Komatsu HYDRAULIC EXCAVATOR PC290 -11 PC290LC -11 PC290NLC-11 Shop Manual UENBM00353

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Komatsu HYDRAULIC EXCAVATOR PC290 -11 PC290LC -11 PC290NLC-11 Shop Manual UENBM00353 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC290 -11 PC290LC -11 PC290NLC-11 Shop Manual UENBM00353 – PDF DOWNLOAD

Language : English
Pages :2802
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC290 -11 PC290LC -11 PC290NLC-11 Shop Manual UENBM00353 – PDF DOWNLOAD

SERIAL NUMBERS K70001 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 PC290 -11 PC290LC -11 PC290NLC-11 Shop Manual UENBM00353 – PDF DOWNLOAD

SERIAL NUMBERS K70001 and up

00 INDEX AND FOREWORD 3
INDEX 4
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
STORE AdBlue/DEF 43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 57
PRACTICAL USE OF KOMTRAX 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 73
HOW TO READ ELECTRICAL WIRE CODE 74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 78
STANDARD TIGHTENING TORQUE TABLE 81
CONVERSION TABLE 88
01 SPECIFICATIONS 93
CONTENTS 94
ABBREVIATION LIST 95
SPECIFICATIONS 101
SPECIFICATION DRAWING 101
SPECIFICATION DRAWING: PC290LC-11, PC290NLC-11 101
WORKING RANGE DRAWINGS 103
WORKING RANGE: PC290LC-11, PC290NLC-11 103
SPECIFICATIONS 104
SPECIFICATIONS: PC290LC-11, PC290NLC-11 104
WEIGHT TABLE 107
WEIGHT TABLE: PC290LC-11, PC290NLC-11 107
TABLE OF FUEL, COOLANT, AND LUBRICANTS 109
10 STRUCTURE AND FUNCTION 111
CONTENTS 112
ABBREVIATION LIST 116
UREA SCR SYSTEM 122
LAYOUT DRAWING OF UREA SCR SYSTEM 123
UREA SCR SYSTEM DIAGRAM 128
FUNCTION OF UREA SCR SYSTEM 129
FUNCTION OF AdBlue/DEF SYSTEM 129
INDUCEMENT STRATEGY 131
COMPONENT PARTS OF UREA SCR SYSTEM 139
AdBlue/DEF MIXING TUBE 139
SCR ASSEMBLY 139
AdBlue/DEF TANK 142
AdBlue/DEF PUMP 144
AdBlue/DEF INJECTOR 145
AdBlue/DEF HOSE 146
AdBlue/DEF TANK HEATING VALVE 147
BOOT-UP SYSTEM 148
LAYOUT DRAWING OF BOOT-UP SYSTEM 148
SYSTEM OPERATING LAMP SYSTEM 150
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 150
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 150
BATTERY DISCONNECT SWITCH 152
FUNCTION OF BATTERY DISCONNECT SWITCH 152
ENGINE SYSTEM 153
LAYOUT DRAWING OF ENGINE SYSTEM 153
SPECIFICATIONS OF ENGINE SYSTEM 154
FUNCTION OF ENGINE SYSTEM 154
ENGINE CONTROL SYSTEM 155
ENGINE CONTROL SYSTEM DIAGRAM 155
FUNCTION OF ENGINE CONTROL SYSTEM 156
AUTO-DECELERATION SYSTEM 158
AUTO-DECELERATION SYSTEM DIAGRAM 158
FUNCTION OF AUTO-DECELERATION SYSTEM 158
OPERATION OF AUTO-DECELERATION SYSTEM 159
ENGINE AUTOMATIC WARM-UP SYSTEM 160
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 160
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 161
OVERHEAT PREVENTION SYSTEM 162
OVERHEAT PREVENTION SYSTEM DIAGRAM 162
FUNCTION OF OVERHEAT PREVENTION SYSTEM 163
TURBOCHARGER PROTECTION SYSTEM 165
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 165
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 166
AUTOMATIC IDLE STOP SYSTEM 167
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 167
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 167
COMPONENT PARTS OF ENGINE SYSTEM 170
VGT 170
EGR SYSTEM 174
EGR VALVE 176
EGR COOLER 178
KCCV SYSTEM 179
KCCV VENTILATOR 181
KDPF 183
COOLING SYSTEM 188
LAYOUT DRAWING OF COOLING SYSTEM 188
SPECIFICATIONS OF COOLING SYSTEM 189
CONTROL SYSTEM 190
LAYOUT DRAWING OF CONTROL SYSTEM 190
MACHINE MONITOR SYSTEM 193
MACHINE MONITOR SYSTEM DIAGRAM 193
KomVision SYSTEM 194
LAYOUT DRAWING OF KOMVISION SYSTEM 194
KomVision SYSTEM DIAGRAM 196
FUNCTION OF KomVision SYSTEM 196
KOMTRAX SYSTEM 198
KOMTRAX SYSTEM DIAGRAM 198
FUNCTION OF KOMTRAX SYSTEM 198
PPC LEVERS 199
LH PPC LEVER 199
RH PPC LEVER 200
AUTOMATIC GREASE SYSTEM 201
OUTLINE OF AUTO GREASE SYSTEM 201
COMPONENT PARTS OF CONTROL SYSTEM 216
MACHINE MONITOR 216
KomVision CONTROLLER 229
KomVision CAMERA 233
KOMTRAX TERMINAL 233
PUMP CONTROLLER 236
RESISTOR FOR PC-EPC VALVE 240
CAN TERMINATING RESISTOR 240
PPC OIL PRESSURE SWITCH 241
ENGINE CONTROLLER 242
FUEL CONTROL DIAL 248
STRUCTURE OF ENGINE OIL PRESSURE SWITCH 249
FUNCTION OF ENGINE OIL PRESSURE SWITCH 250
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 250
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 251
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 251
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 251
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 251
FUNCTION OF AUTO GREASE PRESSURE SWITCH 251
STRUCTURE OF OVERLOAD CAUTION SENSOR 251
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 252
FUNCTION OF OVERLOAD CAUTION SENSOR 252
HYDRAULIC SYSTEM 253
LAYOUT DRAWING OF HYDRAULIC SYSTEM 253
CLSS 259
STRUCTURE OF CLSS 259
OPERATION OF UNLOAD VALVE AND LS PRESSURE 261
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 262
PRESSURE COMPENSATION CONTROL 275
ENGINE AND PUMP COMBINED CONTROL SYSTEM 278
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 278
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 279
PUMP AND VALVE CONTROL SYSTEM 284
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 284
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 285
COMPONENT PARTS OF HYDRAULIC SYSTEM 287
HYDRAULIC TANK 287
MAIN PUMP 289
PC-EPC VALVE 313
PILOT OIL FILTER 315
CONTROL VALVE 315
WORK EQUIPMENT SYSTEM 372
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 372
STRUCTURE OF VALVE CONTROL 377
ONE-TOUCH POWER MAXIMIZING SYSTEM 379
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 379
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 380
PPC LOCK SYSTEM 381
PPC LOCK SYSTEM DIAGRAM 381
FUNCTION OF PPC LOCK SYSTEM 381
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 382
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 382
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 382
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 383
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 384
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 384
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 386
TOOL CONTROL SYSTEM 387
TOOL CONTROL SYSTEM DIAGRAM 387
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 389
WORK EQUIPMENT AND SWING PPC VALVE 389
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 394
SOLENOID VALVE 400
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 403
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 405
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE 408
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE 410
ATTACHMENT BYPASS SOLENOID VALVE 413
ATT EPC VALVE ASSEMBLY 415
PILOT CIRCUIT ACCUMULATOR 416
ATTACHMENT CIRCUIT ACCUMULATOR 417
SWING SYSTEM 418
LAYOUT DRAWING OF SWING SYSTEM 418
SWING CONTROL SYSTEM DIAGRAM 422
FUNCTION OF SWING CONTROL SYSTEM 422
COMPONENT PARTS OF SWING SYSTEM 426
SWING MOTOR 426
SWING MACHINERY 437
SWING CIRCLE 438
TRAVEL SYSTEM 440
LAYOUT DRAWING OF TRAVEL SYSTEM 440
TRAVEL CONTROL SYSTEM DIAGRAM 444
FUNCTION OF TRAVEL CONTROL SYSTEM 444
COMPONENT PARTS OF TRAVEL SYSTEM 446
TRAVEL MOTOR 446
FINAL DRIVE 458
TRAVEL PPC VALVE 460
CENTER SWIVEL JOINT 465
UNDERCARRIAGE AND FRAME 467
LAYOUT DRAWING OF UNDERCARRIAGE 467
SPECIFICATIONS OF UNDERCARRIAGE 468
WORK EQUIPMENT 469
STRUCTURE OF WORK EQUIPMENT 469
FUNCTION OF WORK EQUIPMENT 470
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 471
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 471
BUCKET CLEARANCE ADJUSTMENT SHIM 472
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 472
CAB AND ITS ATTACHMENTS 473
ROPS CAB 473
STRUCTURE OF ROPS CAB 473
FUNCTION OF ROPS CAB 473
CAB MOUNT 474
STRUCTURE OF CAB MOUNT 474
FUNCTION OF CAB MOUNT 474
CAB TIPPING STOPPER 475
STRUCTURE OF CAB TIPPING STOPPER 475
FUNCTION OF CAB TIPPING STOPPER 475
20 STANDARD VALUE TABLE 477
CONTENTS 478
ABBREVIATION LIST 479
STANDARD VALUE TABLE FOR ENGINE 485
STANDARD VALUE TABLE FOR ENGINE: PC290LC-11, PC290NLC-11 485
STANDARD VALUE TABLE FOR MACHINE 489
STANDARD VALUE TABLE FOR MACHINE: PC290LC-11, PC290NLC-11 489
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 502
STANDARD VALUE TABLE FOR ELECTRICAL 506
STANDARD VALUE TABLE FOR ELECTRICAL 506
30 TESTING AND ADJUSTING 517
CONTENTS 518
ABBREVIATION LIST 521
RELATED INFORMATION ON TESTING AND ADJUSTING 527
TOOLS FOR TESTING AND ADJUSTING 527
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 534
ENGINE AND COOLING SYSTEM 536
TEST ENGINE SPEED 536
METHOD FOR TESTING ENGINE SPEED 536
TEST BOOST PRESSURE 539
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 539
METHOD FOR TESTING BOOST PRESSURE 540
TEST EXHAUST GAS COLOR 541
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 541
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 542
TEST AND ADJUST VALVE CLEARANCE 544
METHOD FOR TESTING VALVE CLEARANCE 544
METHOD FOR ADJUSTING VALVE CLEARANCE 545
TEST COMPRESSION PRESSURE 547
METHOD FOR TESTING COMPRESSION PRESSURE 547
TEST BLOWBY PRESSURE 552
METHOD FOR TESTING BLOWBY PRESSURE 552
TEST ENGINE OIL PRESSURE 554
METHOD FOR TESTING ENGINE OIL PRESSURE 554
TEST EGR VALVE AND VGT OIL PRESSURE 555
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 555
TEST FUEL PRESSURE 557
METHOD FOR TESTING FUEL PRESSURE 558
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 563
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 564
BLEEDING AIR FROM FUEL SYSTEM 570
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 570
TEST FUEL CIRCUIT FOR LEAKAGE 571
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 571
HANDLE CYLINDER CUT-OUT MODE OPERATION 573
HANDLE NO-INJECTION CRANKING OPERATION 574
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 575
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 575
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 575
REPLACING FAN BELT 577
METHOD FOR REPLACING FAN BELT 577
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 578
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 578
TEST SCR RELATED FUNCTIONS 579
TEST AdBlue/DEF PUMP RAISED PRESSURE 582
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 585
TEST AdBlue/DEF LINE HEATER RELAY 1 589
TEST AdBlue/DEF LINE HEATER RELAY 2 592
TEST AdBlue/DEF PUMP HEATER RELAY 594
TEST AdBlue/DEF TANK HEATER VALVE 597
TEST DENITRATION EFFICIENCY OF SCR 600
CLEAN AdBlue/DEF TANK 604
METHOD FOR CLEANING AdBlue/DEF TANK 604
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 608
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 608
POWER TRAIN 610
TEST SWING CIRCLE BEARING CLEARANCE 610
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 610
UNDERCARRIAGE AND FRAME 611
TEST AND ADJUST TRACK TENSION 611
METHOD FOR TESTING TRACK TENSION 611
METHOD FOR ADJUSTING TRACK TENSION 611
HYDRAULIC SYSTEM 613
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 613
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 613
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 617
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 619
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 620
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 626
TEST OIL PRESSURE OF CONTROL CIRCUIT 629
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 629
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 631
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 631
TEST PC-EPC VALVE OUTLET PRESSURE 632
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 633
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 635
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 635
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL 636
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 639
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 640
METHOD FOR ADJUSTING LS VALVE 641
TEST OUTLET PRESSURE OF SOLENOID VALVE 642
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 642
OPERATING CONDITION OF SOLENOID VALVE 643
TEST PPC VALVE OUTLET PRESSURE 646
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 646
TEST ATTACHMENT CIRCUIT OIL PRESSURE 648
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 648
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 650
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 650
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE 651
TEST PUMP SWASH PLATE SENSOR 653
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 653
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 654
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 654
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 654
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 655
TEST OIL LEAKAGE 656
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 656
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 656
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 657
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 658
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 658
BLEED AIR FROM HYDRAULIC CIRCUIT 659
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 661
CAB AND ITS ATTACHMENTS 663
TEST CAB TIPPING STOPPER 663
METHOD FOR TESTING CAB TIPPING STOPPER 663
METHOD FOR ADJUSTING MIRRORS 664
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 664
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 665
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 666
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 667
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 668
ELECTRICAL SYSTEM 670
ELECTRICAL SYSTEM 671
SET AND OPERATE MACHINE MONITOR 671
OPERATOR MODE 674
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 675
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 675
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 676
CHECKING FUNCTION OF SERVICE METER 676
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 676
SERVICE MODE 679
METHOD FOR OPERATING SERVICE MODE 680
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 683
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 689
ABNORMALITY RECORD MENU 699
METHOD FOR CONFIRMING MAINTENANCE RECORD 704
METHOD FOR OPERATING MAINTENANCE MODE SETTING 705
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 709
DEFAULT MENU 710
DIAGNOSTIC TESTS MENU 734
ADJUSTMENT MENU 743
METHOD FOR PERFORMING NO-INJECTION CRANKING 764
KOMTRAX SETTINGS MENU 765
METHOD FOR DISPLAYING SERVICE MESSAGE 768
METHOD FOR STARTING UP KOMTRAX TERMINAL 770
ADJUST REARVIEW CAMERA ANGLE 775
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 775
ADJUST KomVision CAMERA ANGLE 778
METHOD FOR ADJUSTING KomVision CAMERA ANGLE 779
ADJUST KomVision RELATED ITEMS 783
SETTING OF KomVision (MAIN SETTING) 783
SETTING OF KomVision (CAMERA SETTING) 785
SETTING OF KomVision (CAMERA CALIBRATION) 785
KomVision screen – Check 12 m visibility 799
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 802
HANDLE BATTERY DISCONNECT SWITCH 803
TEST DIODES 804
METHOD FOR TESTING DIODE USING DIGITAL TESTER 804
METHOD FOR TESTING DIODE USING ANALOG TESTER 804
Pm CLINIC 805
Pm CLINIC SERVICE 805
Pm CLINIC CHECK SHEET 809
40 TROUBLESHOOTING 821
CONTENTS 822
ABBREVIATION LIST 833
RELATED INFORMATION ON TROUBLESHOOTING 839
GENERAL TROUBLESHOOTING POINTS 839
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 840
SEQUENCE OF EVENTS IN TROUBLESHOOTING 852
CHECKS BEFORE TROUBLESHOOTING 854
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 856
WALK-AROUND CHECK 856
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 858
CHECK FUEL LEVEL AND TYPE 858
CHECK IMPURE INGREDIENT IN FUEL 858
CHECK FUEL PREFILTER 859
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 859
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 860
CHECK MAIN FILTER 861
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 863
CHECK COOLANT LEVEL (RESERVOIR TANK) 864
CHECK CLOGGING OF AIR CLEANER 864
OUTER ELEMENT – CLEAN 865
ELEMENTS – REPLACE 867
CHECK HYDRAULIC OIL LEVEL 868
CHECK HYDRAULIC OIL STRAINER 869
CHECK HYDRAULIC FILTER 870
CHECK OIL LEVEL IN SWING MACHINERY CASE 871
CHECK OIL LEVEL IN DAMPER CASE 872
CHECK OIL LEVEL IN FINAL DRIVE CASE 872
BLEED AIR FROM FUEL SYSTEM 873
BLEED AIR FROM HYDRAULIC SYSTEM 873
ELECTRICAL EQUIPMENT – CHECK METHOD 873
AUTOMATIC GREASE SYSTEM 881
FINDING MALFUNCTIONS 881
MALFUNCTION FINDING PROCEDURES 883
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM 885
PROCEDURE FOR TESTING AND TROUBLESHOOTING 895
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 898
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 902
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 904
CONNECTOR LIST AND LAYOUT 907
CONNECTOR CONTACT IDENTIFICATION 920
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 960
FUSE LOCATION TABLE 966
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 968
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 972
FAILURE CODE TABLE 974
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 992
FAILURE CODE [879AKA] 992
FAILURE CODE [879AKB] 993
FAILURE CODE [879BKA] 994
FAILURE CODE [879BKB] 996
FAILURE CODE [879CKA] 998
FAILURE CODE [879CKB] 999
FAILURE CODE [879DKZ]1000
FAILURE CODE [879EMC]1002
FAILURE CODE [879FMC]1003
FAILURE CODE [879GKX]1004
FAILURE CODE [989L00]1006
FAILURE CODE [989M00]1007
FAILURE CODE [989N00]1008
FAILURE CODE [A1U0N3]1009
FAILURE CODE [A1U0N4]1011
FAILURE CODE [A900FR]1013
FAILURE CODE [A900N6]1014
FAILURE CODE [A900NY]1015
FAILURE CODE [AA10NX]1016
FAILURE CODE [AB00KE]1018
FAILURE CODE [AQ10N3]1021
FAILURE CODE [AS00N3]1023
FAILURE CODE [AS00R2]1025
FAILURE CODE [AS00R3]1026
FAILURE CODE [AS00R4]1027
FAILURE CODE [AS00R5]1028
FAILURE CODE [AS00R6]1029
FAILURE CODE [AS00ZK]1030
FAILURE CODE [AS10KM]1031
FAILURE CODE [AS10NR]1032
FAILURE CODE [AS10NT]1033
FAILURE CODE [B@BAZG]1034
FAILURE CODE [B@BAZK]1035
FAILURE CODE [B@BCNS]1037
FAILURE CODE [B@BCQA]1038
FAILURE CODE [B@BCZK]1040
FAILURE CODE [B@HANS]1042
FAILURE CODE [CA115]1043
FAILURE CODE [CA122]1044
FAILURE CODE [CA123]1046
FAILURE CODE [CA131]1048
FAILURE CODE [CA132]1050
FAILURE CODE [CA144]1052
FAILURE CODE [CA145]1054
FAILURE CODE [CA153]1056
FAILURE CODE [CA154]1059
FAILURE CODE [CA187]1061
FAILURE CODE [CA221]1063
FAILURE CODE [CA222]1065
FAILURE CODE [CA227]1067
FAILURE CODE [CA234]1068
FAILURE CODE [CA238]1069
FAILURE CODE [CA239]1071
FAILURE CODE [CA249]1073
FAILURE CODE [CA256]1075
FAILURE CODE [CA271]1077
FAILURE CODE [CA272]1079
FAILURE CODE [CA322]1081
FAILURE CODE [CA323]1083
FAILURE CODE [CA324]1085
FAILURE CODE [CA325]1087
FAILURE CODE [CA331]1089
FAILURE CODE [CA332]1091
FAILURE CODE [CA343]1093
FAILURE CODE [CA351]1094
FAILURE CODE [CA352]1095
FAILURE CODE [CA356]1098
FAILURE CODE [CA357]1100
FAILURE CODE [CA386]1102
FAILURE CODE [CA428]1103
FAILURE CODE [CA429]1105
FAILURE CODE [CA435]1107
FAILURE CODE [CA441]1109
FAILURE CODE [CA442]1111
FAILURE CODE [CA449]1112
FAILURE CODE [CA451]1113
FAILURE CODE [CA452]1115
FAILURE CODE [CA488]1117
FAILURE CODE [CA515]1118
FAILURE CODE [CA516]1120
FAILURE CODE [CA553]1122
FAILURE CODE [CA555]1123
FAILURE CODE [CA556]1124
FAILURE CODE [CA559]1125
FAILURE CODE [CA595]1128
FAILURE CODE [CA687]1129
FAILURE CODE [CA689]1131
FAILURE CODE [CA691]1134
FAILURE CODE [CA692]1136
FAILURE CODE [CA697]1138
FAILURE CODE [CA698]1139
FAILURE CODE [CA731]1140
FAILURE CODE [CA778]1142
FAILURE CODE [CA1117]1147
FAILURE CODE [CA1664]1148
FAILURE CODE [CA1669]1150
FAILURE CODE [CA1673]1151
FAILURE CODE [CA1677]1152
FAILURE CODE [CA1678]1153
FAILURE CODE [CA1682]1154
FAILURE CODE [CA1683]1156
FAILURE CODE [CA1684]1158
FAILURE CODE [CA1686]1160
FAILURE CODE [CA1691]1161
FAILURE CODE [CA1694]1164
FAILURE CODE [CA1695]1167
FAILURE CODE [CA1696]1168
FAILURE CODE [CA1712]1170
FAILURE CODE [CA1713]1173
FAILURE CODE [CA1714]1175
FAILURE CODE [CA1715]1176
FAILURE CODE [CA1776]1177
FAILURE CODE [CA1777]1180
FAILURE CODE [CA1843]1183
FAILURE CODE [CA1844]1185
FAILURE CODE [CA1879]1188
FAILURE CODE [CA1881]1190
FAILURE CODE [CA1883]1192
FAILURE CODE [CA1885]1195
FAILURE CODE [CA1887]1197
FAILURE CODE [CA1921]1199
FAILURE CODE [CA1922]1202
FAILURE CODE [CA1942]1207
FAILURE CODE [CA1993]1208
FAILURE CODE [CA2185]1211
FAILURE CODE [CA2186]1212
FAILURE CODE [CA2249]1214
FAILURE CODE [CA2271]1215
FAILURE CODE [CA2272]1218
FAILURE CODE [CA2288]1221
FAILURE CODE [CA2311]1222
FAILURE CODE [CA2349]1223
FAILURE CODE [CA2353]1226
FAILURE CODE [CA2357]1228
FAILURE CODE [CA2381]1229
FAILURE CODE [CA2382]1232
FAILURE CODE [CA2383]1235
FAILURE CODE [CA2386]1238
FAILURE CODE [CA2387]1240
FAILURE CODE [CA2555]1241
FAILURE CODE [CA2556]1244
FAILURE CODE [CA2637]1247
FAILURE CODE [CA2639]1249
FAILURE CODE [CA2771]1252
FAILURE CODE [CA2777]1258
FAILURE CODE [CA2976]1261
FAILURE CODE [CA3133]1263
FAILURE CODE [CA3134]1266
FAILURE CODE [CA3135]1268
FAILURE CODE [CA3142]1271
FAILURE CODE [CA3143]1272
FAILURE CODE [CA3144]1273
FAILURE CODE [CA3146]1275
FAILURE CODE [CA3147]1276
FAILURE CODE [CA3148]1277
FAILURE CODE [CA3151]1279
FAILURE CODE [CA3165]1285
FAILURE CODE [CA3229]1287
FAILURE CODE [CA3231]1289
FAILURE CODE [CA3232]1291
FAILURE CODE [CA3235]1295
FAILURE CODE [CA3239]1297
FAILURE CODE [CA3241]1300
FAILURE CODE [CA3242]1303
FAILURE CODE [CA3251]1306
FAILURE CODE [CA3253]1308
FAILURE CODE [CA3254]1311
FAILURE CODE [CA3255]1314
FAILURE CODE [CA3256]1318
FAILURE CODE [CA3311]1320
FAILURE CODE [CA3312]1322
FAILURE CODE [CA3313]1325
FAILURE CODE [CA3314]1326
FAILURE CODE [CA3315]1327
FAILURE CODE [CA3316]1329
FAILURE CODE [CA3317]1330
FAILURE CODE [CA3318]1331
FAILURE CODE [CA3319]1333
FAILURE CODE [CA3321]1334
FAILURE CODE [CA3322]1336
FAILURE CODE [CA3419]1338
FAILURE CODE [CA3421]1340
FAILURE CODE [CA3497]1342
FAILURE CODE [CA3498]1343
FAILURE CODE [CA3543]1344
FAILURE CODE [CA3545]1351
FAILURE CODE [CA3547]1353
FAILURE CODE [CA3558]1354
FAILURE CODE [CA3559]1356
FAILURE CODE [CA3562]1358
FAILURE CODE [CA3563]1360
FAILURE CODE [CA3567]1363
FAILURE CODE [CA3568]1366
FAILURE CODE [CA3571]1370
FAILURE CODE [CA3572]1372
FAILURE CODE [CA3574]1374
FAILURE CODE [CA3575]1376
FAILURE CODE [CA3577]1378
FAILURE CODE [CA3578]1380
FAILURE CODE [CA3582]1382
FAILURE CODE [CA3583]1388
FAILURE CODE [CA3596]1390
FAILURE CODE [CA3649]1392
FAILURE CODE [CA3681]1394
FAILURE CODE [CA3682]1399
FAILURE CODE [CA3713]1405
FAILURE CODE [CA3717]1408
FAILURE CODE [CA3718]1409
FAILURE CODE [CA3725]1410
FAILURE CODE [CA3741]1413
FAILURE CODE [CA3748]1414
FAILURE CODE [CA3751]1416
FAILURE CODE [CA3755]1418
FAILURE CODE [CA3866]1420
FAILURE CODE [CA3867]1424
FAILURE CODE [CA3868]1427
FAILURE CODE [CA3899]1431
FAILURE CODE [CA3911]1433
FAILURE CODE [CA3912]1437
FAILURE CODE [CA3932]1439
FAILURE CODE [CA3933]1441
FAILURE CODE [CA3934]1443
FAILURE CODE [CA3935]1446
FAILURE CODE [CA3936]1448
FAILURE CODE [CA4151]1450
FAILURE CODE [CA4152]1454
FAILURE CODE [CA4155]1458
FAILURE CODE [CA4156]1460
FAILURE CODE [CA4157]1463
FAILURE CODE [CA4158]1465
FAILURE CODE [CA4159]1466
FAILURE CODE [CA4161]1467
FAILURE CODE [CA4162]1470
FAILURE CODE [CA4163]1473
FAILURE CODE [CA4164]1474
FAILURE CODE [CA4165]1476
FAILURE CODE [CA4166]1478
FAILURE CODE [CA4168]1479
FAILURE CODE [CA4169]1482
FAILURE CODE [CA4171]1484
FAILURE CODE [CA4249]1487
FAILURE CODE [CA4251]1489
FAILURE CODE [CA4259]1491
FAILURE CODE [CA4261]1494
FAILURE CODE [CA4277]1497
FAILURE CODE [CA4281]1501
FAILURE CODE [CA4459]1504
FAILURE CODE [CA4461]1507
FAILURE CODE [CA4658]1510
FAILURE CODE [CA4731]1514
FAILURE CODE [CA4732]1515
FAILURE CODE [CA4739]1516
FAILURE CODE [CA4768]1517
FAILURE CODE [CA4769]1519
FAILURE CODE [CA4842]1522
FAILURE CODE [CA4952]1526
FAILURE CODE [CA5115]1528
FAILURE CODE [CA5179]1531
FAILURE CODE [CA5181]1533
FAILURE CODE [CA5383]1535
FAILURE CODE [D110KB]1537
FAILURE CODE [D19JKZ]1539
FAILURE CODE [D811MC]1542
FAILURE CODE [D862KA]1543
FAILURE CODE [D8ALKA]1544
FAILURE CODE [D8ALKB]1546
FAILURE CODE [D8AQKR]1548
FAILURE CODE [DA20MC]1550
FAILURE CODE [DA22KK]1551
FAILURE CODE [DA25KP]1554
FAILURE CODE [DA26KP]1557
FAILURE CODE [DA29KQ]1560
FAILURE CODE [DA2LKA]1562
FAILURE CODE [DA2LKB]1564
FAILURE CODE [DA2QKR]1566
FAILURE CODE [DA2RKR]1569
FAILURE CODE [DAF0KM]1570
FAILURE CODE [DAF0MB]1571
FAILURE CODE [DAF0MC]1572
FAILURE CODE [DAF8KB]1573
FAILURE CODE [DAF9KQ]1575
FAILURE CODE [DAFGMC]1576
FAILURE CODE [DAFLKA]1577
FAILURE CODE [DAFLKB]1579
FAILURE CODE [DAFQKR]1581
FAILURE CODE [DAZ9KQ]1582
FAILURE CODE [DAZQKR]1583
FAILURE CODE [DB2QKR]1588
FAILURE CODE [DBP0KM]1593
FAILURE CODE [DBP0KT]1594
FAILURE CODE [DB2RKR]1595
FAILURE CODE [DBP5KB]1600
FAILURE CODE [DBP5KY]1603
FAILURE CODE [DBPQKR]1606
FAILURE CODE [DDNRKA]1611
FAILURE CODE [DDNRKY]1613
FAILURE CODE [DDNS00]1615
FAILURE CODE [DFB1KZ]1617
FAILURE CODE [DFB2KZ]1619
FAILURE CODE [DFB3L8]1621
FAILURE CODE [DFB4L8]1623
FAILURE CODE [DFB5KZ]1625
FAILURE CODE [DFB6KZ]1627
FAILURE CODE [DGH2KA]1629
FAILURE CODE [DGH2KB]1631
FAILURE CODE [DHA4KA]1633
FAILURE CODE [DHAAMA]1635
FAILURE CODE [DHACMA]1637
FAILURE CODE [DHPAMA]1639
FAILURE CODE [DHPBMA]1642
FAILURE CODE [DHS3MA]1645
FAILURE CODE [DHS4MA]1648
FAILURE CODE [DHS8MA]1651
FAILURE CODE [DHS9MA]1654
FAILURE CODE [DHSAMA]1657
FAILURE CODE [DHSBMA]1660
FAILURE CODE [DHSCMA]1663
FAILURE CODE [DHSDMA]1666
FAILURE CODE [DHSFMA]1669
FAILURE CODE [DHSGMA]1672
FAILURE CODE [DHSHMA]1675
FAILURE CODE [DHSJMA]1678
FAILURE CODE [DHX1MA]1681
FAILURE CODE [DKR0MA]1684
FAILURE CODE [DKR1MA]1687
FAILURE CODE [DKULKA]1690
FAILURE CODE [DKULKB]1692
FAILURE CODE [DKULKY]1694
FAILURE CODE [DR10KA]1696
FAILURE CODE [DR12KA]1699
FAILURE CODE [DR20KA]1701
FAILURE CODE [DR21KX]1703
FAILURE CODE [DR30KA]1705
FAILURE CODE [DR31KX]1707
FAILURE CODE [DR40KA]1709
FAILURE CODE [DUMBKA]1711
FAILURE CODE [DUMBKB]1713
FAILURE CODE [DV20KB]1715
FAILURE CODE [DW43KA]1717
FAILURE CODE [DW43KB]1719
FAILURE CODE [DW43KY]1721
FAILURE CODE [DW45KA]1723
FAILURE CODE [DW45KB]1726
FAILURE CODE [DW45KY]1729
FAILURE CODE [DW4CKY]1731
FAILURE CODE [DW91KA]1733
FAILURE CODE [DW91KB]1735
FAILURE CODE [DW91KY]1737
FAILURE CODE [DWA2KA]1739
FAILURE CODE [DWA2KB]1741
FAILURE CODE [DWA2KY]1743
FAILURE CODE [DWK0KA]1745
FAILURE CODE [DWK0KB]1747
FAILURE CODE [DWK0KY]1749
FAILURE CODE [DWK2KA]1751
FAILURE CODE [DWK2KB]1753
FAILURE CODE [DWK2KY]1755
FAILURE CODE [DWK8KA]1757
FAILURE CODE [DWK8KB]1759
FAILURE CODE [DWK8KY]1761
FAILURE CODE [DXA8KA]1763
FAILURE CODE [DXA8KB]1765
FAILURE CODE [DXA9KA]1767
FAILURE CODE [DXA9KB]1769
FAILURE CODE [DXE0KA]1771
FAILURE CODE [DXE0KB]1772
FAILURE CODE [DXE4KA]1774
FAILURE CODE [DXE4KB]1776
FAILURE CODE [DXE4KY]1778
FAILURE CODE [DXE5KA]1780
FAILURE CODE [DXE5KB]1782
FAILURE CODE [DXE6KA]1784
FAILURE CODE [DXE6KB]1786
FAILURE CODE [DXE7KA]1788
FAILURE CODE [DXE7KB]1790
FAILURE CODE [DXE7KY]1792
FAILURE CODE [DXE8KA]1794
FAILURE CODE [DXE8KB]1796
FAILURE CODE [DXE8KY]1798
FAILURE CODE [DXE9KA]1800
FAILURE CODE [DXE9KB]1802
FAILURE CODE [DXE9KY]1804
FAILURE CODE [DXEAKA]1806
FAILURE CODE [DXEAKB]1808
FAILURE CODE [DXEAKY]1810
FAILURE CODE [DY20KA]1812
FAILURE CODE [DY20MA]1814
FAILURE CODE [DY2CKB]1816
FAILURE CODE [DY2DKB]1819
FAILURE CODE [DY2EKB]1821
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1823
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1823
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1829
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1832
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1834
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING1836
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW1839
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW1840
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1841
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1842
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING1843
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1844
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1845
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1846
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1847
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1848
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1849
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1850
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL1852
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1853
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE1854
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1855
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE1857
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED1858
E-24 FUNCTION SWITCH DOES NOT OPERATE1859
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)1860
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF1861
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER1862
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED1863
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED1864
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE1865
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE1866
E-32 ALARM BUZZER CANNOT BE CANCELED1868
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION1869
E-34 SERVICE MODE CANNOT BE SELECTED1870
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE1871
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK1874
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING1876
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE1879
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR1881
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED1884
E-41 ALARM DOES NOT SOUND DURING TRAVEL1885
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED1887
E-43 HORN DOES NOT SOUND1888
E-44 HORN DOES NOT STOP SOUNDING1891
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF1893
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE1894
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE1896
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1897
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1898
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1899
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1900
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1901
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1902
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1903
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1904
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1905
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED1907
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY1908
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1909
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)1909
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS1910
FAILURE MODE AND CAUSE TABLE1912
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK1921
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER1922
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR1925
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP1926
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS1927
H-6 SPEED OR POWER OF BOOM IS LOW1929
H-7 ARM SPEED OR POWER IS LOW1933
H-8 BUCKET SPEED OR POWER IS LOW1938
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION1941
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE1942
H-11 HYDRAULIC DRIFT OF ARM IS LARGE1944
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE1946
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES1947
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE1948
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE1949
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED1950
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED1951
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER1952
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY1953
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW1954
H-21 MACHINE DOES NOT TRAVEL STRAIGHT1955
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW1957
H-23 TRAVEL SPEED IS LOW1960
H-24 ONE OF TRACKS DOES NOT RUN1962
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST1963
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT1964
H-27 SWINGS ONLY IN ONE DIRECTION1965
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)1966
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION1967
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)1968
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)1969
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING1970
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING1971
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)1972
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)1973
H-36 Quick coupler cylinder will not extend1974
H-37 Quick coupler cylinder will not retract (but buzzer doesnot sound)1976
H-38 Buzzer does not sound (but quick coupler cylinder doesretract)1978
H-39 Quick coupler cylinder extends and retracts slowly1980
TROUBLESHOOTING OF ENGINE (S-MODE)1981
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)1981
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION1982
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT1983
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)1984
S-4 ENGINE STARTABILITY IS POOR1986
S-5 ENGINE DOES NOT PICK UP SMOOTHLY1988
S-6 ENGINE STOPS DURING OPERATION1990
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE1992
S-8 ENGINE LACKS POWER1993
S-9 KDPF GETS CLOGGED IN A SHORT TIME1995
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE1997
S-11 OIL BECOMES CONTAMINATED QUICKLY1998
S-12 FUEL CONSUMPTION IS EXCESSIVE1999
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2000
S-14 OIL PRESSURE DROPS2001
S-15 FUEL MIXES INTO ENGINE OIL2003
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2004
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2005
S-18 UNUSUAL NOISE IS HEARD2006
S-19 VIBRATION IS EXCESSIVE2007
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2008
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2009
S-22 ACTIVE REGENERATION TAKES TIME2011
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2012
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE2013
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)2015
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2016
50 DISASSEMBLY AND ASSEMBLY2017
CONTENTS2018
ABBREVIATION LIST2023
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2029
HOW TO READ THIS MANUAL2029
COATING MATERIALS LIST2031
SPECIAL TOOLS LIST2035
SKETCHES OF SPECIAL TOOLS2047
ENGINE AND COOLING SYSTEM2053
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2053
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2053
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2056
REMOVE AND INSTALL INJECTOR ASSEMBLY2060
METHOD FOR REMOVING INJECTOR ASSEMBLY2060
METHOD FOR INSTALLING INJECTOR ASSEMBLY2065
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2073
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2074
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2083
REMOVE AND INSTALL EGR VALVE ASSEMBLY2099
METHOD FOR REMOVING EGR VALVE ASSEMBLY2099
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2100
REMOVE AND INSTALL EGR COOLER ASSEMBLY2103
METHOD FOR REMOVING EGR COOLER ASSEMBLY2103
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2106
REMOVE AND INSTALL STARTER ASSEMBLY2111
METHOD FOR REMOVING STARTER ASSEMBLY2111
METHOD FOR INSTALLING STARTER ASSEMBLY2113
REMOVE AND INSTALL ALTERNATOR BELT2115
METHOD FOR REMOVING ALTERNATOR BELT2115
METHOD FOR INSTALLING ALTERNATOR BELT2117
REMOVE AND INSTALL RADIATOR ASSEMBLY2119
METHOD FOR REMOVING RADIATOR ASSEMBLY2119
METHOD FOR INSTALLING RADIATOR ASSEMBLY2121
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2123
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2123
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2126
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2129
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2129
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2130
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY2132
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY2133
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY2141
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2152
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2152
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2155
REMOVE AND INSTALL ENGINE REAR OIL SEAL2159
METHOD FOR REMOVING ENGINE REAR OIL SEAL2159
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2160
REMOVE AND INSTALL FUEL COOLER ASSEMBLY2163
METHOD FOR REMOVING FUEL COOLER ASSEMBLY2163
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY2164
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2165
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2165
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2167
REMOVE AND INSTALL FUEL TANK ASSEMBLY2173
METHOD FOR REMOVING FUEL TANK ASSEMBLY2173
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2177
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2183
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2183
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2188
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2194
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2194
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2199
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2205
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2205
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2205
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2212
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2212
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2212
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER2213
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER2213
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER2215
REMOVE AND INSTALL KDPF ASSEMBLY2218
METHOD FOR REMOVING KDPF ASSEMBLY2218
METHOD FOR INSTALLING KDPF ASSEMBLY2220
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2222
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2223
METHOD FOR ASSEMBLING KDPF ASSEMBLY2226
REMOVE AND INSTALL SCR ASSEMBLY2231
METHOD FOR REMOVING SCR ASSEMBLY2231
METHOD FOR INSTALLING SCR ASSEMBLY2233
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2235
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2235
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2241
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET2247
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET2247
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET2255
REMOVE AND INSTALL KCCV ASSEMBLY2264
METHOD FOR REMOVING KCCV ASSEMBLY2264
METHOD FOR INSTALLING KCCV ASSEMBLY2266
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2271
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2271
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2276
REMOVE AND INSTALL AdBlue/DEF INJECTOR2281
METHOD FOR REMOVING AdBlue/DEF INJECTOR2281
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2283
REMOVE AND INSTALL AdBlue/DEF PUMP2285
METHOD FOR REMOVING AdBlue/DEF PUMP2285
METHOD FOR INSTALLING AdBlue/DEF PUMP2287
REMOVE AND INSTALL AdBlue/DEF HOSE2290
METHOD FOR REMOVING AdBlue/DEF HOSE2290
METHOD FOR INSTALLING AdBlue/DEF HOSE2298
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2304
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2304
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2305
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2307
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2307
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2309
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2312
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2312
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2313
POWER TRAIN2314
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2314
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2314
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2315
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY2316
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY2316
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY2320
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY2329
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY2329
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY2331
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY2335
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY2335
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY2339
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY2346
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY2346
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY2346
UNDERCARRIAGE AND FRAME2348
SEPARATION AND CONNECTION OF TRACK ASSEMBLY2348
METHOD FOR SEPARATING TRACK ASSEMBLY2348
METHOD FOR INSTALLING TRACK ASSEMBLY2350
REMOVE AND INSTALL SPROCKET2353
METHOD FOR REMOVING SPROCKET2353
METHOD FOR INSTALLING SPROCKET2353
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY2355
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY2355
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY2356
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2357
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2357
METHOD FOR ASSEMBLING IDLER ASSEMBLY2358
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY2362
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY2363
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY2364
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2365
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2366
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2367
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY2369
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY2369
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY2370
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY2373
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY2373
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY2375
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2377
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2377
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2380
HYDRAULIC SYSTEM2384
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY2384
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY2384
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY2386
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2389
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2390
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2391
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2392
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2392
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2395
REMOVE AND INSTALL MAIN PUMP ASSEMBLY2398
METHOD FOR REMOVING MAIN PUMP ASSEMBLY2398
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY2401
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2404
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2404
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2411
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY2419
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING2419
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY2421
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2425
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2425
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2425
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2427
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY2427
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY2428
REMOVE AND INSTALL QUICK COUPLER VALVE2430
WORK EQUIPMENT2432
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2432
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2432
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2436
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2442
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2442
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2445
CAB AND ITS ATTACHMENTS2451
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2451
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2451
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2457
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)2464
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2466
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2466
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY2476
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY2476
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY2479
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY2485
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY2485
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY2492
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2499
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2499
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2505
REMOVE AND INSTALL OPERATOR’S SEAT2512
METHOD FOR REMOVING OPERATOR’S SEAT2512
METHOD FOR INSTALLING OPERATOR’S SEAT2514
REMOVE AND INSTALL SEAT BELT2517
METHOD FOR REMOVING SEAT BELT2517
METHOD FOR INSTALLING SEAT BELT2518
REMOVE AND INSTALL FRONT WIPER ASSEMBLY2519
METHOD FOR REMOVING FRONT WIPER ASSEMBLY2519
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY2524
ELECTRICAL SYSTEM2533
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2533
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2533
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2534
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY2536
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY2536
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY2540
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY2545
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY2545
METHOD FOR INSTALLING KomVision CONTROLLER2546
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2548
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2548
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY2551
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR2555
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR2555
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR2556
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2557
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR2557
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR2557
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2559
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR2559
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR2560
REMOVE AND INSTALL SCR TEMPERATURE SENSOR2562
METHOD FOR REMOVING SCR TEMPERATURE SENSOR2562
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR2564
REMOVE AND INSTALL KomVision CAMERA2567
METHOD FOR REMOVING KomVision CAMERA2567
METHOD FOR INSTALLING KomVision CAMERA2570
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY2573
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY2573
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY2576
60 MAINTENANCE STANDARD2579
CONTENTS2580
ABBREVIATION LIST2581
ENGINE AND COOLING SYSTEM2587
MAINTENANCE STANDARD OF ENGINE MOUNT2587
MAINTENANCE STANDARD OF COOLING SYSTEM2588
POWER TRAIN2589
MAINTENANCE STANDARD OF SWING CIRCLE2589
MAINTENANCE STANDARD OF SWING MACHINERY2590
MAINTENANCE STANDARD OF FINAL DRIVE2592
MAINTENANCE STANDARD OF SPROCKET2594
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING2595
UNDERCARRIAGE AND FRAME2597
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION2597
MAINTENANCE STANDARD OF IDLER2599
MAINTENANCE STANDARD OF TRACK ROLLER2601
MAINTENANCE STANDARD OF CARRIER ROLLER2603
MAINTENANCE STANDARD OF TRACK SHOE2604
MAINTENANCE STANDARD OF TRIPLE SHOE2607
HYDRAULIC SYSTEM2608
MAINTENANCE STANDARD OF HYDRAULIC TANK2608
MAINTENANCE STANDARD OF MAIN PUMP2609
MAINTENANCE STANDARD OF LS-EPC VALVE2610
MAINTENANCE STANDARD OF PC-EPC VALVE2611
MAINTENANCE STANDARD OF SWING MOTOR2612
MAINTENANCE STANDARD OF TRAVEL MOTOR2615
MAINTENANCE STANDARD OF CONTROL VALVE2618
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE2628
MAINTENANCE STANDARD OF TRAVEL PPC VALVE2631
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)2634
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE2636
MAINTENANCE STANDARD OF SOLENOID VALVE2637
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)2638
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)2639
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT2640
WORK EQUIPMENT2641
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE2641
DIMENSION OF ARM2646
DIMENSIONS OF BUCKET2648
MAINTENANCE STANDARD OF BOOM CYLINDER2650
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON)2651
MAINTENANCE STANDARD OF ARM CYLINDER2652
MAINTENANCE STANDARD OF BUCKET CYLINDER2653
80 APPENDIX2655
CONTENTS2656
ABBREVIATION LIST2658
AIR CONDITIONER SYSTEM2664
PRECAUTIONS FOR REFRIGERANT2664
AIR CONDITIONER COMPONENT2665
SPECIFICATIONS OF AIR CONDITIONER2667
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2668
OUTLINE OF REFRIGERATION CYCLE2669
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2671
AIR CONDITIONER UNIT2671
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2671
FUNCTION OF AIR CONDITIONER UNIT2673
COMPONENT PARTS OF AIR CONDITIONER UNIT2675
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2676
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2676
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT2676
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT2676
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2677
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2677
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2677
FUNCTION OF DUAL PRESSURE SWITCH2678
AIR CONDITIONER CONTROLLER2679
STRUCTURE OF AIR CONDITIONER CONTROLLER2679
COMPRESSOR2680
STRUCTURE OF COMPRESSOR2680
SPECIFICATIONS OF COMPRESSOR2680
FUNCTION OF COMPRESSOR2680
CONDENSER2681
STRUCTURE OF CONDENSER2681
SPECIFICATIONS OF CONDENSER2681
FUNCTION OF CONDENSER2681
SENSORS FOR AIR CONDITIONER SYSTEM2683
STRUCTURE OF SUNLIGHT SENSOR2683
FUNCTION OF SUNLIGHT SENSOR2683
STRUCTURE OF AMBIENT TEMPERATURE SENSOR2683
FUNCTION OF AMBIENT TEMPERATURE SENSOR2683
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2685
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER2687
AIR CONDITIONER SYSTEM DIAGRAM2689
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER2690
FUNCTION OF AIR CONDITIONER CONTROLLER2691
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2692
TESTING AIR LEAKAGE (DUCT)2696
METHOD FOR TESTING AIR LEAKAGE (DUCT)2696
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION2698
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR2699
TEST VENT (MODE) CHANGEOVER2700
METHOD FOR TESTING VENT (MODE) CHANGEOVER2700
TESTING FRESH/RECIRC AIR CHANGEOVER2702
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER2702
TEST SUNLIGHT SENSOR2703
METHOD FOR TESTING SUNLIGHT SENSOR2703
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT2704
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT2704
TEST RELAYS2705
METHOD FOR TESTING RELAYS2705
AIR CONDITIONER TROUBLESHOOTING CHART 12706
AIR CONDITIONER TROUBLESHOOTING CHART 22707
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2710
FAILURE CODE [879AKA]2712
FAILURE CODE [879AKB]2713
FAILURE CODE [879BKA]2714
FAILURE CODE [879BKB]2716
FAILURE CODE [879CKA]2718
FAILURE CODE [879CKB]2719
FAILURE CODE [879DKZ]2720
FAILURE CODE [879EMC]2722
FAILURE CODE [879FMC]2723
FAILURE CODE [879GKX]2724
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)2726
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)2728
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)2731
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER2733
TROUBLESHOOTING USING GAUGE PRESSURE2735
CONNECTION OF SERVICE TOOL2738
METHOD FOR CONNECTING SERVICE TOOL2738
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS2740
HANDLE COMPRESSOR OIL2742
METHOD FOR REPLACING DESICCANT2744
90 CIRCUIT DIAGRAMS2747
CONTENTS2748
ABBREVIATION LIST2749
HYDRAULIC CIRCUIT DIAGRAM2755
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2755
HYDRAULIC CIRCUIT DIAGRAM (1/2)2759
HYDRAULIC CIRCUIT DIAGRAM (2/2)2761
ELECTRICAL CIRCUIT DIAGRAM2763
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM2763
ELECTRICAL CIRCUIT DIAGRAM (1/8)2767
ELECTRICAL CIRCUIT DIAGRAM (2/8)2769
ELECTRICAL CIRCUIT DIAGRAM (3/8)2771
ELECTRICAL CIRCUIT DIAGRAM (4/8)2773
ELECTRICAL CIRCUIT DIAGRAM (5/8)2775
ELECTRICAL CIRCUIT DIAGRAM (6/8)2777
ELECTRICAL CIRCUIT DIAGRAM (7/8)2779
ELECTRICAL CIRCUIT DIAGRAM (8/8)2781
INDEX2783

S.M 31/12/24