swing PPC valve 483
TesTest pump swash plate sensor 484
Test pump swash plate sensor 484
Test parts causing hydraulic drift in work equipment 485
Test parts causing hydraulic drift of boom cylinder and bucket cylinder 485
Test parts causing hydraulic drift of arm cylinder 485
Test parts causing hydraulic drift of boom hydraulic drift prevention valve 486
Test parts causing hydraulic drift of PPC valve 486
Test oil leakage 487
TEST OIL LEAKAGE FROM BOOM CYLINDER 487
TEST OIL LEAKAGE FROM ARM CYLINDER 488
TEST OIL LEAKAGE FROM BUCKET CYLINDER 489
Test oil leakage from swing motor 489
Test oil leakage from travel motor 490
Bleed air from hydraulic system 492
Bleed air from main pump 493
BLEED AIR FROM CYLINDER 494
BLEED AIR FROM SWING MOTOR 495
BLEED AIR FROM TRAVEL MOTOR 495
CAB RELATED PARTS 497
Test cab tipping stopper 497
Test cab tipping stopper 497
ADJUST MIRRORS 498
ADJUST MACHINE LEFT FRONT MIRROR (A) 498
Adjust regular position of machine left front mirror (A) 499
ADJUST MACHINE RIGHT FRONT MIRROR (B) 500
ADJUST REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 500
ADJUST MACHINE RIGHT SIDE MIRROR (C) 501
ELECTRICAL SYSTEM 503
SETTING AND OPERATION OF MACHINE MONITOR 503
OPERATOR MODE 507
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 507
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 507
CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 508
CHECK FUNCTION OF SERVICE METER 508
SET USAGE LIMITATION AND CHANGE MAINTENANCE PASSWORD 508
SERVICE MODE 511
Operation of service mode 511
Check pre-defined monitoring information 512
CHECK MONITORING INFORMATION 516
ABNORMALITY RECORD MENU 524
CHECK MAINTENANCE RECORD 527
MAINTENANCE MODE SETTING 529
Phone number entry setting 533
DEFAULT SETTING MENU 534
TESTING MENU 542
ADJUSTMENT MENU 544
NO-INJECTION CRANKING OPERATION 561
KOMTRAX SETTINGS MENU 563
Display service message 565
START UP KOMTRAX TERMINAL 566
Adjust rearview camera angle 570
ADJUST REARVIEW CAMERA ANGLE 570
ENGINE CONTROLLER VOLTAGE CIRCUIT 572
TEST DIODES 573
TEST DIODES BY DIGITAL TESTER 573
TEST DIODES BY ANALOG TESTER 573
Pm-CLINIC 574
PM CLINIC SERVICE 574
PM CLINIC CHECK SHEET: PC210-10M0 577
PM CLINIC CHECK SHEET: PC210LC-10M0 585
40 TROUBLESHOOTING 593
ABBREVIATION LIST 594
CONTENTS 599
RELATED INFORMATION TO TROUBLESHOOT 605
PRECAUTIONS FOR TROUBLESHOOTING 605
SEQUENCE OF EVENTS IN TROUBLESHOOTING 606
CHECKS BEFORE TROUBLESHOOTING 608
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 610
WALK-AROUND CHECK 610
TEST ENGINE RELATED PARTS 611
TEST WORK EQUIPMENT AND UNDERCARRIAGE 613
CHECK ELECTRIC EQUIPMENT 614
CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER 619
CONNECT ADAPTER TO TROUBLESHOOT MONITOR 619
CONNECT ADAPTER TO TROUBLESHOOT PUMP CONTROLLER 621
CONNECT ADAPTER TO TROUBLESHOOT KOMTRAX TERMINAL 625
CONNECT ADAPTER TO TROUBLESHOOT ENGINE CONTROLLER 627
CONNECT ADAPTER TO TROUBLESHOOT ENGINE INTERMEDIATE CONNECTOR 628
DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PUSH 630
DISCONNECT AND CONNECT DEUTSCH CONNECTOR 630
DISCONNECT AND CONNECT BOSCH CONNECTOR 630
DISCONNECT AND CONNECT AMP CONNECTOR 631
DISCONNECT AND CONNECT SUMITOMO CONNECTOR 632
DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PULL 633
DISCONNECT AND CONNECT DELPHI CONNECTOR AND PACKARD CONNECTOR 633
DISCONNECT AND CONNECT SLIDE TYPE CONNECTOR 634
DISCONNECT AND CONNECT FRAMATOME CONNECTOR 634
DISCONNECT AND CONNECT TYCO CONNECTOR 635
DISCONNECT AND CONNECT CONNECTOR WITH HOUSING TO ROTATE 636
PROCEDURE FOR TROUBLESHOOTING 637
INFORMATION DESCRIBED IN TROUBLESHOOTING 638
DIAGNOSE OPEN CIRCUIT OF HYDRAULIC PRESSURE SENSOR SYSTEM WIRING HARNESS 641
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE 644
CONNECTOR LAYOUT 718
CONNECTOR CONTACT IDENTIFICATION 724
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 766
FUSE LOCATION AND CONNECTION TABLE 772
DRAWING OF SHORT CIRCUIT ELECTRICAL CONNECTOR FOR TROUBLESHOOTING 775
FAILURE CODES TABLE 777
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 785
FAILURE CODE [602KNX] 785
FAILURE CODE [6AZ0ZG] 788
FAILURE CODE [879AKA] 792
FAILURE CODE [879AKB] 794
FAILURE CODE [879BKA] 796
FAILURE CODE [879BKB] 799
FAILURE CODE [879CKA] 802
FAILURE CODE [879CKB] 804
FAILURE CODE [879DKZ] 806
FAILURE CODE [879EMC] 810
FAILURE CODE [879FMC] 812
FAILURE CODE [879GKX] 814
FAILURE CODE [989L00] 817
FAILURE CODE [989M00] 819
FAILURE CODE [989N00] 821
FAILURE CODE [AA10NX] 822
FAILURE CODE [AB00KE] 825
FAILURE CODE [B@BAZG] 829
FAILURE CODE [B@BAZK] 833
FAILURE CODE [B@BCZK] 836
FAILURE CODE [B@BCNS] 838
FAILURE CODE [B@BCQA] 842
FAILURE CODE [B@HANS] 844
FAILURE CODE [CA111] 846
FAILURE CODE [CA115] 851
ENGINE Ne (CRANKSHAFT) SPEED SENSOR 857
FAILURE CODE [CA122] 859
FAILURE CODE [CA123] 862
FAILURE CODE [CA131] 866
FAILURE CODE [CA132] 869
FAILURE CODE [CA144] 873
FAILURE CODE [CA145] 877
FAILURE CODE [CA153] 881
FAILURE CODE [CA154] 885
FAILURE CODE [CA155] 889
FAILURE CODE [CA187] 891
FAILURE CODE [CA221] 894
FAILURE CODE [CA222] 897
FAILURE CODE [CA227] 900
FAILURE CODE [CA234] 903
FAILURE CODE [CA238] 905
FAILURE CODE [CA271] 908
FAILURE CODE [CA272] 911
FAILURE CODE [CA322] 913
FAILURE CODE [CA323] 917
FAILURE CODE [CA324] 921
FAILURE CODE [CA325] 925
FAILURE CODE [CA331] 929
FAILURE CODE [CA332] 933
FAILURE CODE [CA342] 937
FAILURE CODE [CA351] 942
FAILURE CODE [CA352] 947
FAILURE CODE [CA386] 950
FAILURE CODE [CA435] 952
FAILURE CODE [CA441] 955
FAILURE CODE [CA442] 960
FAILURE CODE [CA449] 964
FAILURE CODE [CA451] 970
FAILURE CODE [CA452] 973
FAILURE CODE [CA488] 976
FAILURE CODE [CA553] 979
FAILURE CODE [CA559] 984
TEST LOW PRESSURE FUEL CIRCUIT DEVICES 990
FAILURE CODE [CA689] 992
FAILURE CODE [CA731] 997
INSTALLATION POINTS OF CRANKSHAFT AND CAMSHAFT SPEED SENSORS1000
FAILURE CODE [CA757]1002
FAILURE CODE [CA778]1007
ENGINE Ne (CRANKSHAFT) SPEED SENSOR1012
FAILURE CODE [CA2185]1014
FAILURE CODE [CA2186]1016
FAILURE CODE [CA2249]1019
TEST LOW PRESSURE FUEL CIRCUIT DEVICES1025
FAILURE CODE [CA2311]1027
FAILURE CODE [CA2555]1034
FAILURE CODE [CA2556]1038
FAILURE CODE [D110KB]1042
FAILURE CODE [D19JKZ]1045
FAILURE CODE [D1N0KA]1050
FAILURE CODE [D1N0KB]1052
FAILURE CODE [D1N0KY]1054
FAILURE CODE [D811MC]1055
FAILURE CODE [D862KA]1056
FAILURE CODE [D8AQKR]1058
FAILURE CODE [D8ALKA]1066
FAILURE CODE [D8ALKB]1070
FAILURE CODE [DA20MC]1073
FAILURE CODE [DA22KK]1074
FAILURE CODE [DA25KP]1079
FAILURE CODE [DA26KP]1083
FAILURE CODE [DA29KQ]1089
FAILURE CODE [DA2LKA]1094
FAILURE CODE [DA2LKB]1098
FAILURE CODE [DA2QKR]1101
FAILURE CODE [DA2RKR]1110
FAILURE CODE [DAF0MB]1118
FAILURE CODE [DAF0MC]1119
FAILURE CODE [DAF9KQ]1120
FAILURE CODE [DAFGMC]1122
FAILURE CODE [DAFLKA]1123
FAILURE CODE [DAFLKB]1127
FAILURE CODE [DAFQKR]1130
FAILURE CODE [DAZ9KQ]1139
FAILURE CODE [DAZQKR]1141
FAILURE CODE [DB2QKR]1149
FAILURE CODE [DDPAKA]1158
FAILURE CODE [DGH2KA]1161
FAILURE CODE [DGH2KB]1164
FAILURE CODE [DHA4KA]1167
FAILURE CODE [DHE5MA]1170
FAILURE CODE [DHPAMA]1174
FAILURE CODE [DHPBMA]1178
FAILURE CODE [DHS3MA]1182
FAILURE CODE [DHS4MA]1186
FAILURE CODE [DHS8MA]1190
FAILURE CODE [DHS9MA]1194
FAILURE CODE [DHSAMA]1198
FAILURE CODE [DHSBMA]1202
FAILURE CODE [DHSCMA]1206
FAILURE CODE [DHSDMA]1210
FAILURE CODE [DHSFMA]1214
FAILURE CODE [DHSGMA]1218
FAILURE CODE [DHSHMA]1222
FAILURE CODE [DHSJMA]1226
FAILURE CODE [DJG1KX]1230
FAILURE CODE [DKR0MA]1234
FAILURE CODE [DKR1MA]1238
FAILURE CODE [DKR2MA]1242
FAILURE CODE [DKR2NX]1246
FAILURE CODE [DLM5KA]1248
FAILURE CODE [DLM5MB]1252
FAILURE CODE [DR21KX]1256
FAILURE CODE [DR31KX]1259
FAILURE CODE [DV20KB]1260
FAILURE CODE [DW43KA]1263
FAILURE CODE [DW43KB]1266
FAILURE CODE [DW43KY]1269
FAILURE CODE [DW45KA]1271
FAILURE CODE [DW45KB]1275
FAILURE CODE [DW45KY]1279
FAILURE CODE [DW91KA]1282
FAILURE CODE [DW91KB]1284
FAILURE CODE [DW91KY]1287
FAILURE CODE [DW97KA]1289
FAILURE CODE [DW97KB]1291
FAILURE CODE [DW97KY]1294
FAILURE CODE [DWA2KA]1296
FAILURE CODE [DWA2KB]1298
FAILURE CODE [DWA2KY]1301
FAILURE CODE [DWK0KA]1303
FAILURE CODE [DWK0KB]1305
FAILURE CODE [DWK0KY]1308
FAILURE CODE [DWK2KA]1310
FAILURE CODE [DWK2KB]1312
FAILURE CODE [DWK2KY]1315
FAILURE CODE [DWK8KA]1317
FAILURE CODE [DWK8KB]1319
FAILURE CODE [DWK8KY]1322
FAILURE CODE [DWN5KA]1324
FAILURE CODE [DWN5KB]1327
FAILURE CODE [DWN5KY]1330
FAILURE CODE [DXA8KA]1332
FAILURE CODE [DXA8KB]1335
FAILURE CODE [DXA9KA]1339
FAILURE CODE [DXA9KB]1342
FAILURE CODE [DXE0KA]1346
FAILURE CODE [DXE0KB]1348
FAILURE CODE [DXE4KA]1351
FAILURE CODE [DXE4KB]1353
FAILURE CODE [DXE4KY]1356
FAILURE CODE [DXE5KA]1358
FAILURE CODE [DXE5KB]1360
FAILURE CODE [DXE6KA]1363
FAILURE CODE [DXE6KB]1365
FAILURE CODE [DY20KA]1368
FAILURE CODE [DY20MA]1372
FAILURE CODE [DY2CKB]1376
FAILURE CODE [DY2DKB]1381
FAILURE CODE [DY2EKB]1384
FAILURE CODE [F@BBZL]1387
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1390
ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1390
MANUAL PREHEATING SYSTEM DOES NOT WORK1400
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1404
WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP1408
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING1413
WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL CAUTION LAMP LIGHTS UP IN YELLOW1418
WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL CAUTION LAMP LIGHTS UP IN YELLOW1420
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION1422
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION1424
AIR CLEANER CLOGGING MONITOR LIGHT UP IN YELLOW WHILE ENGINE IS IN OPERATION1426
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1428
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1432
WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1433
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1434
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1436
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1437
FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM1439
FUEL GAUGE INDICATES INCORRECT LEVEL1442
COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM1444
COOLANT TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE1445
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM1447
HYDRAULIC OIL TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE1450
MACHINE MONITOR SHOWS INCORRECT MODEL1452
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED1453
FUNCTION SWITCH DOES NOT OPERATE1454
AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER)1455
AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED1457
AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION1458
WORK MODE SELECTOR SCREEN DOES NOT APPEAR WHILE WORK MODE SWITCH IS OPERATED1461
ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED1462
TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED1463
TRAVEL SPEED DOES NOT CHANGE WHILE TRAVEL SPEED IS CHANGED1464
ALARM BUZZER DOES NOT STOP1466
SERVICE METER IS NOT DISPLAYED WHILE STARTING SWITCH IS IN OFF POSITION1467
MACHINE DOES NOT CHANGE TO SERVICE MODE1468
ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE1469
ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK1473
MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED1475
MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON1479
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY1482
ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED1486
TRAVEL ALARM DOES NOT SOUND1488
TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS1491
HORN DOES NOT SOUND1493
HORN DOES NOT STOP1497
WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED1499
WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED1500
WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED1503
BOOM RAISE IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION1506
BOOM LOWER IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION1507
ARM OUT IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION1508
ARM IN IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION1509
BUCKET DUMP IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION1510
BUCKET CURL IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION1511
SWING IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION1512
TRAVEL IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION1513
SERVICE IN IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION1514
ATTACHMENT CIRCUIT CANNOT BE CHANGED1517
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY1519
QUICK COUPLER DOES NOT WORK1521
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1526
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (H MODE)1526
ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK1527
All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER1529
FINE CONTROL PERFORMANCE OR RESPONSE IS POOR1542
UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP1547
ENGINE SPEED DROPS LARGELY OR ENGINE STOPS1549
BOOM SPEED OR POWER IS LOW1558
Arm speed or power is low1570
BUCKET SPEED OR POWER IS LOW1581
WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION1591
HYDRAULIC DRIFT OF BOOM IS LARGE1595
HYDRAULIC DRIFT OF ARM IS LARGE1597
HYDRAULIC DRIFT OF BUCKET IS LARGE1601
WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES1604
TIME LAG OF WORK EQUIPMENT IS LARGE1606
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE1613
ATTACHMENT CIRCUIT CANNOT BE CHANGED1616
OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED1618
IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER1620
IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY1622
IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISE SPEED IS LOW1623
MACHINE DOES NOT TRAVEL STRAIGHT1624
MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW1635
TRAVEL SPEED IS SLOW1650
ONE OF TRACKS DOES NOT RUN1661
TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST1670
MACHINE DOES NOT SWING TO RIGHT OR LEFT1673
SWINGS ONLY IN ONE DIRECTION1678
SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)1681
SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION1688
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)1692
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)1694
SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS1698
LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS1700
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)1703
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)1705
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT MOVE)1709
UNUSUAL NOISE IS HEARD FROM AROUND FAN1711
50 DISASSEMBLY AND ASSEMBLY1713
CONTENTS1714
ABBREVIATION LIST1718
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY1723
HOW TO READ THIS MANUAL1723
COATING MATERIALS LIST1725
SPECIAL TOOLS LIST1729
SKETCHES OF SPECIAL TOOLS1738
PREPARATION1744
DRAIN AND ADD COOLANT1744
DRAIN COOLANT1744
ADD COOLANT1745
DRAIN AND AD HYDRAULIC OIL1747
DRAIN HYDRAULIC OIL1747
ADD HYDRAULIC OIL1748
DRAIN AND ADD FUEL1750
DRAIN FUEL1750
ADD FUEL1751
COLLECT AND REFILL REFRIGERANT1754
COLLECT REFRIGERANT1754
REFILL REFRIGERANT1754
ENGINE AND COOLING SYSTEM1755
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY1755
REMOVE SUPPLY PUMP ASSEMBLY1756
INSTALL SUPPLY PUMP ASSEMBLY1760
REMOVE AND INSTALL INJECTOR ASSEMBLY1764
REMOVE INJECTOR ASSEMBLY1765
INSTALL INJECTOR ASSEMBLY1768
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY1775
REMOVE CYLINDER HEAD ASSEMBLY1776
INSTALL CYLINDER HEAD ASSEMBLY1787
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY1802
REMOVE STARTING MOTOR ASSEMBLY1802
INSTALL STARTING MOTOR ASSEMBLY1804
REMOVE AND INSTALL ALTERNATOR BELT1807
REMOVE ALTERNATOR BELT1807
INSTALL ALTERNATOR BELT1811
REMOVE AND INSTALL RADIATOR ASSEMBLY1814
REMOVE RADIATOR ASSEMBLY1814
INSTALL RADIATOR ASSEMBLY1817
REMOVE AND INSTALL HYDRAULIC COOLER ASSEMBLY1820
REMOVE HYDRAULIC COOLER ASSEMBLY1821
INSTALL HYDRAULIC COOLER ASSEMBLY1824
REMOVE AND INSTALL AFTER COOLER ASSEMBLY1827
REMOVE AFTER COOLER ASSEMBLY1827
INSTALL AFTER COOLER ASSEMBLY1829
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY1833
REMOVE FAN CLUTCH ASSEMBLY1834
INSTALL FAN CLUTCH ASSEMBLY1838
REMOVE AND INSTALL FAN1844
REMOVE FAN1844
INSTALL FAN1844
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY1846
REMOVE ENGINE AND MAIN PUMP ASSEMBLY1847
INSTALL ENGINE AND MAIN PUMP ASSEMBLY1863
REMOVE AND INSTALL ENGINE FRONT OIL SEAL1880
REMOVE ENGINE FRONT OIL SEAL1880
INSTALL ENGINE FRONT OIL SEAL1883
REMOVE AND INSTALL ENGINE REAR OIL SEAL1886
REMOVE ENGINE REAR OIL SEAL1886
INSTALL ENGINE REAR OIL SEAL1888
REMOVE AND INSTALL FUEL COOLER ASSEMBLY1892
REMOVE FUEL COOLER ASSEMBLY1892
INSTALL FUEL COOLER ASSEMBLY1893
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY1895
REMOVE ENGINE HOOD ASSEMBLY1895
INSTALL ENGINE HOOD ASSEMBLY1897
REMOVE AND INSTALL FUEL TANK ASSEMBLY1899
REMOVE FUEL TANK ASSEMBLY1900
INSTALL FUEL TANK ASSEMBLY1904
REMOVE AND INSTALL AIR CLEANER ASSEMBLY1910
REMOVE AIR CLEANER ASSEMBLY1910
INSTALL AIR CLEANER ASSEMBLY1912
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY1914
REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY1914
INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY1917
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY1920
REMOVE AIR CONDITIONER CONDENSER ASSEMBLY1920
INSTALL AIR CONDITIONER CONDENSER ASSEMBLY1922
POWER TRAIN1924
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY1924
REMOVE TRAVEL MOTOR AND FIANL DRIVE ASSEMBLY1925
INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY1927
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY1929
DISASSEMBLE FINAL DRIVE ASSEMBLY1930
ASSEMBLE FINAL DRIVE ASSEMBLY1935
REMOVE AND INSTALL SWIVEL MOTOR AND SWING MACHINERY ASSEMBLY1947
REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY1948
INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY1950
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY1954
DISASSEMBLE SWING MACHINERY ASSEMBLY1955
ASSEMBLE SWING MACHINERY ASSEMBLY1961
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY1970
REMOVE SWING CIRCLE ASSEMBLY1970
INSTALL SWING CIRCLE ASSEMBLY1971
UNDERCARRIAGE AND FRAME1972
SEPARATION AND CONNECTION OF TRACK ASSEMBLY1972
SEPARATE TRACK ASSEMBLY1972
INSTALL TRACK ASSEMBLY1975
REMOVE AND INSTALL SPROCKET1979
REMOVE SPROCKET1979
INSTALL SPROCKET1980
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY1981
REMOVE IDLER AND IDLER CUSHION ASSEMBLY1981
INSTALL IDLER AND IDLER CUSHION ASSEMBLY1982
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY1984
DISASSEMBLE IDLER ASSEMBLY1984
ASSEMBLE IDLER ASSEMBLY1986
DISASSEMBLE AND ASSEMBLE IDLER CUSHION ASSEMBLY1993
DISASSEMBLE IDLER CUSHION ASSEMBLY1994
ASSEMBLE IDLER CUSHION ASSEMBLY1995
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY1997
DISASSEMBLE TRACK ROLLER ASSEMBLY1998
ASSEMBLE TRUCK ROLLER ASSEMBLY1999
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY2001
DISASSEMBLE CARRIER ROLLER ASSEMBLY2001
ASSEMBLE CARRIER ROLLER ASSEMBLY2003
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY2006
REMOVE REVOLVING FRAME ASSEMBLY2007
INSTALL REVOLVING FRAME ASSEMBLY2010
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2013
REMOVE COUNTERWEIGHT ASSEMBLY2013
INSTALL COUNTERWEIGHT ASSEMBLY2014
HYDRAULIC SYSTEM2016
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY2016
REMOVE CENTER SWIVEL JOINT ASSEMBLY2017
INSTALL CENTER SWIVEL JOINT ASSEMBLY2020
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2024
DISASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2025
ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2026
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2028
REMOVE HYDRAULIC TANK ASSEMBLY2029
INSTALL HYDRAULIC TANK ASSEMBLY2033
REMOVE AND INSTALL MAIN PUMP ASSEMBLY2039
REMOVE MAIN PUMP ASSEMBLY2040
INSTALL MAIN PUMP ASSEMBLY2047
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2054
REMOVE CONTROL VALVE ASSEMBLY2055
INSTALL CONTROL VALVE ASSEMBLY2067
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY2080
REPLACE PRESSURE COMPENSATION VALVE SEAL RING2081
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2083
DISASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2084
ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2084
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2086
DISASSEMBLE TRAVEL PPC VALVE ASSEMBLY2086
ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2087
WORK EQUIPMENT2089
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2089
REMOVE WORK EQUIPMENT ASSEMBLY2090
INSTALL WORK EQUIPMENT ASSEMBLY2093
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2096
DISASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2097
ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2102
CAB RELATED PARTS2111
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY2111
REMOVE OPERATOR CAB ASSEMBLY2112
INSTALL OPERATOR CAB ASSEMBLY2122
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)2132
REMOVE OPERATOR CAB GLASS (ADHERED GLASS)2134
INSTALL OPERATOR CAB GLASS (ADHERED GLASS)2134
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY2145
REMOVE FRONT WINDOW ASSEMBLY2146
INSTALL FRONT WINDOW ASSEMBLY2149
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY2155
REMOVE FLOOR FRAME ASSEMBLY2156
INSTALL FLOOR FRAME ASSEMBLY2162
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2170
REMOVE AIR CONDITIONER UNIT ASSEMBLY2171
INSTALL AIR CONDITIONER UNIT ASSEMBLY2179
REMOVE AND INSTALL OPERATOR SEAT2187
REMOVE OPERATOR SEAT2187
INSTALL OPERATOR SEAT2188
REMOVE AND INSTALL SEATBELT2190
REMOVE SEATBELT2190
INSTALL SEATBELT2191
REMOVE AND INSTALL FRONT WIPER ASSEMBLY2192
REMOVE FRONT WIPER ASSEMBLY2192
INSTALL FRONT WIPER ASSEMBLY2198
ELECTRICAL SYSTEM2206
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2206
REMOVE ENGINE CONTROLLER ASSEMBLY2206
INSTALL ENGINE CONTROLLER ASSEMBLY2208
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY2210
REMOVE PUMP CONTROLLER ASSEMBLY2210
INSTALL PUMP CONTROLLER ASSEMBLY2212
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2216
REMOVE MACHINE MONITOR ASSEMBLY2216
INSTALL MACHINE MONITOR ASSEMBLY2219
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR2223
REMOVE PUMP SWASH PLATE SENSOR2223
INSTALL PUMP SWASH PLATE SENSOR2225
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY2228
REMOVE KOMTRAX TERMINAL ASSEMBLY2228
INSTALL KOMTRAX TERMINAL ASSEMBLY2231
60 MAINTENANCE STANDARD2235
CONTENTS2236
ABBREVIATION LIST2237
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD2242
ENGINE AND COOLING SYSTEM2244
MAINTENANCE STANDARD OF ENGINE MOUNT2244
MAINTENANCE STANDARD OF COOLING SYSTEM2245
POWER TRAIN2247
MAINTENANCE STANDARD OF SWING CIRCLE2247
MAINTENANCE STANDARD OF SWING MACHINERY2248
MAINTENANCE STANDARD OF FINAL DRIVE2251
MAINTENANCE STANDARD OF SPROCKET2253
SPROCKET TOOTH PROFILE FULL-SCALE DRAWING2254
UNDERCARRIAGE AND FRAME2255
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION2255
MAINTENANCE STANDARD OF IDLER2256
MAINTENANCE STANDARD OF TRACK ROLLER2258
MAINTENANCE STANDARD OF CARRIER ROLLER2260
MAINTENANCE STANDARD OF TRACK SHOE2261
MAINTENANCE STANDARD OF TRIPLE SHOE2264
MAINTENANCE STANDARD OF SWAMP SHOE2265
MAINTENANCE STANDARD OF ROAD LINER2266
HYDRAULIC SYSTEM2267
MAINTENANCE STANDARD OF HYDRAULIC TANK2267
MAINTENANCE STANDARD OF MAIN PUMP2268
MAINTENANCE STANDARD OF LS-EPC VALVE2270
MAINTENANCE STANDARD OF PC-EPC VALVE2271
MAINTENANCE STANDARD OF SWING MOTOR2272
MAINTENANCE STANDARD OF TRAVEL MOTOR2274
MAINTENANCE STANDARD OF CONTROL VALVE2277
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE2287
MAINTENANCE STANDARD OF TRAVEL PPC VALVE2290
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)2293
MAINTENANCE STANDARD OF ATTACHMENT OIL FLOW ADJUSTER EPC VALVE2294
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE2295
MAINTENANCE STANDARD OF SOLENOID VALVE2296
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)2298
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)2299
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT2300
WORK EQUIPMENT2301
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE2301
DIMENSIONS OF ARM2307
DIMENSIONS OF BUCKET2309
MAINTENANCE STANDARD OF BOOM CYLINDER2311
MAINTENANCE STANDARD OF ARM CYLINDER2312
MAINTENANCE STANDARD OF BUCKET CYLINDER2313
80 OTHERS2315
ABBREVIATION2316
AIR CONDITIONER SYSTEM2321
PRECAUTIONS FOR REFRIGERANT2321
LAYOUT DRAWING OF AIR CONDITIONER SYSTEM2322
SPECIFICATION OF AIR CONDITIONER2324
CONFIGURATION OF REFRIGERATION CYCLE2325
FUNCTION OF REFRIGERATION CYCLE2326
SYSTEM DIAGRAM OF AIR CONDITIONER2327
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2328
AIR CONDITIONER UNIT2328
STRUCTURE OF AIR CONDITIONER UNIT2328
FUNCTION OF AIR CONDITIONER UNIT2329
COMPONENT PARTS OF AIR CONDITIONER UNIT2330
AIR CONDITIONER CONTROLLER2334
STRUCTURE OF AIR CONDITIONER CONTROLLER2334
FUNCTION OF AIR CONDITIONER CONTROLLER2334
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER2334
COMPRESSOR2336
STRUCTURE OF COMPRESSOR2336
SPECIFICATIONS OF COMPRESSOR2336
FUNCTION OF COMPRESSOR2336
OPERATION OF COMPRESSOR2336
CONDENSER2337
STRUCTURE OF CONDENSER2337
SPECIFICATIONS OF CONDENSOR2337
FUNCTION OF COMPRESSOR2337
AIR CONDITIONER RELATED SENSORS2339
STRUCTURE OF SUNLIGHT SENSOR2339
FUNCTION OF SUNLIGHT SENSOR2339
STRUCTURE OF OUTSIDE TEMPERATURE SENSOR2339
FUNCTION OF OUTSIDE AIR TEMPERATURE SENSOR2339
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS OF AIR CONDITIONER2340
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2343
TEST AIR LEAKAGE (DUCT CONNECTION)2347
TEST AIR LEAKAGE (DUCT CONNECTION)2347
TEST AIR CONDITIONER BY SELF-DIAGNOSIS FUNCTION2350
TEST VENT (MODE) CHANGEOVER2351
TEST VENT (MODE) CHANGEOVER2351
TEST FRESH/RECIRC AIR CHANGEOVER2353
TEST FRESH/RECIRC AIR CHANGEOVER2353
TEST SUNLIGHT SENSOR2354
TEST SUNLIGHT SENSOR2354
TEST DUAL PRESSURE SWITCH2355
TEST DUAL PRESSURE SWITCH2355
TEST RELAY2356
TEST RELAY2356
SIMPLE CHECK OF REFRIGERANT VOLUME THROUGH SIGHT GLASS2358
PROCEDURE FOR TROUBLE SHOOTING OF AIR CONDITIONER2359
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2360
FAILURE CODE [879AKA]2363
FAILURE CODE [879AKB]2365
FAILURE CODE [879BKA]2367
FAILURE CODE [879BKB]2370
FAILURE CODE [879CKA]2373
FAILURE CODE [879CKB]2375
FAILURE CODE [879DKZ]2377
FAILURE CODE [879EMC]2381
FAILURE CODE [879FMC]2383
FAILURE CODE [879GKX]2385
AIR CONDITIONER DOES NOT OPERATE2388
DEFECTIVE COOLING2391
HEATER DOES NOT OPERATE2400
COOL AIR DOES NOT COME OUT2404
NO AIR COMES OUT OR AIR FLOW IS ABNORMAL2410
FRESH/RECIRC AIR CHANGEOVER NOT POSSIBLE2414
CONNECT SERVICE TOOL2418
CONNECT SERVICE TOOL2419
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPING2420
HANDLE COMPRESSOR OIL2422
REPLACE DESICCANT2424
90 CIRCUIT DIAGRAMS2427
CONTENTS2428
ABBREVIATION LIST2429
HOW TO READ THE CODES FOR ELECTRIC CABLE2434
HYDRAULIC CIRCUIT DIAGRAM2439
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2439
HYDRAULIC CIRCUIT DIAGRAM2443
ELECTRICAL CIRCUIT DIAGRAM2445
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM2445
ELECTRICAL CIRCUIT DIAGRAM (1/7)2449
ELECTRICAL CIRCUIT DIAGRAM (2/7)2451
ELECTRICAL CIRCUIT DIAGRAM (3/7)2453
ELECTRICAL CIRCUIT DIAGRAM (4/7)2455
ELECTRICAL CIRCUIT DIAGRAM (5/7)2457
ELECTRICAL CIRCUIT DIAGRAM (6/7)2459
ELECTRICAL CIRCUIT DIAGRAM (7/7)2461
CONNECTOR AND WIRING HARNESS CHART2463
CONNECTOR AND WIRING HARNESS CHART (1/11)2465
CONNECTOR AND WIRING HARNESS CHART (2/11)2467
CONNECTOR AND WIRING HARNESS CHART (3/11)2469
CONNECTOR AND WIRING HARNESS CHART (4/11)2471
CONNECTOR AND WIRING HARNESS CHART (5/11)2473
CONNECTOR AND WIRING HARNESS CHART (6/11)2475
CONNECTOR AND WIRING HARNESS CHART (7/11)2477
CONNECTOR AND WIRING HARNESS CHART (8/11)2479
CONNECTOR AND WIRING HARNESS CHART (9/11)2481
CONNECTOR AND WIRING HARNESS CHART (10/11)2483
CONNECTOR AND WIRING HARNESS CHART (11/11)2485
INDEX2487

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24