Komatsu HYDRAULIC EXCAVATOR PC210LC-11 Shop Manual SEN06516-C6 PDF

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Komatsu HYDRAULIC EXCAVATOR PC210LC-11 Shop Manual SEN06516-C6 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC210LC-11 Shop Manual SEN06516-C6 – PDF DOWNLOAD

Language : English
Pages :2763
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC210LC-11 Shop Manual SEN06516-C6 – PDF DOWNLOAD

SERIAL NUMBERS C80001 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 PC210LC-11 Shop Manual SEN06516-C6 – PDF DOWNLOAD

SERIAL NUMBERS C80001 and up

COVER 1
00 INDEX AND FOREWORD 2
INDEX 3
ABBREVIATION LIST 21
FOREWORD, SAFETY, BASIC INFORMATION 27
HOW TO READ THE SHOP MANUAL 27
SAFETY NOTICE FOR OPERATION 29
PRECAUTIONS TO PREVENT FIRE 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 41
PRECAUTIONS FOR DEF 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 42
PRECAUTIONS FOR ADDING 42
PRECAUTIONS FOR STORING 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 42
THE OTHER PRECAUTIONS 42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 53
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 55
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 56
PRACTICAL USE OF KOMTRAX 57
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 60
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 62
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 66
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 72
HOW TO READ ELECTRICAL WIRE CODE 73
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 77
STANDARD TIGHTENING TORQUE TABLE 80
CONVERSION TABLE 87
01 SPECIFICATIONS 92
CONTENTS 93
ABBREVIATION LIST 94
SPECIFICATIONS 100
SPECIFICATION DRAWING 100
SPECIFICATION DRAWING: PC210LC-11 100
WORKING RANGE DRAWINGS 101
WORKING RANGE: PC210LC-11 101
SPECIFICATIONS 102
SPECIFICATIONS: PC210LC-11 102
WEIGHT TABLE 105
WEIGHT TABLE: PC210LC-11 105
TABLE OF FUEL, COOLANT, AND LUBRICANTS 107
108
USE OF FUEL, COOLANT AND LUBRICANTS TO ACCORDING TO AMBIENT TEMPERATURE 108
10 STRUCTURE AND FUNCTION 110
CONTENTS 111
ABBREVIATION LIST 114
UREA SCR SYSTEM 120
LAYOUT DRAWING OF UREA SCR SYSTEM 121
UREA SCR SYSTEM DIAGRAM 126
FUNCTION OF UREA SCR SYSTEM 127
FUNCTION OF AdBlue/DEF SYSTEM 127
INDUCEMENT STRATEGY 129
COMPONENT PARTS OF UREA SCR SYSTEM 143
AdBlue/DEF MIXING TUBE 143
SCR ASSEMBLY 144
AdBlue/DEF TANK 146
AdBlue/DEF PUMP 148
AdBlue/DEF INJECTOR 149
AdBlue/DEF HOSE 150
AdBlue/DEF TANK HEATING VALVE 151
BOOT-UP SYSTEM 152
LAYOUT DRAWING OF BOOT-UP SYSTEM 152
SYSTEM OPERATING LAMP SYSTEM 154
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 154
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 154
BATTERY DISCONNECT SWITCH 155
FUNCTION OF BATTERY DISCONNECT SWITCH 155
ENGINE SYSTEM 156
LAYOUT DRAWING OF ENGINE SYSTEM 156
SPECIFICATIONS OF ENGINE SYSTEM 157
FUNCTION OF ENGINE SYSTEM 157
ENGINE CONTROL SYSTEM 158
ENGINE CONTROL SYSTEM DIAGRAM 158
FUNCTION OF ENGINE CONTROL SYSTEM 159
AUTO-DECELERATION SYSTEM 161
AUTO-DECELERATION SYSTEM DIAGRAM 161
FUNCTION OF AUTO-DECELERATION SYSTEM 161
OPERATION OF AUTO-DECELERATION SYSTEM 162
ENGINE AUTOMATIC WARM-UP SYSTEM 163
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 163
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 164
OVERHEAT PREVENTION SYSTEM 165
OVERHEAT PREVENTION SYSTEM DIAGRAM 165
FUNCTION OF OVERHEAT PREVENTION SYSTEM 166
TURBOCHARGER PROTECTION SYSTEM 168
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 168
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 169
AUTOMATIC IDLE STOP SYSTEM 170
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 170
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 170
COMPONENT PARTS OF ENGINE SYSTEM 173
VGT 173
EGR SYSTEM 177
EGR VALVE 180
EGR COOLER 182
KCCV SYSTEM 184
KCCV VENTILATOR 186
KDPF 188
COOLING SYSTEM 192
LAYOUT DRAWING OF COOLING SYSTEM 192
SPECIFICATIONS OF COOLING SYSTEM 193
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 194
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 194
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 195
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 196
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 196
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 196
COMPONENT PARTS OF COOLING SYSTEM 198
FAN CLUTCH 198
CONTROL SYSTEM 199
LAYOUT DRAWING OF CONTROL SYSTEM 199
MACHINE MONITOR SYSTEM 202
MACHINE MONITOR SYSTEM DIAGRAM 202
KOMTRAX SYSTEM 203
KOMTRAX SYSTEM DIAGRAM 203
FUNCTION OF KOMTRAX SYSTEM 203
COMPONENT PARTS OF CONTROL SYSTEM 204
MACHINE MONITOR 204
KOMTRAX TERMINAL 219
PUMP CONTROLLER 221
RESISTOR FOR PC-EPC VALVE 225
CAN TERMINATING RESISTOR 226
ENGINE CONTROLLER 227
FUEL CONTROL DIAL 234
HYDRAULIC SYSTEM 236
LAYOUT DRAWING OF HYDRAULIC SYSTEM 236
CLSS 242
STRUCTURE OF CLSS 242
OPERATION OF UNLOAD VALVE AND LS PRESSURE 244
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 245
PRESSURE COMPENSATION CONTROL 258
ENGINE AND PUMP COMBINED CONTROL SYSTEM 262
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 262
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 263
PUMP AND VALVE CONTROL SYSTEM 268
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 268
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 269
COMPONENT PARTS OF HYDRAULIC SYSTEM 271
HYDRAULIC TANK 271
MAIN PUMP 273
CONTROL VALVE 299
WORK EQUIPMENT SYSTEM 356
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 356
STRUCTURE OF VALVE CONTROL 361
ONE-TOUCH POWER MAXIMIZING SYSTEM 363
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 363
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 364
PPC LOCK SYSTEM 365
PPC LOCK SYSTEM DIAGRAM 365
FUNCTION OF PPC LOCK SYSTEM 365
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 366
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 366
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 366
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 367
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 368
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 368
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 369
TOOL CONTROL SYSTEM 370
TOOL CONTROL SYSTEM DIAGRAM 370
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 372
WORK EQUIPMENT AND SWING PPC VALVE 372
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 378
2ND-LINE ATTACHMENT PPC VALVE 385
SOLENOID VALVE 387
ANTI-DROP VALVE FOR BOOM 390
ANTI-DROP VALVE FOR ARM 394
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 399
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 401
PILOT CIRCUIT ACCUMULATOR 403
ATTACHMENT CIRCUIT ACCUMULATOR 404
SWING SYSTEM 405
LAYOUT DRAWING OF SWING SYSTEM 405
SWING CONTROL SYSTEM DIAGRAM 409
FUNCTION OF SWING CONTROL SYSTEM 409
COMPONENT PARTS OF SWING SYSTEM 413
SWING MOTOR 413
SWING MACHINERY 425
SWING CIRCLE 427
TRAVEL SYSTEM 428
LAYOUT DRAWING OF TRAVEL SYSTEM 428
TRAVEL CONTROL SYSTEM DIAGRAM 432
FUNCTION OF TRAVEL CONTROL SYSTEM 433
COMPONENT PARTS OF TRAVEL SYSTEM 434
TRAVEL MOTOR 434
FINAL DRIVE 447
TRAVEL PPC VALVE 449
CENTER SWIVEL JOINT 453
UNDERCARRIAGE AND FRAME 455
LAYOUT DRAWING OF UNDERCARRIAGE 455
SPECIFICATIONS OF UNDERCARRIAGE 456
WORK EQUIPMENT 457
STRUCTURE OF WORK EQUIPMENT 457
FUNCTION OF WORK EQUIPMENT 457
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 458
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 458
BUCKET CLEARANCE ADJUSTMENT SHIM 458
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 458
CAB AND ITS ATTACHMENTS 459
ROPS CAB 459
STRUCTURE OF ROPS CAB 459
FUNCTION OF ROPS CAB 459
CAB MOUNT 460
STRUCTURE OF CAB MOUNT 460
FUNCTION OF CAB MOUNT 460
CAB TIPPING STOPPER 461
STRUCTURE OF CAB TIPPING STOPPER 461
FUNCTION OF CAB TIPPING STOPPER 461
20 STANDARD VALUE TABLE 462
CONTENTS 463
ABBREVIATION LIST 464
STANDARD VALUE TABLE FOR ENGINE 470
STANDARD VALUE TABLE FOR ENGINE: PC210LC-11 470
STANDARD VALUE TABLE FOR MACHINE 474
STANDARD VALUE TABLE FOR MACHINE: PC210LC-11 474
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 487
STANDARD VALUE TABLE FOR ELECTRICAL 491
STANDARD VALUE TABLE FOR ELECTRICAL 491
30 TESTING AND ADJUSTING 502
CONTENTS 503
ABBREVIATION LIST 506
RELATED INFORMATION ON TESTING AND ADJUSTING 512
TOOLS FOR TESTING AND ADJUSTING 512
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 518
ENGINE AND COOLING SYSTEM 520
TEST ENGINE SPEED 520
METHOD FOR TESTING ENGINE SPEED 520
TEST BOOST PRESSURE 523
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 523
METHOD FOR TESTING BOOST PRESSURE 524
TEST EXHAUST GAS COLOR 525
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 525
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 526
TEST AND ADJUST VALVE CLEARANCE 528
METHOD FOR TESTING VALVE CLEARANCE 528
METHOD FOR ADJUSTING VALVE CLEARANCE 529
TEST COMPRESSION PRESSURE 530
METHOD FOR TESTING COMPRESSION PRESSURE 530
TEST BLOWBY PRESSURE 535
METHOD FOR TESTING BLOWBY PRESSURE 535
TEST ENGINE OIL PRESSURE 537
METHOD FOR TESTING ENGINE OIL PRESSURE 537
TEST EGR VALVE AND VGT OIL PRESSURE 538
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 538
TEST FUEL PRESSURE 540
METHOD FOR TESTING FUEL PRESSURE 541
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 546
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 547
BLEEDING AIR FROM FUEL SYSTEM 553
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 553
TEST FUEL CIRCUIT FOR LEAKAGE 554
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 554
HANDLE CYLINDER CUT-OUT MODE OPERATION 556
HANDLE NO-INJECTION CRANKING OPERATION 557
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 558
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 558
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 558
TEST COOLING FAN SPEED 560
METHOD FOR TESTING COOLING FAN SPEED 560
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 561
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 561
TEST SCR RELATED FUNCTIONS 562
TEST AdBlue/DEF PUMP RAISED PRESSURE 566
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 569
TEST AdBlue/DEF LINE HEATER RELAY 1 574
TEST AdBlue/DEF LINE HEATER RELAY 2 577
TEST AdBlue/DEF PUMP HEATER RELAY 580
TEST AdBlue/DEF TANK HEATER VALVE 583
TEST DENITRATION EFFICIENCY OF SCR 586
CLEAN AdBlue/DEF TANK 590
METHOD FOR CLEANING AdBlue/DEF TANK 590
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 594
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 594
POWER TRAIN 596
TEST SWING CIRCLE BEARING CLEARANCE 596
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 596
UNDERCARRIAGE AND FRAME 597
TEST AND ADJUST TRACK TENSION 597
METHOD FOR TESTING TRACK TENSION 597
METHOD FOR ADJUSTING TRACK TENSION 597
HYDRAULIC SYSTEM 599
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 599
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 599
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 600
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 601
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 607
TEST OIL PRESSURE OF CONTROL CIRCUIT 610
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 610
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 612
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 612
TEST PC-EPC VALVE OUTLET PRESSURE 613
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 614
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 615
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 615
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL 616
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 619
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 620
METHOD FOR ADJUSTING LS VALVE 621
TEST OUTLET PRESSURE OF SOLENOID VALVE 622
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 622
OPERATING CONDITION OF SOLENOID VALVE 623
TEST PPC VALVE OUTLET PRESSURE 626
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 626
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 628
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 628
TEST PUMP SWASH PLATE SENSOR 629
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 629
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 630
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 630
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 630
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 631
TEST OIL LEAKAGE 632
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 632
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 632
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 633
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 634
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 634
BLEED AIR FROM HYDRAULIC CIRCUIT 635
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 637
TEST AND CHARGE ACCUMULATOR (MANUFACTURED BY NOK) NITROGEN GAS PRESSURE FOR ATTACHMENT (LOW PRESSURE SIDE) 639
TEST ACCUMULATOR (MANUFACTURED BY NOK) NITROGEN GAS PRESSURE FOR ATTACHMENT (LOW PRESSURE SIDE) 639
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH PRESSURE SIDE) 643
TEST ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH PRESSURE SIDE) 643
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ACCUMULATOR PIPING 647
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ACCUMULATOR PIPING 647
CAB AND ITS ATTACHMENTS 654
TEST CAB TIPPING STOPPER 654
METHOD FOR TESTING CAB TIPPING STOPPER 654
METHOD FOR ADJUSTING MIRRORS 655
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 655
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 656
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 657
ELECTRICAL SYSTEM 659
SET AND OPERATE MACHINE MONITOR 659
OPERATOR MODE 663
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 663
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 663
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 664
CHECKING FUNCTION OF SERVICE METER 664
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 664
SERVICE MODE 667
METHOD FOR OPERATING SERVICE MODE 667
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 669
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 675
ABNORMALITY RECORD MENU 687
METHOD FOR CONFIRMING MAINTENANCE RECORD 691
METHOD FOR OPERATING MAINTENANCE MODE SETTING 692
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 696
DEFAULT MENU 698
DIAGNOSTIC TESTS MENU 709
ADJUSTMENT MENU 719
METHOD FOR PERFORMING NO-INJECTION CRANKING 737
KOMTRAX SETTINGS MENU 739
METHOD FOR DISPLAYING SERVICE MESSAGE 741
METHOD FOR STARTING UP KOMTRAX TERMINAL 743
ADJUST REARVIEW CAMERA ANGLE 748
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 748
ADJUST KomVision CAMERA ANGLE 751
752
SETTING OF KomVision (CAMERA CALIBRATION) 752
KomVision screen – Check 12 m visibility 765
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 768
HANDLE BATTERY DISCONNECT SWITCH 769
TEST DIODES 770
METHOD FOR TESTING DIODE USING DIGITAL TESTER 770
METHOD FOR TESTING DIODE USING ANALOG TESTER 770
Pm CLINIC 771
Pm CLINIC SERVICE 771
Pm CLINIC CHECK SHEET 773
40 TROUBLESHOOTING 784
CONTENTS 785
ABBREVIATION LIST 796
RELATED INFORMATION ON TROUBLESHOOTING 802
GENERAL TROUBLESHOOTING POINTS 802
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 803
SEQUENCE OF EVENTS IN TROUBLESHOOTING 815
CHECKS BEFORE TROUBLESHOOTING 817
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 819
WALK-AROUND CHECK 819
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 821
CHECK FUEL LEVEL AND TYPE 821
CHECK IMPURE INGREDIENT IN FUEL 821
CHECK FUEL PREFILTER 822
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 822
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 823
CHECK MAIN FILTER 824
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 826
CHECK COOLANT LEVEL (RESERVOIR TANK) 827
CHECK CLOGGING OF AIR CLEANER 827
OUTER ELEMENT – CLEAN 828
ELEMENTS – REPLACE 830
CHECK HYDRAULIC OIL LEVEL 831
CHECK HYDRAULIC OIL STRAINER 832
CHECK HYDRAULIC FILTER 833
CHECK OIL LEVEL IN SWING MACHINERY CASE 834
CHECK OIL LEVEL IN DAMPER CASE 835
CHECK OIL LEVEL IN FINAL DRIVE CASE 835
BLEED AIR FROM FUEL SYSTEM 836
BLEED AIR FROM HYDRAULIC SYSTEM 836
ELECTRICAL EQUIPMENT – CHECK METHOD 836
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 844
PROCEDURE FOR TESTING AND TROUBLESHOOTING 854
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 857
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 861
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 863
CONNECTOR LIST AND LAYOUT 866
CONNECTOR CONTACT IDENTIFICATION 879
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 919
FUSE LOCATION TABLE 925
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 927
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 931
FAILURE CODES TABLE 933
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 951
FAILURE CODE [879AKA] 951
FAILURE CODE [879AKB] 952
FAILURE CODE [879BKA] 953
FAILURE CODE [879BKB] 955
FAILURE CODE [879CKA] 957
FAILURE CODE [879CKB] 958
FAILURE CODE [879DKZ] 959
FAILURE CODE [879EMC] 961
FAILURE CODE [879FMC] 962
FAILURE CODE [879GKX] 963
FAILURE CODE [989L00] 965
FAILURE CODE [989M00] 966
FAILURE CODE [989N00] 967
FAILURE CODE [A1U0N3] 968
FAILURE CODE [A1U0N4] 970
FAILURE CODE [A900FR] 972
FAILURE CODE [A900N6] 973
FAILURE CODE [A900NY] 974
FAILURE CODE [AA10NX] 975
FAILURE CODE [AB00KE] 977
FAILURE CODE [AQ10N3] 980
FAILURE CODE [AS00N3] 982
FAILURE CODE [AS00R2] 984
FAILURE CODE [AS00R3] 985
FAILURE CODE [AS00R4] 986
FAILURE CODE [AS00R5] 987
FAILURE CODE [AS00R6] 988
FAILURE CODE [AS00ZK] 989
FAILURE CODE [AS10KM] 990
FAILURE CODE [AS10NR] 991
FAILURE CODE [AS10NT] 992
FAILURE CODE [B@BAZG] 993
FAILURE CODE [B@BAZK] 994
FAILURE CODE [B@BCNS] 996
FAILURE CODE [B@BCQA] 997
FAILURE CODE [B@BCZK] 999
FAILURE CODE [B@HANS]1001
FAILURE CODE [CA115]1002
FAILURE CODE [CA122]1003
FAILURE CODE [CA123]1005
FAILURE CODE [CA131]1007
FAILURE CODE [CA132]1009
FAILURE CODE [CA144]1011
FAILURE CODE [CA145]1013
FAILURE CODE [CA153]1015
FAILURE CODE [CA154]1018
FAILURE CODE [CA187]1020
FAILURE CODE [CA221]1022
FAILURE CODE [CA222]1024
FAILURE CODE [CA227]1026
FAILURE CODE [CA234]1027
FAILURE CODE [CA238]1028
FAILURE CODE [CA239]1030
FAILURE CODE [CA249]1032
FAILURE CODE [CA256]1034
FAILURE CODE [CA271]1036
FAILURE CODE [CA272]1038
FAILURE CODE [CA322]1040
FAILURE CODE [CA323]1042
FAILURE CODE [CA324]1044
FAILURE CODE [CA325]1046
FAILURE CODE [CA331]1048
FAILURE CODE [CA332]1050
FAILURE CODE [CA343]1052
FAILURE CODE [CA351]1053
FAILURE CODE [CA352]1054
FAILURE CODE [CA356]1057
FAILURE CODE [CA357]1059
FAILURE CODE [CA386]1061
FAILURE CODE [CA428]1062
FAILURE CODE [CA429]1064
FAILURE CODE [CA435]1066
FAILURE CODE [CA441]1068
FAILURE CODE [CA442]1070
FAILURE CODE [CA449]1071
FAILURE CODE [CA451]1072
FAILURE CODE [CA452]1074
FAILURE CODE [CA488]1076
FAILURE CODE [CA515]1077
FAILURE CODE [CA516]1079
FAILURE CODE [CA553]1081
FAILURE CODE [CA555]1082
FAILURE CODE [CA556]1083
FAILURE CODE [CA559]1084
FAILURE CODE [CA595]1087
FAILURE CODE [CA687]1088
FAILURE CODE [CA689]1090
FAILURE CODE [CA691]1093
FAILURE CODE [CA692]1095
FAILURE CODE [CA697]1097
FAILURE CODE [CA698]1098
FAILURE CODE [CA731]1099
FAILURE CODE [CA778]1101
FAILURE CODE [CA1117]1106
FAILURE CODE [CA1664]1107
FAILURE CODE [CA1669]1109
FAILURE CODE [CA1673]1110
FAILURE CODE [CA1677]1111
FAILURE CODE [CA1678]1112
FAILURE CODE [CA1682]1113
FAILURE CODE [CA1683]1115
FAILURE CODE [CA1684]1117
FAILURE CODE [CA1686]1119
FAILURE CODE [CA1691]1120
FAILURE CODE [CA1694]1123
FAILURE CODE [CA1695]1126
FAILURE CODE [CA1696]1127
FAILURE CODE [CA1712]1129
FAILURE CODE [CA1713]1132
FAILURE CODE [CA1714]1134
FAILURE CODE [CA1715]1135
FAILURE CODE [CA1776]1136
FAILURE CODE [CA1777]1139
FAILURE CODE [CA1843]1142
FAILURE CODE [CA1844]1144
FAILURE CODE [CA1879]1147
FAILURE CODE [CA1881]1149
FAILURE CODE [CA1883]1151
FAILURE CODE [CA1885]1154
FAILURE CODE [CA1887]1156
FAILURE CODE [CA1921]1158
FAILURE CODE [CA1922]1161
FAILURE CODE [CA1942]1166
FAILURE CODE [CA1993]1167
FAILURE CODE [CA2185]1170
FAILURE CODE [CA2186]1171
FAILURE CODE [CA2249]1173
FAILURE CODE [CA2271]1174
FAILURE CODE [CA2272]1177
FAILURE CODE [CA2288]1180
FAILURE CODE [CA2311]1181
FAILURE CODE [CA2349]1182
FAILURE CODE [CA2353]1185
FAILURE CODE [CA2357]1187
FAILURE CODE [CA2381]1188
FAILURE CODE [CA2382]1191
FAILURE CODE [CA2383]1194
FAILURE CODE [CA2386]1197
FAILURE CODE [CA2387]1199
FAILURE CODE [CA2555]1200
FAILURE CODE [CA2556]1203
FAILURE CODE [CA2637]1206
FAILURE CODE [CA2639]1208
FAILURE CODE [CA2771]1211
FAILURE CODE [CA2777]1217
FAILURE CODE [CA2976]1220
FAILURE CODE [CA3133]1222
FAILURE CODE [CA3134]1225
FAILURE CODE [CA3135]1227
FAILURE CODE [CA3142]1230
FAILURE CODE [CA3143]1231
FAILURE CODE [CA3144]1232
FAILURE CODE [CA3146]1234
FAILURE CODE [CA3147]1235
FAILURE CODE [CA3148]1236
FAILURE CODE [CA3151]1238
FAILURE CODE [CA3165]1244
FAILURE CODE [CA3229]1246
FAILURE CODE [CA3231]1248
FAILURE CODE [CA3232]1250
FAILURE CODE [CA3235]1254
FAILURE CODE [CA3239]1256
FAILURE CODE [CA3241]1259
FAILURE CODE [CA3242]1262
FAILURE CODE [CA3251]1265
FAILURE CODE [CA3253]1267
FAILURE CODE [CA3254]1270
FAILURE CODE [CA3255]1273
FAILURE CODE [CA3256]1277
FAILURE CODE [CA3311]1279
FAILURE CODE [CA3312]1281
FAILURE CODE [CA3313]1284
FAILURE CODE [CA3314]1285
FAILURE CODE [CA3315]1286
FAILURE CODE [CA3316]1288
FAILURE CODE [CA3317]1289
FAILURE CODE [CA3318]1290
FAILURE CODE [CA3319]1292
FAILURE CODE [CA3321]1293
FAILURE CODE [CA3322]1295
FAILURE CODE [CA3419]1297
FAILURE CODE [CA3421]1299
FAILURE CODE [CA3497]1301
FAILURE CODE [CA3498]1302
FAILURE CODE [CA3543]1303
FAILURE CODE [CA3545]1310
FAILURE CODE [CA3547]1312
FAILURE CODE [CA3558]1313
FAILURE CODE [CA3559]1315
FAILURE CODE [CA3562]1317
FAILURE CODE [CA3563]1319
FAILURE CODE [CA3567]1322
FAILURE CODE [CA3568]1325
FAILURE CODE [CA3571]1329
FAILURE CODE [CA3572]1331
FAILURE CODE [CA3574]1333
FAILURE CODE [CA3575]1335
FAILURE CODE [CA3577]1337
FAILURE CODE [CA3578]1339
FAILURE CODE [CA3582]1341
FAILURE CODE [CA3583]1347
FAILURE CODE [CA3596]1349
FAILURE CODE [CA3649]1351
FAILURE CODE [CA3681]1353
FAILURE CODE [CA3682]1358
FAILURE CODE [CA3713]1364
FAILURE CODE [CA3717]1367
FAILURE CODE [CA3718]1368
FAILURE CODE [CA3725]1369
FAILURE CODE [CA3741]1372
FAILURE CODE [CA3748]1373
FAILURE CODE [CA3751]1375
FAILURE CODE [CA3755]1377
FAILURE CODE [CA3866]1379
FAILURE CODE [CA3867]1383
FAILURE CODE [CA3868]1386
FAILURE CODE [CA3899]1390
FAILURE CODE [CA3911]1392
FAILURE CODE [CA3912]1396
FAILURE CODE [CA3932]1398
FAILURE CODE [CA3933]1400
FAILURE CODE [CA3934]1402
FAILURE CODE [CA3935]1405
FAILURE CODE [CA3936]1407
FAILURE CODE [CA4151]1409
FAILURE CODE [CA4152]1413
FAILURE CODE [CA4155]1417
FAILURE CODE [CA4156]1419
FAILURE CODE [CA4157]1422
FAILURE CODE [CA4158]1424
FAILURE CODE [CA4159]1425
FAILURE CODE [CA4161]1426
FAILURE CODE [CA4162]1429
FAILURE CODE [CA4163]1432
FAILURE CODE [CA4164]1433
FAILURE CODE [CA4165]1435
FAILURE CODE [CA4166]1437
FAILURE CODE [CA4168]1438
FAILURE CODE [CA4169]1441
FAILURE CODE [CA4171]1443
FAILURE CODE [CA4249]1446
FAILURE CODE [CA4251]1448
FAILURE CODE [CA4259]1450
FAILURE CODE [CA4261]1453
FAILURE CODE [CA4277]1456
FAILURE CODE [CA4281]1459
FAILURE CODE [CA4459]1462
FAILURE CODE [CA4461]1465
FAILURE CODE [CA4658]1468
FAILURE CODE [CA4731]1472
FAILURE CODE [CA4732]1473
FAILURE CODE [CA4739]1474
FAILURE CODE [CA4768]1475
FAILURE CODE [CA4769]1477
FAILURE CODE [CA4842]1480
FAILURE CODE [CA4952]1484
FAILURE CODE [CA5115]1486
FAILURE CODE [CA5179]1489
FAILURE CODE [CA5181]1491
FAILURE CODE [CA5383]1493
FAILURE CODE [D110KB]1495
FAILURE CODE [D19JKZ]1497
FAILURE CODE [D811MC]1500
FAILURE CODE [D862KA]1501
FAILURE CODE [D8ALKA]1502
FAILURE CODE [D8ALKB]1504
FAILURE CODE [D8AQKR]1506
FAILURE CODE [DA20MC]1508
FAILURE CODE [DA22KK]1509
FAILURE CODE [DA25KP]1512
FAILURE CODE [DA26KP]1515
FAILURE CODE [DA29KQ]1518
FAILURE CODE [DA2LKA]1520
FAILURE CODE [DA2LKB]1522
FAILURE CODE [DA2QKR]1524
FAILURE CODE [DA2RKR]1527
FAILURE CODE [DAF0MB]1528
FAILURE CODE [DAF0MC]1529
FAILURE CODE [DAF8KB]1530
FAILURE CODE [DAF9KQ]1534
FAILURE CODE [DAFGMC]1535
FAILURE CODE [DAFLKA]1536
FAILURE CODE [DAFLKB]1538
FAILURE CODE [DAFQKR]1540
FAILURE CODE [DAZ9KQ]1541
FAILURE CODE [DAZQKR]1542
FAILURE CODE [DB2QKR]1547
FAILURE CODE [DB2RKR]1552
FAILURE CODE [DBP5KB]1557
FAILURE CODE [DBP5KY]1560
FAILURE CODE [DDNRKA]1563
FAILURE CODE [DDNRKY]1565
FAILURE CODE [DDNS00]1567
FAILURE CODE [DGH2KA]1569
FAILURE CODE [DGH2KB]1571
FAILURE CODE [DHA4KA]1573
FAILURE CODE [DHAAMA]1575
FAILURE CODE [DHACMA]1577
FAILURE CODE [DHPAMA]1579
FAILURE CODE [DHPBMA]1582
FAILURE CODE [DHS3MA]1585
FAILURE CODE [DHS4MA]1588
FAILURE CODE [DHS8MA]1591
FAILURE CODE [DHS9MA]1594
FAILURE CODE [DHSAMA]1597
FAILURE CODE [DHSBMA]1600
FAILURE CODE [DHSCMA]1603
FAILURE CODE [DHSDMA]1606
FAILURE CODE [DHSFMA]1609
FAILURE CODE [DHSGMA]1612
FAILURE CODE [DHSHMA]1615
FAILURE CODE [DHSJMA]1618
FAILURE CODE [DHZAMA]1621
FAILURE CODE [DHZCL8]1625
FAILURE CODE [DKR0MA]1626
FAILURE CODE [DKR1MA]1629
FAILURE CODE [DKULKA]1632
FAILURE CODE [DKULKB]1634
FAILURE CODE [DKULKY]1636
FAILURE CODE [DLM5KA]1638
FAILURE CODE [DLM5MB]1640
FAILURE CODE [DR12KA]1642
FAILURE CODE [DR20KA]1644
FAILURE CODE [DR21KX]1646
FAILURE CODE [DR30KA]1648
FAILURE CODE [DR31KX]1650
FAILURE CODE [DR40KA]1652
FAILURE CODE [DV20KB]1654
FAILURE CODE [DW43KA]1656
FAILURE CODE [DW43KB]1658
FAILURE CODE [DW43KY]1660
FAILURE CODE [DW45KA]1662
FAILURE CODE [DW45KB]1665
FAILURE CODE [DW45KY]1668
FAILURE CODE [DW4CKY]1670
FAILURE CODE [DW91KA]1672
FAILURE CODE [DW91KB]1674
FAILURE CODE [DW91KY]1676
FAILURE CODE [DWA2KA]1678
FAILURE CODE [DWA2KB]1680
FAILURE CODE [DWA2KY]1682
FAILURE CODE [DWK0KA]1684
FAILURE CODE [DWK0KB]1686
FAILURE CODE [DWK0KY]1688
FAILURE CODE [DWK2KA]1690
FAILURE CODE [DWK2KB]1692
FAILURE CODE [DWK2KY]1694
FAILURE CODE [DWK8KA]1696
FAILURE CODE [DWK8KB]1698
FAILURE CODE [DWK8KY]1700
FAILURE CODE [DWN5KA]1702
FAILURE CODE [DWN5KB]1704
FAILURE CODE [DWN5KY]1706
FAILURE CODE [DWPUKA]1708
FAILURE CODE [DWPUKB]1710
FAILURE CODE [DWPUKY]1712
FAILURE CODE [DXA8KA]1714
FAILURE CODE [DXA8KB]1716
FAILURE CODE [DXA9KA]1718
FAILURE CODE [DXA9KB]1720
FAILURE CODE [DXE0KA]1722
FAILURE CODE [DXE0KB]1723
FAILURE CODE [DXE4KA]1725
FAILURE CODE [DXE4KB]1727
FAILURE CODE [DXE4KY]1729
FAILURE CODE [DXE5KA]1731
FAILURE CODE [DXE5KB]1733
FAILURE CODE [DXE6KA]1735
FAILURE CODE [DXE6KB]1737
FAILURE CODE [DXE7KA]1739
FAILURE CODE [DXE7KB]1741
FAILURE CODE [DXE7KY]1743
FAILURE CODE [DXE8KA]1745
FAILURE CODE [DXE8KB]1747
FAILURE CODE [DXE8KY]1749
FAILURE CODE [DXE9KA]1751
FAILURE CODE [DXE9KB]1753
FAILURE CODE [DXE9KY]1755
FAILURE CODE [DXEAKA]1757
FAILURE CODE [DXEAKB]1759
FAILURE CODE [DXEAKY]1761
FAILURE CODE [DXEKKA]1763
FAILURE CODE [DXEKKB]1765
FAILURE CODE [DXEKKY]1767
FAILURE CODE [DXELKA]1769
FAILURE CODE [DXELKB]1771
FAILURE CODE [DXELKY]1773
FAILURE CODE [DY20KA]1775
FAILURE CODE [DY20MA]1777
FAILURE CODE [DY2CKB]1779
FAILURE CODE [DY2DKB]1782
FAILURE CODE [DY2EKB]1784
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1786
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1786
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1792
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1795
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1797
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING1799
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW1802
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW1803
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1804
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1805
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING1806
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1807
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1808
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1809
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1810
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1811
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1812
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1813
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL1815
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1816
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE1817
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1818
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE1820
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED1821
E-24 FUNCTION SWITCH DOES NOT OPERATE1822
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)1823
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF1824
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER1825
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED1826
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED1827
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE1828
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE1829
E-32 ALARM BUZZER CANNOT BE CANCELED1831
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION1832
E-34 SERVICE MODE CANNOT BE SELECTED1833
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE1834
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK1837
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING1839
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE1842
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR1844
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED1847
E-41 ALARM DOES NOT SOUND DURING TRAVEL1848
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED1850
E-43 HORN DOES NOT SOUND1851
E-44 HORN DOES NOT STOP SOUNDING1854
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF1856
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE1857
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE1859
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1860
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1861
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1862
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1863
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1864
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1865
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1866
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1867
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1868
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED1870
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY1871
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1872
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)1872
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS1873
FAILURE MODE AND CAUSE TABLE1875
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK1887
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER1888
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR1891
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP1892
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS1893
H-6 SPEED OR POWER OF BOOM IS LOW1895
H-7 ARM SPEED OR POWER IS LOW1899
H-8 BUCKET SPEED OR POWER IS LOW1904
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION1907
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE1908
H-11 HYDRAULIC DRIFT OF ARM IS LARGE1910
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE1912
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES1913
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE1914
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE1915
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED1916
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED1917
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER1918
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY1919
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW1920
H-21 MACHINE DOES NOT TRAVEL STRAIGHT1921
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW1923
H-23 TRAVEL SPEED IS LOW1926
H-24 ONE OF TRACKS DOES NOT RUN1928
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST1929
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT1930
H-27 SWINGS ONLY IN ONE DIRECTION1931
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)1932
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION1933
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)1934
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)1935
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING1936
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING1937
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)1938
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)1939
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)1940
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN1941
TROUBLESHOOTING OF ENGINE (S-MODE)1942
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)1942
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION1943
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT1944
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)1945
S-4 ENGINE STARTABILITY IS POOR1947
S-5 ENGINE DOES NOT PICK UP SMOOTHLY1949
S-6 ENGINE STOPS DURING OPERATION1951
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE1953
S-8 ENGINE LACKS POWER1954
S-9 KDPF GETS CLOGGED IN A SHORT TIME1956
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE1958
S-11 OIL BECOMES CONTAMINATED QUICKLY1959
S-12 FUEL CONSUMPTION IS EXCESSIVE1960
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)1961
S-14 OIL PRESSURE DROPS1962
S-15 FUEL MIXES INTO ENGINE OIL1964
S-16 WATER MIXES INTO ENGINE OIL (MILKY)1965
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)1966
S-18 UNUSUAL NOISE IS HEARD1967
S-19 VIBRATION IS EXCESSIVE1968
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT1969
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY1970
S-22 ACTIVE REGENERATION TAKES TIME1972
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION1973
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE1974
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)1976
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)1977
50 DISASSEMBLY AND ASSEMBLY1978
CONTENTS1979
ABBREVIATION LIST1984
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY1990
HOW TO READ THIS MANUAL1990
COATING MATERIALS LIST1992
SPECIAL TOOLS LIST1996
SKETCHES OF SPECIAL TOOLS2008
ENGINE AND COOLING SYSTEM2014
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2014
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2014
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2017
REMOVE AND INSTALL INJECTOR ASSEMBLY2020
METHOD FOR REMOVING INJECTOR ASSEMBLY2020
METHOD FOR INSTALLING INJECTOR ASSEMBLY2025
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2033
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2034
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2043
REMOVE AND INSTALL EGR VALVE ASSEMBLY2059
METHOD FOR REMOVING EGR VALVE ASSEMBLY2059
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2060
REMOVE AND INSTALL EGR COOLER ASSEMBLY2062
METHOD FOR REMOVING EGR COOLER ASSEMBLY2062
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2066
REMOVE AND INSTALL STARTER ASSEMBLY2071
METHOD FOR REMOVING STARTER ASSEMBLY2071
METHOD FOR INSTALLING STARTER ASSEMBLY2072
REMOVE AND INSTALL ALTERNATOR BELT2075
METHOD FOR REMOVING ALTERNATOR BELT2075
METHOD FOR INSTALLING ALTERNATOR BELT2077
REMOVE AND INSTALL RADIATOR ASSEMBLY2079
METHOD FOR REMOVING RADIATOR ASSEMBLY2079
METHOD FOR INSTALLING RADIATOR ASSEMBLY2081
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2084
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2084
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2087
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2090
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2090
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2092
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY2094
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY2094
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY2098
REMOVE AND INSTALL FAN2102
METHOD FOR INSTALLING FAN2102
METHOD FOR REMOVING FAN2102
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY2103
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY2103
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY2112
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2124
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2124
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2127
REMOVE AND INSTALL ENGINE REAR OIL SEAL2131
METHOD FOR REMOVING ENGINE REAR OIL SEAL2131
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2132
REMOVE AND INSTALL FUEL COOLER ASSEMBLY2135
METHOD FOR REMOVING FUEL COOLER ASSEMBLY2135
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY2135
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2137
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2137
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2139
REMOVE AND INSTALL FUEL TANK ASSEMBLY2144
METHOD FOR REMOVING FUEL TANK ASSEMBLY2144
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2148
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2152
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2152
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2158
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2164
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2164
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2170
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2176
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2176
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2176
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2178
METHOD FOR REMOVING AdBlue/DEF STRAINER2178
METHOD FOR INSTALLING AdBlue/DEF STRAINER2178
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER2179
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER2179
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER2181
REMOVE AND INSTALL KDPF ASSEMBLY2184
METHOD FOR REMOVING KDPF ASSEMBLY2184
METHOD FOR INSTALLING KDPF ASSEMBLY2186
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2188
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2189
METHOD FOR ASSEMBLING KDPF ASSEMBLY2192
REMOVE AND INSTALL SCR ASSEMBLY2197
METHOD FOR REMOVING SCR ASSEMBLY2197
METHOD FOR INSTALLING SCR ASSEMBLY2199
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2201
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2201
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2207
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET2213
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET2213
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET2221
REMOVE AND INSTALL KCCV ASSEMBLY2229
METHOD FOR REMOVING KCCV ASSEMBLY2229
METHOD FOR INSTALLING KCCV ASSEMBLY2231
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2236
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2236
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2242
REMOVE AND INSTALL AdBlue/DEF INJECTOR2248
METHOD FOR REMOVING AdBlue/DEF INJECTOR2248
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2251
REMOVE AND INSTALL AdBlue/DEF PUMP2254
METHOD FOR REMOVING AdBlue/DEF PUMP2254
METHOD FOR INSTALLING AdBlue/DEF PUMP2257
REMOVE AND INSTALL AdBlue/DEF HOSE2260
METHOD FOR REMOVING AdBlue/DEF HOSE2260
METHOD FOR INSTALLING AdBlue/DEF HOSE2267
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2273
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2273
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2274
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2276
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2276
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2278
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2281
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2281
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2282
POWER TRAIN2283
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2283
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2283
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2284
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY2286
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY2286
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY2290
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY2299
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY2299
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY2301
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY2305
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY2305
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY2309
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY2316
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY2316
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY2316
UNDERCARRIAGE AND FRAME2318
SEPARATION AND CONNECTION OF TRACK ASSEMBLY2318
METHOD FOR SEPARATING TRACK ASSEMBLY2318
METHOD FOR INSTALLING TRACK ASSEMBLY2320
REMOVE AND INSTALL SPROCKET2323
METHOD FOR REMOVING SPROCKET2323
METHOD FOR INSTALLING SPROCKET2323
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY2325
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY2325
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY2326
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2327
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2327
METHOD FOR ASSEMBLING IDLER ASSEMBLY2328
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY2332
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY2332
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY2333
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2335
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2336
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2337
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY2339
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY2339
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY2340
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY2343
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY2343
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY2345
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2348
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2348
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2351
HYDRAULIC SYSTEM2355
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY2355
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY2355
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY2357
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2360
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2360
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2361
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2363
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2363
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2365
REMOVE AND INSTALL MAIN PUMP ASSEMBLY2368
METHOD FOR REMOVING MAIN PUMP ASSEMBLY2368
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY2371
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2374
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2374
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2381
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY2389
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING2389
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY2390
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2394
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2394
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2394
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2396
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY2396
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY2397
WORK EQUIPMENT2399
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2399
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2399
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2403
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM2408
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM2408
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM2410
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM2411
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM2411
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM2413
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY2414
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY2414
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY2414
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2415
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2415
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2418
CAB AND ITS ATTACHMENTS2424
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2424
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY2424
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY2430
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)2437
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)2439
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)2439
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY2449
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY2449
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY2452
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY2458
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY2458
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY2465
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2472
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2472
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2477
REMOVE AND INSTALL OPERATOR’S SEAT2483
METHOD FOR REMOVING OPERATOR’S SEAT2483
METHOD FOR INSTALLING OPERATOR’S SEAT2485
REMOVE AND INSTALL SEAT BELT2488
METHOD FOR REMOVING SEAT BELT2488
METHOD FOR INSTALLING SEAT BELT2489
REMOVE AND INSTALL FRONT WIPER ASSEMBLY2490
METHOD FOR REMOVING FRONT WIPER ASSEMBLY2490
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY2495
ELECTRICAL SYSTEM2504
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2504
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2504
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2505
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY2507
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY2507
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY2511
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2516
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2516
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY2519
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR2523
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR2523
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR2524
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2525
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR2525
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR2525
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2527
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR2527
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR2528
REMOVE AND INSTALL SCR TEMPERATURE SENSOR2529
METHOD FOR REMOVING SCR TEMPERATURE SENSOR2529
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR2531
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY2533
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY2533
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY2536
60 MAINTENANCE STANDARD2540
CONTENTS2541
ABBREVIATION LIST2542
ENGINE AND COOLING SYSTEM2548
MAINTENANCE STANDARD OF ENGINE MOUNT2548
MAINTENANCE STANDARD OF COOLING SYSTEM2549
POWER TRAIN2551
MAINTENANCE STANDARD OF SWING CIRCLE2551
MAINTENANCE STANDARD OF SWING MACHINERY2552
MAINTENANCE STANDARD OF FINAL DRIVE2554
MAINTENANCE STANDARD OF SPROCKET2556
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING2557
UNDERCARRIAGE AND FRAME2559
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION2559
MAINTENANCE STANDARD OF IDLER2561
MAINTENANCE STANDARD OF TRACK ROLLER2563
MAINTENANCE STANDARD OF CARRIER ROLLER2564
MAINTENANCE STANDARD OF TRACK SHOE2565
MAINTENANCE STANDARD OF TRIPLE SHOE2568
MAINTENANCE STANDARD OF SWAMP SHOE2569
MAINTENANCE STANDARD OF ROAD LINER2570
HYDRAULIC SYSTEM2571
MAINTENANCE STANDARD OF HYDRAULIC TANK2571
MAINTENANCE STANDARD OF MAIN PUMP2572
MAINTENANCE STANDARD OF LS-EPC VALVE2573
MAINTENANCE STANDARD OF PC-EPC VALVE2574
MAINTENANCE STANDARD OF SWING MOTOR2575
MAINTENANCE STANDARD OF TRAVEL MOTOR2578
MAINTENANCE STANDARD OF CONTROL VALVE2581
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM2591
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM2593
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE2595
MAINTENANCE STANDARD OF TRAVEL PPC VALVE2598
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)2601
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE2602
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE2604
MAINTENANCE STANDARD OF SOLENOID VALVE2606
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)2607
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)2608
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT2609
WORK EQUIPMENT2610
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE2610
DIMENSION OF ARM2615
DIMENSIONS OF BUCKET2617
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON)2619
MAINTENANCE STANDARD OF ARM CYLINDER2620
MAINTENANCE STANDARD OF BUCKET CYLINDER2621
80 APPENDIX2622
CONTENTS2623
ABBREVIATION LIST2625
AIR CONDITIONER SYSTEM2631
PRECAUTIONS FOR REFRIGERANT2631
AIR CONDITIONER COMPONENT2632
SPECIFICATIONS OF AIR CONDITIONER2634
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2635
OUTLINE OF REFRIGERATION CYCLE2636
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2638
AIR CONDITIONER UNIT2638
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2638
FUNCTION OF AIR CONDITIONER UNIT2640
COMPONENT PARTS OF AIR CONDITIONER UNIT2642
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2643
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2643
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT2643
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT2643
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2644
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2644
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2644
FUNCTION OF DUAL PRESSURE SWITCH2645
AIR CONDITIONER CONTROLLER2646
STRUCTURE OF AIR CONDITIONER CONTROLLER2646
COMPRESSOR2647
STRUCTURE OF COMPRESSOR2647
SPECIFICATIONS OF COMPRESSOR2647
FUNCTION OF COMPRESSOR2647
CONDENSER2648
STRUCTURE OF CONDENSER2648
SPECIFICATIONS OF CONDENSER2648
FUNCTION OF CONDENSER2648
SENSORS FOR AIR CONDITIONER SYSTEM2650
STRUCTURE OF SUNLIGHT SENSOR2650
FUNCTION OF SUNLIGHT SENSOR2650
STRUCTURE OF AMBIENT TEMPERATURE SENSOR2650
FUNCTION OF AMBIENT TEMPERATURE SENSOR2650
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2652
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER2654
AIR CONDITIONER SYSTEM DIAGRAM2656
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER2657
FUNCTION OF AIR CONDITIONER CONTROLLER2658
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2659
TESTING AIR LEAKAGE (DUCT)2663
METHOD FOR TESTING AIR LEAKAGE (DUCT)2663
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION2665
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR2666
TEST VENT (MODE) CHANGEOVER2667
METHOD FOR TESTING VENT (MODE) CHANGEOVER2667
TESTING FRESH/RECIRC AIR CHANGEOVER2669
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER2669
TEST SUNLIGHT SENSOR2670
METHOD FOR TESTING SUNLIGHT SENSOR2670
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT2671
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT2671
TEST RELAYS2672
METHOD FOR TESTING RELAYS2672
AIR CONDITIONER TROUBLESHOOTING CHART 12673
AIR CONDITIONER TROUBLESHOOTING CHART 22674
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2677
FAILURE CODE [879AKA]2679
FAILURE CODE [879AKB]2680
FAILURE CODE [879BKA]2681
FAILURE CODE [879BKB]2683
FAILURE CODE [879CKA]2685
FAILURE CODE [879CKB]2686
FAILURE CODE [879DKZ]2687
FAILURE CODE [879EMC]2689
FAILURE CODE [879FMC]2690
FAILURE CODE [879GKX]2691
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)2693
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)2695
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)2698
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER2700
TROUBLESHOOTING USING GAUGE PRESSURE2702
CONNECTION OF SERVICE TOOL2705
METHOD FOR CONNECTING SERVICE TOOL2705
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS2707
HANDLE COMPRESSOR OIL2709
METHOD FOR REPLACING DESICCANT2711
90 CIRCUIT DIAGRAMS2714
CONTENTS2715
ABBREVIATION LIST2716
HYDRAULIC CIRCUIT DIAGRAM2722
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2722
HYDRAULIC CIRCUIT DIAGRAM2726
ELECTRICAL CIRCUIT DIAGRAM2728
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM2728
ELECTRICAL CIRCUIT DIAGRAM (1/7)2732
ELECTRICAL CIRCUIT DIAGRAM (2/7)2734
ELECTRICAL CIRCUIT DIAGRAM (3/7)2736
ELECTRICAL CIRCUIT DIAGRAM (4/7)2738
ELECTRICAL CIRCUIT DIAGRAM (5/7)2740
ELECTRICAL CIRCUIT DIAGRAM (6/7)2742
ELECTRICAL CIRCUIT DIAGRAM (7/7)2744
INDEX2746

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24