Komatsu HYDRAULIC EXCAVATOR PC290 -11E0 PC290LC -11E0 PC290NLC-11E0 Shop Manual UENBM00720

Description

Komatsu HYDRAULIC EXCAVATOR PC290 -11E0 PC290LC -11E0 PC290NLC-11E0 Shop Manual UENBM00720 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HYDRAULIC EXCAVATOR PC290 -11E0 PC290LC -11E0 PC290NLC-11E0 Shop Manual UENBM00720 – PDF DOWNLOAD

Language : English
Pages :2890
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC290 -11E0 PC290LC -11E0 PC290NLC-11E0 Shop Manual UENBM00720 – PDF DOWNLOAD

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 -11E0 PC290LC -11E0 PC290NLC-11E0 Shop Manual UENBM00720 – PDF DOWNLOAD

SERIAL NUMBERS
PC290LC-11E0 – K75600 and up
PC290NLC-11E0 – K75600 and up

00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 22
FOREWORD, SAFETY, BASIC INFORMATION 28
HOW TO READ THE SHOP MANUAL 28
SAFETY NOTICE FOR OPERATION 30
PRECAUTIONS TO PREVENT FIRE 38
ACTIONS IF FIRE OCCURS 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 42
METHOD FOR CHECKING ENGINE TYPE 43
PRECAUTIONS FOR DEF 45
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 45
PRECAUTIONS FOR ADDING 45
PRECAUTIONS FOR STORING 45
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 45
THE OTHER PRECAUTIONS 45
STORE AdBlue/DEF 46
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 47
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 50
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 57
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 59
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 60
PRACTICAL USE OF KOMTRAX 61
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 64
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 66
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 70
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 74
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 76
HOW TO READ ELECTRICAL WIRE CODE 77
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 81
STANDARD TIGHTENING TORQUE TABLE 84
CONVERSION TABLE 91
01 SPECIFICATIONS 97
CONTENTS 98
ABBREVIATION LIST 99
SPECIFICATIONS 105
SPECIFICATION DRAWING 105
SPECIFICATION DRAWING: PC290LC-11E0, PC290NLC-11E0 105
WORKING RANGE DRAWINGS 107
WORKING RANGE: PC290LC-11E0, PC290NLC-11E0 107
SPECIFICATIONS 108
SPECIFICATIONS: PC290LC-11E0, PC290NLC-11E0 108
WEIGHT TABLE 111
WEIGHT TABLE: PC290LC-11E0, PC290NLC-11E0 111
TABLE OF FUEL, COOLANT, AND LUBRICANTS 113
10 STRUCTURE AND FUNCTION 115
CONTENTS 116
ABBREVIATION LIST 120
UREA SCR SYSTEM 126
LAYOUT DRAWING OF UREA SCR SYSTEM 127
UREA SCR SYSTEM DIAGRAM 132
FUNCTION OF UREA SCR SYSTEM 133
FUNCTION OF AdBlue/DEF SYSTEM 133
INDUCEMENT STRATEGY 137
COMPONENT PARTS OF UREA SCR SYSTEM 156
AdBlue/DEF MIXING TUBE 156
SCR ASSEMBLY 156
AdBlue/DEF TANK 159
AdBlue/DEF PUMP 161
AdBlue/DEF INJECTOR 162
AdBlue/DEF HOSE 163
AdBlue/DEF TANK HEATING VALVE 164
BOOT-UP SYSTEM 165
LAYOUT DRAWING OF BOOT-UP SYSTEM 165
SYSTEM OPERATING LAMP SYSTEM 167
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 167
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 167
BATTERY DISCONNECT SWITCH 169
FUNCTION OF BATTERY DISCONNECT SWITCH 169
ENGINE SYSTEM 170
LAYOUT DRAWING OF ENGINE SYSTEM 170
SPECIFICATIONS OF ENGINE SYSTEM 171
FUNCTION OF ENGINE SYSTEM 171
ENGINE CONTROL SYSTEM 172
ENGINE CONTROL SYSTEM DIAGRAM 172
FUNCTION OF ENGINE CONTROL SYSTEM 173
AUTO-DECELERATION SYSTEM 175
AUTO-DECELERATION SYSTEM DIAGRAM 175
FUNCTION OF AUTO-DECELERATION SYSTEM 175
OPERATION OF AUTO-DECELERATION SYSTEM 176
ENGINE AUTOMATIC WARM-UP SYSTEM 177
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 177
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 178
OVERHEAT PREVENTION SYSTEM 179
OVERHEAT PREVENTION SYSTEM DIAGRAM 179
FUNCTION OF OVERHEAT PREVENTION SYSTEM 180
TURBOCHARGER PROTECTION SYSTEM 182
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 182
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 183
AUTOMATIC IDLE STOP SYSTEM 184
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 184
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 184
COMPONENT PARTS OF ENGINE SYSTEM 187
VGT 187
EGR SYSTEM 191
EGR VALVE 193
EGR COOLER 195
KCCV SYSTEM 196
KCCV VENTILATOR 198
KDPF 200
COOLING SYSTEM 205
LAYOUT DRAWING OF COOLING SYSTEM 205
SPECIFICATIONS OF COOLING SYSTEM 206
CONTROL SYSTEM 207
LAYOUT DRAWING OF CONTROL SYSTEM 207
MACHINE MONITOR SYSTEM 210
MACHINE MONITOR SYSTEM DIAGRAM 210
FUNCTION OF MACHINE MONITOR SYSTEM 210
KomVision SYSTEM 212
LAYOUT DRAWING OF KOMVISION SYSTEM 212
KomVision SYSTEM DIAGRAM 214
FUNCTION OF KomVision SYSTEM 214
KOMTRAX SYSTEM 216
KOMTRAX SYSTEM DIAGRAM 216
FUNCTION OF KOMTRAX SYSTEM 216
PPC LEVERS 217
LH PPC LEVER 217
RH PPC LEVER 218
AUTOMATIC GREASE SYSTEM 219
OUTLINE OF AUTO GREASE SYSTEM 219
COMPONENT PARTS OF CONTROL SYSTEM 233
MACHINE MONITOR 233
KomVision CONTROLLER 251
KomVision CAMERA 255
KOMTRAX TERMINAL 255
PUMP CONTROLLER 258
RESISTOR FOR PC-EPC VALVE 262
CAN TERMINATING RESISTOR 262
PPC OIL PRESSURE SWITCH 263
ENGINE CONTROLLER 264
FUEL CONTROL DIAL 270
STRUCTURE OF ENGINE OIL PRESSURE SWITCH 271
FUNCTION OF ENGINE OIL PRESSURE SWITCH 272
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 272
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 273
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 273
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 273
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 273
FUNCTION OF AUTO GREASE PRESSURE SWITCH 273
STRUCTURE OF OVERLOAD CAUTION SENSOR 273
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 274
FUNCTION OF OVERLOAD CAUTION SENSOR 274
HYDRAULIC SYSTEM 275
LAYOUT DRAWING OF HYDRAULIC SYSTEM 275
CLSS 281
STRUCTURE OF CLSS 281
OPERATION OF UNLOAD VALVE AND LS PRESSURE 283
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 284
PRESSURE COMPENSATION CONTROL 297
ENGINE AND PUMP COMBINED CONTROL SYSTEM 300
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 300
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 301
PUMP AND VALVE CONTROL SYSTEM 306
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 306
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 307
COMPONENT PARTS OF HYDRAULIC SYSTEM 309
HYDRAULIC TANK 309
MAIN PUMP 311
PC-EPC VALVE 335
PILOT OIL FILTER 337
CONTROL VALVE 337
WORK EQUIPMENT SYSTEM 394
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 394
STRUCTURE OF VALVE CONTROL 399
ONE-TOUCH POWER MAXIMIZING SYSTEM 401
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 401
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 402
PPC LOCK SYSTEM 403
PPC LOCK SYSTEM DIAGRAM 403
FUNCTION OF PPC LOCK SYSTEM 403
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 404
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 404
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 404
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 405
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 406
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 406
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 408
TOOL CONTROL SYSTEM 409
TOOL CONTROL SYSTEM DIAGRAM 409
FUNCTION OF TOOL CONTROL SYSTEM 410
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 411
WORK EQUIPMENT AND SWING PPC VALVE 411
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 416
SOLENOID VALVE 422
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 425
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 427
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE 430
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE 432
ATTACHMENT BYPASS SOLENOID VALVE 435
ATT EPC VALVE ASSEMBLY 437
PILOT CIRCUIT ACCUMULATOR 438
ATTACHMENT CIRCUIT ACCUMULATOR 439
SWING SYSTEM 440
LAYOUT DRAWING OF SWING SYSTEM 440
SWING CONTROL SYSTEM DIAGRAM 444
FUNCTION OF SWING CONTROL SYSTEM 444
COMPONENT PARTS OF SWING SYSTEM 448
SWING MOTOR 448
SWING MACHINERY 460
SWING CIRCLE 461
TRAVEL SYSTEM 463
LAYOUT DRAWING OF TRAVEL SYSTEM 463
TRAVEL CONTROL SYSTEM DIAGRAM 467
FUNCTION OF TRAVEL CONTROL SYSTEM 467
COMPONENT PARTS OF TRAVEL SYSTEM 469
TRAVEL MOTOR 469
FINAL DRIVE 481
TRAVEL PPC VALVE 483
CENTER SWIVEL JOINT 488
UNDERCARRIAGE AND FRAME 490
LAYOUT DRAWING OF UNDERCARRIAGE 490
SPECIFICATIONS OF UNDERCARRIAGE 491
WORK EQUIPMENT 492
STRUCTURE OF WORK EQUIPMENT 492
FUNCTION OF WORK EQUIPMENT 493
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 494
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 494
BUCKET CLEARANCE ADJUSTMENT SHIM 495
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 495
CAB AND ITS ATTACHMENTS 496
ROPS CAB 496
STRUCTURE OF ROPS CAB 496
FUNCTION OF ROPS CAB 496
CAB MOUNT 497
STRUCTURE OF CAB MOUNT 497
FUNCTION OF CAB MOUNT 497
CAB TIPPING STOPPER 498
STRUCTURE OF CAB TIPPING STOPPER 498
FUNCTION OF CAB TIPPING STOPPER 498
20 STANDARD VALUE TABLE 499
CONTENTS 500
ABBREVIATION LIST 501
STANDARD VALUE TABLE FOR ENGINE 507
STANDARD VALUE TABLE FOR ENGINE: PC290LC-11E0, PC290NLC-11E0 507
STANDARD VALUE TABLE FOR MACHINE 511
STANDARD VALUE TABLE FOR MACHINE: PC290LC-11E0, PC290NLC-11E0 511
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 524
STANDARD VALUE TABLE FOR ELECTRICAL 528
STANDARD VALUE TABLE FOR ELECTRICAL 528
30 TESTING AND ADJUSTING 539
CONTENTS 540
ABBREVIATION LIST 543
RELATED INFORMATION ON TESTING AND ADJUSTING 549
TOOLS FOR TESTING AND ADJUSTING 549
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 556
ENGINE AND COOLING SYSTEM 558
TEST ENGINE SPEED 558
METHOD FOR TESTING ENGINE SPEED 558
TEST BOOST PRESSURE 561
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 561
METHOD FOR TESTING BOOST PRESSURE 562
TEST EXHAUST GAS COLOR 563
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 563
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 564
TEST AND ADJUST VALVE CLEARANCE 566
METHOD FOR TESTING VALVE CLEARANCE 566
METHOD FOR ADJUSTING VALVE CLEARANCE 567
TEST COMPRESSION PRESSURE 569
METHOD FOR TESTING COMPRESSION PRESSURE 569
TEST BLOWBY PRESSURE 574
METHOD FOR TESTING BLOWBY PRESSURE 574
TEST ENGINE OIL PRESSURE 576
METHOD FOR TESTING ENGINE OIL PRESSURE 576
TEST EGR VALVE AND VGT OIL PRESSURE 577
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 577
TEST FUEL PRESSURE 579
METHOD FOR TESTING FUEL PRESSURE 580
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 585
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 586
BLEEDING AIR FROM FUEL SYSTEM 592
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 592
TEST FUEL CIRCUIT FOR LEAKAGE 593
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 593
HANDLE CYLINDER CUT-OUT MODE OPERATION 595
HANDLE NO-INJECTION CRANKING OPERATION 596
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 597
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 597
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 597
REPLACING FAN BELT 599
METHOD FOR REPLACING FAN BELT 599
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 600
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 600
TEST SCR RELATED FUNCTIONS 601
TEST AdBlue/DEF PUMP RAISED PRESSURE 604
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 607
TEST AdBlue/DEF LINE HEATER RELAY 1 611
TEST AdBlue/DEF LINE HEATER RELAY 2 614
TEST AdBlue/DEF PUMP HEATER RELAY 616
TEST AdBlue/DEF TANK HEATER VALVE 619
TEST DENITRATION EFFICIENCY OF SCR 622
CLEAN AdBlue/DEF TANK 626
METHOD FOR CLEANING AdBlue/DEF TANK 626
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 630
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 630
POWER TRAIN 632
TEST SWING CIRCLE BEARING CLEARANCE 632
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 632
UNDERCARRIAGE AND FRAME 633
TEST AND ADJUST TRACK TENSION 633
METHOD FOR TESTING TRACK TENSION 633
METHOD FOR ADJUSTING TRACK TENSION 633
HYDRAULIC SYSTEM 635
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 635
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 635
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 635
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 641
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 642
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 648
TEST OIL PRESSURE OF CONTROL CIRCUIT 651
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 651
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 653
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 653
TEST PC-EPC VALVE OUTLET PRESSURE 654
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 655
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 657
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 657
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL 658
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 661
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 662
METHOD FOR ADJUSTING LS VALVE 663
TEST OUTLET PRESSURE OF SOLENOID VALVE 664
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 664
OPERATING CONDITION OF SOLENOID VALVE 665
TEST PPC VALVE OUTLET PRESSURE 668
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 668
TEST ATTACHMENT CIRCUIT OIL PRESSURE 670
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 670
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 672
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 672
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE 673
TEST PUMP SWASH PLATE SENSOR 675
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 675
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 676
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 676
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 676
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 677
TEST OIL LEAKAGE 678
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 678
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 678
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 679
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 680
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 680
BLEED AIR FROM HYDRAULIC CIRCUIT 681
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 683
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 685
CAB AND ITS ATTACHMENTS 690
TEST CAB TIPPING STOPPER 690
METHOD FOR TESTING CAB TIPPING STOPPER 690
METHOD FOR ADJUSTING MIRRORS 691
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 691
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 692
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 693
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 694
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 695
ELECTRICAL SYSTEM 697
ELECTRICAL SYSTEM 698
SET AND OPERATE MACHINE MONITOR 698
OPERATOR MODE 701
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 702
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 702
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 703
CHECKING FUNCTION OF SERVICE METER 703
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 703
SERVICE MODE 706
METHOD FOR OPERATING SERVICE MODE 707
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 709
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 716
ABNORMALITY RECORD MENU 726
METHOD FOR CONFIRMING MAINTENANCE RECORD 731
METHOD FOR OPERATING MAINTENANCE MODE SETTING 732
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 736
DEFAULT MENU 737
DIAGNOSTIC TESTS MENU 748
ADJUSTMENT MENU 758
METHOD FOR PERFORMING NO-INJECTION CRANKING 792
KOMTRAX SETTINGS MENU 793
METHOD FOR DISPLAYING SERVICE MESSAGE 795
METHOD FOR STARTING UP KOMTRAX TERMINAL 797
ADJUST REARVIEW CAMERA ANGLE 802
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 802
ADJUST KomVision CAMERA ANGLE 805
METHOD FOR ADJUSTING KomVision CAMERA ANGLE 806
ADJUST KomVision RELATED ITEMS 810
SETTING OF KomVision (MAIN SETTING) 810
SETTING OF KomVision (CAMERA SETTING) 812
SETTING OF KomVision (CAMERA CALIBRATION) 814
KomVision screen – Check 12 m visibility 827
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 830
HANDLE BATTERY DISCONNECT SWITCH 831
TEST DIODES 832
METHOD FOR TESTING DIODE USING DIGITAL TESTER 832
METHOD FOR TESTING DIODE USING ANALOG TESTER 832
Pm CLINIC 833
Pm CLINIC SERVICE 833
Pm CLINIC CHECK SHEET 837
40 TROUBLESHOOTING 849
CONTENTS 850
ABBREVIATION LIST 861
RELATED INFORMATION ON TROUBLESHOOTING 867
GENERAL TROUBLESHOOTING POINTS 867
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 868
SEQUENCE OF EVENTS IN TROUBLESHOOTING 880
CHECKS BEFORE TROUBLESHOOTING 882
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 884
WALK-AROUND CHECK 884
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 886
CHECK FUEL LEVEL AND TYPE 886
CHECK IMPURE INGREDIENT IN FUEL 886
CHECK FUEL PREFILTER 887
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 887
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 888
CHECK MAIN FILTER 889
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 891
CHECK COOLANT LEVEL (RESERVOIR TANK) 892
CHECK CLOGGING OF AIR CLEANER 892
OUTER ELEMENT – CLEAN 893
ELEMENTS – REPLACE 895
CHECK HYDRAULIC OIL LEVEL 896
CHECK HYDRAULIC OIL STRAINER 897
CHECK HYDRAULIC FILTER 898
CHECK OIL LEVEL IN SWING MACHINERY CASE 899
CHECK OIL LEVEL IN DAMPER CASE 900
CHECK OIL LEVEL IN FINAL DRIVE CASE 900
BLEED AIR FROM FUEL SYSTEM 901
BLEED AIR FROM HYDRAULIC SYSTEM 901
ELECTRICAL EQUIPMENT – CHECK METHOD 901
AUTOMATIC GREASE SYSTEM 909
FINDING MALFUNCTIONS 909
MALFUNCTION FINDING PROCEDURES 913
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM 915
PROCEDURE FOR TESTING AND TROUBLESHOOTING 925
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 928
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 932
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 934
CONNECTOR LIST AND LAYOUT 937
CONNECTOR CONTACT IDENTIFICATION 950
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 990
FUSE LOCATION TABLE 996
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 999
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])1003
FAILURE CODE TABLE1005
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1023
FAILURE CODE [879AKA]1023
FAILURE CODE [879AKB]1024
FAILURE CODE [879BKA]1025
FAILURE CODE [879BKB]1027
FAILURE CODE [879CKA]1029
FAILURE CODE [879CKB]1030
FAILURE CODE [879DKZ]1031
FAILURE CODE [879EMC]1033
FAILURE CODE [879FMC]1034
FAILURE CODE [879GKX]1035
FAILURE CODE [989L00]1037
FAILURE CODE [989M00]1038
FAILURE CODE [989N00]1039
FAILURE CODE [A1U0N3]1040
FAILURE CODE [A1U0N4]1042
FAILURE CODE [A900FR]1044
FAILURE CODE [A900N6]1045
FAILURE CODE [A900NY]1046
FAILURE CODE [AA10NX]1047
FAILURE CODE [AB00KE]1049
FAILURE CODE [AQ10N3]1052
FAILURE CODE [AS00N3]1054
FAILURE CODE [AS00R2]1056
FAILURE CODE [AS00R3]1057
FAILURE CODE [AS00R4]1058
FAILURE CODE [AS00R5]1059
FAILURE CODE [AS00R6]1060
FAILURE CODE [AS00ZK]1061
FAILURE CODE [AS10KM]1062
FAILURE CODE [AS10NR]1063
FAILURE CODE [AS10NT]1064
FAILURE CODE [B@BAZG]1065
FAILURE CODE [B@BAZK]1066
FAILURE CODE [B@BCNS]1068
FAILURE CODE [B@BCQA]1069
FAILURE CODE [B@BCZK]1071
FAILURE CODE [B@HANS]1073
FAILURE CODE [CA115]1074
FAILURE CODE [CA122]1075
FAILURE CODE [CA123]1077
FAILURE CODE [CA131]1079
FAILURE CODE [CA132]1081
FAILURE CODE [CA144]1083
FAILURE CODE [CA145]1085
FAILURE CODE [CA153]1087
FAILURE CODE [CA154]1090
FAILURE CODE [CA187]1092
FAILURE CODE [CA221]1094
FAILURE CODE [CA222]1096
FAILURE CODE [CA227]1098
FAILURE CODE [CA234]1099
FAILURE CODE [CA238]1100
FAILURE CODE [CA239]1102
FAILURE CODE [CA249]1104
FAILURE CODE [CA256]1106
FAILURE CODE [CA271]1108
FAILURE CODE [CA272]1110
FAILURE CODE [CA322]1112
FAILURE CODE [CA323]1114
FAILURE CODE [CA324]1116
FAILURE CODE [CA325]1118
FAILURE CODE [CA331]1120
FAILURE CODE [CA332]1122
FAILURE CODE [CA343]1124
FAILURE CODE [CA351]1125
FAILURE CODE [CA352]1126
FAILURE CODE [CA356]1129
FAILURE CODE [CA357]1131
FAILURE CODE [CA386]1133
FAILURE CODE [CA428]1134
FAILURE CODE [CA429]1136
FAILURE CODE [CA435]1138
FAILURE CODE [CA441]1140
FAILURE CODE [CA442]1142
FAILURE CODE [CA449]1143
FAILURE CODE [CA451]1144
FAILURE CODE [CA452]1146
FAILURE CODE [CA488]1148
FAILURE CODE [CA515]1149
FAILURE CODE [CA516]1151
FAILURE CODE [CA553]1153
FAILURE CODE [CA555]1154
FAILURE CODE [CA556]1155
FAILURE CODE [CA559]1156
FAILURE CODE [CA595]1159
FAILURE CODE [CA687]1160
FAILURE CODE [CA689]1162
FAILURE CODE [CA691]1165
FAILURE CODE [CA692]1167
FAILURE CODE [CA697]1169
FAILURE CODE [CA698]1170
FAILURE CODE [CA731]1171
FAILURE CODE [CA778]1173
FAILURE CODE [CA1117]1178
FAILURE CODE [CA1664]1179
FAILURE CODE [CA1669]1181
FAILURE CODE [CA1673]1182
FAILURE CODE [CA1677]1183
FAILURE CODE [CA1678]1184
FAILURE CODE [CA1682]1185
FAILURE CODE [CA1683]1187
FAILURE CODE [CA1684]1189
FAILURE CODE [CA1686]1191
FAILURE CODE [CA1691]1192
FAILURE CODE [CA1694]1195
FAILURE CODE [CA1695]1198
FAILURE CODE [CA1696]1199
FAILURE CODE [CA1712]1201
FAILURE CODE [CA1713]1204
FAILURE CODE [CA1714]1206
FAILURE CODE [CA1715]1207
FAILURE CODE [CA1776]1208
FAILURE CODE [CA1777]1211
FAILURE CODE [CA1843]1214
FAILURE CODE [CA1844]1216
FAILURE CODE [CA1879]1219
FAILURE CODE [CA1881]1221
FAILURE CODE [CA1883]1223
FAILURE CODE [CA1885]1226
FAILURE CODE [CA1887]1228
FAILURE CODE [CA1921]1230
FAILURE CODE [CA1922]1233
FAILURE CODE [CA1942]1238
FAILURE CODE [CA1993]1239
FAILURE CODE [CA2185]1242
FAILURE CODE [CA2186]1243
FAILURE CODE [CA2249]1245
FAILURE CODE [CA2271]1246
FAILURE CODE [CA2272]1249
FAILURE CODE [CA2288]1252
FAILURE CODE [CA2311]1253
FAILURE CODE [CA2349]1254
FAILURE CODE [CA2353]1257
FAILURE CODE [CA2357]1259
FAILURE CODE [CA2381]1260
FAILURE CODE [CA2382]1263
FAILURE CODE [CA2383]1266
FAILURE CODE [CA2386]1269
FAILURE CODE [CA2387]1271
FAILURE CODE [CA2555]1272
FAILURE CODE [CA2556]1275
FAILURE CODE [CA2637]1278
FAILURE CODE [CA2639]1280
FAILURE CODE [CA2771]1283
FAILURE CODE [CA2777]1289
FAILURE CODE [CA2976]1292
FAILURE CODE [CA3133]1294
FAILURE CODE [CA3134]1297
FAILURE CODE [CA3135]1299
FAILURE CODE [CA3142]1302
FAILURE CODE [CA3143]1303
FAILURE CODE [CA3144]1304
FAILURE CODE [CA3146]1306
FAILURE CODE [CA3147]1307
FAILURE CODE [CA3148]1308
FAILURE CODE [CA3151]1310
FAILURE CODE [CA3165]1316
FAILURE CODE [CA3229]1318
FAILURE CODE [CA3231]1320
FAILURE CODE [CA3232]1322
FAILURE CODE [CA3235]1326
FAILURE CODE [CA3239]1328
FAILURE CODE [CA3241]1331
FAILURE CODE [CA3242]1334
FAILURE CODE [CA3251]1337
FAILURE CODE [CA3253]1339
FAILURE CODE [CA3254]1342
FAILURE CODE [CA3255]1345
FAILURE CODE [CA3256]1349
FAILURE CODE [CA3311]1351
FAILURE CODE [CA3312]1353
FAILURE CODE [CA3313]1356
FAILURE CODE [CA3314]1357
FAILURE CODE [CA3315]1358
FAILURE CODE [CA3316]1360
FAILURE CODE [CA3317]1361
FAILURE CODE [CA3318]1362
FAILURE CODE [CA3319]1364
FAILURE CODE [CA3321]1365
FAILURE CODE [CA3322]1367
FAILURE CODE [CA3419]1369
FAILURE CODE [CA3421]1371
FAILURE CODE [CA3497]1373
FAILURE CODE [CA3498]1374
FAILURE CODE [CA3543]1375
FAILURE CODE [CA3545]1382
FAILURE CODE [CA3547]1384
FAILURE CODE [CA3558]1385
FAILURE CODE [CA3559]1387
FAILURE CODE [CA3562]1389
FAILURE CODE [CA3563]1391
FAILURE CODE [CA3567]1394
FAILURE CODE [CA3568]1397
FAILURE CODE [CA3571]1401
FAILURE CODE [CA3572]1403
FAILURE CODE [CA3574]1405
FAILURE CODE [CA3575]1407
FAILURE CODE [CA3577]1409
FAILURE CODE [CA3578]1411
FAILURE CODE [CA3582]1413
FAILURE CODE [CA3583]1419
FAILURE CODE [CA3596]1421
FAILURE CODE [CA3649]1423
FAILURE CODE [CA3681]1425
FAILURE CODE [CA3682]1430
FAILURE CODE [CA3713]1436
FAILURE CODE [CA3717]1439
FAILURE CODE [CA3718]1440
FAILURE CODE [CA3725]1441
FAILURE CODE [CA3741]1444
FAILURE CODE [CA3748]1445
FAILURE CODE [CA3751]1447
FAILURE CODE [CA3755]1449
FAILURE CODE [CA3866]1451
FAILURE CODE [CA3867]1455
FAILURE CODE [CA3868]1458
FAILURE CODE [CA3899]1462
FAILURE CODE [CA3911]1464
FAILURE CODE [CA3912]1468
FAILURE CODE [CA3932]1470
FAILURE CODE [CA3933]1472
FAILURE CODE [CA3934]1474
FAILURE CODE [CA3935]1477
FAILURE CODE [CA3936]1479
FAILURE CODE [CA4151]1481
FAILURE CODE [CA4152]1485
FAILURE CODE [CA4155]1489
FAILURE CODE [CA4156]1491
FAILURE CODE [CA4157]1493
FAILURE CODE [CA4158]1495
FAILURE CODE [CA4159]1496
FAILURE CODE [CA4161]1497
FAILURE CODE [CA4162]1500
FAILURE CODE [CA4163]1503
FAILURE CODE [CA4164]1504
FAILURE CODE [CA4165]1506
FAILURE CODE [CA4166]1508
FAILURE CODE [CA4168]1509
FAILURE CODE [CA4169]1512
FAILURE CODE [CA4171]1514
FAILURE CODE [CA4249]1517
FAILURE CODE [CA4251]1519
FAILURE CODE [CA4259]1521
FAILURE CODE [CA4261]1524
FAILURE CODE [CA4277]1527
FAILURE CODE [CA4281]1531
FAILURE CODE [CA4459]1534
FAILURE CODE [CA4461]1537
FAILURE CODE [CA4658]1540
FAILURE CODE [CA4731]1544
FAILURE CODE [CA4732]1545
FAILURE CODE [CA4739]1546
FAILURE CODE [CA4768]1547
FAILURE CODE [CA4769]1549
FAILURE CODE [CA4842]1552
FAILURE CODE [CA4952]1556
FAILURE CODE [CA5115]1558
FAILURE CODE [CA5179]1561
FAILURE CODE [CA5181]1563
FAILURE CODE [CA5383]1565
FAILURE CODE [D110KB]1567
FAILURE CODE [D19JKZ]1569
FAILURE CODE [D811MC]1572
FAILURE CODE [D862KA]1573
FAILURE CODE [D8ALKA]1574
FAILURE CODE [D8ALKB]1577
FAILURE CODE [D8AQKR]1579
FAILURE CODE [D8G1KT]1586
FAILURE CODE [D8G6KT]1587
FAILURE CODE [DA20MC]1588
FAILURE CODE [DA22KK]1589
FAILURE CODE [DA25KP]1592
FAILURE CODE [DA26KP]1595
FAILURE CODE [DA29KQ]1598
FAILURE CODE [DA2LKA]1600
FAILURE CODE [DA2LKB]1603
FAILURE CODE [DA2QKR]1605
FAILURE CODE [DA2RKR]1614
FAILURE CODE [DAF0KM]1615
FAILURE CODE [DAF0MB]1616
FAILURE CODE [DAF0MC]1617
FAILURE CODE [DAF8KB]1618
FAILURE CODE [DAF9KQ]1620
FAILURE CODE [DAFGMC]1621
FAILURE CODE [DAFLKA]1622
FAILURE CODE [DAFLKB]1625
FAILURE CODE [DAFQKR]1627
FAILURE CODE [DAZ9KQ]1628
FAILURE CODE [DAZQKR]1629
FAILURE CODE [DB2QKR]1636
FAILURE CODE [DB2RKR]1644
FAILURE CODE [DBP0KM]1649
FAILURE CODE [DBP0KT]1650
FAILURE CODE [DBP5KB]1651
FAILURE CODE [DBP5KY]1654
FAILURE CODE [DBPQKR]1657
FAILURE CODE [DDNRKA]1665
FAILURE CODE [DDNRKY]1667
FAILURE CODE [DDNS00]1669
FAILURE CODE [DFB1KZ]1671
FAILURE CODE [DFB2KZ]1673
FAILURE CODE [DFB3L8]1675
FAILURE CODE [DFB4L8]1677
FAILURE CODE [DFB5KZ]1679
FAILURE CODE [DFB6KZ]1681
FAILURE CODE [DGH2KA]1683
FAILURE CODE [DGH2KB]1685
FAILURE CODE [DHA4KA]1687
FAILURE CODE [DHAAMA]1689
FAILURE CODE [DHACMA]1691
FAILURE CODE [DHPAMA]1693
FAILURE CODE [DHPBMA]1696
FAILURE CODE [DHS3MA]1699
FAILURE CODE [DHS4MA]1702
FAILURE CODE [DHS8MA]1705
FAILURE CODE [DHS9MA]1708
FAILURE CODE [DHSAMA]1711
FAILURE CODE [DHSBMA]1714
FAILURE CODE [DHSCMA]1717
FAILURE CODE [DHSDMA]1720
FAILURE CODE [DHSFMA]1723
FAILURE CODE [DHSGMA]1726
FAILURE CODE [DHSHMA]1729
FAILURE CODE [DHSJMA]1732
FAILURE CODE [DHX1MA]1735
FAILURE CODE [DHZAMA]1738
FAILURE CODE [DHZCL8]1742
FAILURE CODE [DKR0MA]1743
FAILURE CODE [DKR1MA]1746
FAILURE CODE [DKULKA]1749
FAILURE CODE [DKULKB]1751
FAILURE CODE [DKULKY]1753
FAILURE CODE [DR10KA]1755
FAILURE CODE [DR12KA]1758
FAILURE CODE [DR20KA]1760
FAILURE CODE [DR21KX]1762
FAILURE CODE [DR30KA]1764
FAILURE CODE [DR31KX]1766
FAILURE CODE [DR40KA]1768
FAILURE CODE [DUMBKA]1770
FAILURE CODE [DUMBKB]1773
FAILURE CODE [DV00KA]1775
FAILURE CODE [DV00KB]1776
FAILURE CODE [DV20KB]1777
FAILURE CODE [DW43KA]1779
FAILURE CODE [DW43KB]1781
FAILURE CODE [DW43KY]1783
FAILURE CODE [DW45KA]1785
FAILURE CODE [DW45KB]1788
FAILURE CODE [DW45KY]1791
FAILURE CODE [DW4CKY]1793
FAILURE CODE [DW91KA]1795
FAILURE CODE [DW91KB]1797
FAILURE CODE [DW91KY]1799
FAILURE CODE [DWA2KA]1801
FAILURE CODE [DWA2KB]1803
FAILURE CODE [DWA2KY]1805
FAILURE CODE [DWK0KA]1807
FAILURE CODE [DWK0KB]1809
FAILURE CODE [DWK0KY]1811
FAILURE CODE [DWK2KA]1813
FAILURE CODE [DWK2KB]1815
FAILURE CODE [DWK2KY]1817
FAILURE CODE [DWK8KA]1819
FAILURE CODE [DWK8KB]1821
FAILURE CODE [DWK8KY]1823
FAILURE CODE [DWPUKA]1825
FAILURE CODE [DWPUKB]1827
FAILURE CODE [DWPUKY]1829
FAILURE CODE [DXA8KA]1831
FAILURE CODE [DXA8KB]1833
FAILURE CODE [DXA9KA]1835
FAILURE CODE [DXA9KB]1837
FAILURE CODE [DXE0KA]1839
FAILURE CODE [DXE0KB]1840
FAILURE CODE [DXE4KA]1842
FAILURE CODE [DXE4KB]1844
FAILURE CODE [DXE4KY]1846
FAILURE CODE [DXE5KA]1848
FAILURE CODE [DXE5KB]1850
FAILURE CODE [DXE6KA]1852
FAILURE CODE [DXE6KB]1854
FAILURE CODE [DXE7KA]1856
FAILURE CODE [DXE7KB]1858
FAILURE CODE [DXE7KY]1860
FAILURE CODE [DXE8KA]1862
FAILURE CODE [DXE8KB]1864
FAILURE CODE [DXE8KY]1866
FAILURE CODE [DXE9KA]1868
FAILURE CODE [DXE9KB]1870
FAILURE CODE [DXE9KY]1872
FAILURE CODE [DXEAKA]1874
FAILURE CODE [DXEAKB]1876
FAILURE CODE [DXEAKY]1878
FAILURE CODE [DXEKKA]1880
FAILURE CODE [DXEKKB]1882
FAILURE CODE [DXEKKY]1884
FAILURE CODE [DXELKA]1886
FAILURE CODE [DXELKB]1888
FAILURE CODE [DXELKY]1890
FAILURE CODE [DY20KA]1892
FAILURE CODE [DY20MA]1894
FAILURE CODE [DY2CKB]1896
FAILURE CODE [DY2DKB]1899
FAILURE CODE [DY2EKB]1901
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1903
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1903
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1909
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1912
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1914
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING1916
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW1919
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW1920
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1921
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1922
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING1923
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1924
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1925
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1926
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1927
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1928
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1929
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1930
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL1932
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1933
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE1934
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1935
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE1937
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED1938
E-24 FUNCTION SWITCH DOES NOT OPERATE1939
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)1940
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF1941
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER1942
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED1943
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED1944
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE1945
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE1946
E-32 ALARM BUZZER CANNOT BE CANCELED1948
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION1949
E-34 SERVICE MODE CANNOT BE SELECTED1950
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE1951
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK1954
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING1956
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE1959
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR1961
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED1964
E-41 ALARM DOES NOT SOUND DURING TRAVEL1965
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED1967
E-43 HORN DOES NOT SOUND1968
E-44 HORN DOES NOT STOP SOUNDING1971
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF1973
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE1974
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE1976
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1977
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1978
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1979
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1980
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1981
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1982
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1983
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1984
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1985
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED1987
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY1988
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1989
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)1989
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS1990
FAILURE MODE AND CAUSE TABLE1992
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK2001
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER2002
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR2005
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP2006
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS2007
H-6 SPEED OR POWER OF BOOM IS LOW2009
H-7 ARM SPEED OR POWER IS LOW2013
H-8 BUCKET SPEED OR POWER IS LOW2018
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION2021
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE2022
H-11 HYDRAULIC DRIFT OF ARM IS LARGE2024
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE2026
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES2027
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE2028
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE2029
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED2030
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED2031
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER2032
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY2033
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW2034
H-21 MACHINE DOES NOT TRAVEL STRAIGHT2035
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW2037
H-23 TRAVEL SPEED IS LOW2040
H-24 ONE OF TRACKS DOES NOT RUN2042
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST2043
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT2044
H-27 SWINGS ONLY IN ONE DIRECTION2045
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)2046
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION2047
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)2048
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)2049
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING2050
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING2051
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)2052
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)2053
H-36 Quick coupler cylinder will not extend2054
H-37 Quick coupler cylinder will not retract (but buzzer doesnot sound)2056
H-38 Buzzer does not sound (but quick coupler cylinder doesretract)2058
H-39 Quick coupler cylinder extends and retracts slowly2060
TROUBLESHOOTING OF ENGINE (S-MODE)2061
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2061
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2062
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2063
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2064
S-4 ENGINE STARTABILITY IS POOR2066
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2068
S-6 ENGINE STOPS DURING OPERATION2070
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2072
S-8 ENGINE LACKS POWER2073
S-9 KDPF GETS CLOGGED IN A SHORT TIME2075
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2077
S-11 OIL BECOMES CONTAMINATED QUICKLY2078
S-12 FUEL CONSUMPTION IS EXCESSIVE2079
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2080
S-14 OIL PRESSURE DROPS2081
S-15 FUEL MIXES INTO ENGINE OIL2083
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2084
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2085
S-18 UNUSUAL NOISE IS HEARD2086
S-19 VIBRATION IS EXCESSIVE2087
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2088
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2089
S-22 ACTIVE REGENERATION TAKES TIME2091
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2092
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE2093
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)2095
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2096
50 DISASSEMBLY AND ASSEMBLY2097
CONTENTS2098
ABBREVIATION LIST2103
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2109
HOW TO READ THIS MANUAL2109
COATING MATERIALS LIST2111
SPECIAL TOOLS LIST2116
SKETCHES OF SPECIAL TOOLS2128
ENGINE AND COOLING SYSTEM2134
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2134
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2134
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2137
REMOVE AND INSTALL INJECTOR ASSEMBLY2141
METHOD FOR REMOVING INJECTOR ASSEMBLY2141
METHOD FOR INSTALLING INJECTOR ASSEMBLY2146
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2154
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2155
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2164
REMOVE AND INSTALL EGR VALVE ASSEMBLY2180
METHOD FOR REMOVING EGR VALVE ASSEMBLY2180
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2181
REMOVE AND INSTALL EGR COOLER ASSEMBLY2184
METHOD FOR REMOVING EGR COOLER ASSEMBLY2184
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2187
REMOVE AND INSTALL STARTER ASSEMBLY2192
METHOD FOR REMOVING STARTER ASSEMBLY2192
METHOD FOR INSTALLING STARTER ASSEMBLY2194
REMOVE AND INSTALL ALTERNATOR BELT2196
METHOD FOR REMOVING ALTERNATOR BELT2196
METHOD FOR INSTALLING ALTERNATOR BELT2198
REMOVE AND INSTALL RADIATOR ASSEMBLY2200
METHOD FOR REMOVING RADIATOR ASSEMBLY2200
METHOD FOR INSTALLING RADIATOR ASSEMBLY2202
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2204
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2204
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2207
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2210
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2210
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2211
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY2213
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY2214
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY2222
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2233
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2233
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2236
REMOVE AND INSTALL ENGINE REAR OIL SEAL2240
METHOD FOR REMOVING ENGINE REAR OIL SEAL2240
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2241
REMOVE AND INSTALL FUEL COOLER ASSEMBLY2244
METHOD FOR REMOVING FUEL COOLER ASSEMBLY2244
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY2245
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2246
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2246
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2248
REMOVE AND INSTALL FUEL TANK ASSEMBLY2254
METHOD FOR REMOVING FUEL TANK ASSEMBLY2254
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2258
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2264
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2264
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2269
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2275
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2275
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2280
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2286
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2286
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2286
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2293
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2293
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2293
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER2294
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER2294
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER2296
REMOVE AND INSTALL KDPF ASSEMBLY2299
METHOD FOR REMOVING KDPF ASSEMBLY2299
METHOD FOR INSTALLING KDPF ASSEMBLY2301
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2303
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2304
METHOD FOR ASSEMBLING KDPF ASSEMBLY2307
REMOVE AND INSTALL SCR ASSEMBLY2312
METHOD FOR REMOVING SCR ASSEMBLY2312
METHOD FOR INSTALLING SCR ASSEMBLY2314
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2316
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2316
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2322
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET2328
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET2328
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET2336
REMOVE AND INSTALL KCCV ASSEMBLY2345
METHOD FOR REMOVING KCCV ASSEMBLY2345
METHOD FOR INSTALLING KCCV ASSEMBLY2347
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2352
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2352
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2357
REMOVE AND INSTALL AdBlue/DEF INJECTOR2362
METHOD FOR REMOVING AdBlue/DEF INJECTOR2362
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2364
REMOVE AND INSTALL AdBlue/DEF PUMP2366
METHOD FOR REMOVING AdBlue/DEF PUMP2366
METHOD FOR INSTALLING AdBlue/DEF PUMP2368
REMOVE AND INSTALL AdBlue/DEF HOSE2371
METHOD FOR REMOVING AdBlue/DEF HOSE2371
METHOD FOR INSTALLING AdBlue/DEF HOSE2379
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2385
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2385
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2386
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2388
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2388
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2390
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2393
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2393
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2394
POWER TRAIN2395
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2395
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2395
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2396
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY2397
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY2397
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY2401
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY2410
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY2410
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY2412
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY2416
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY2416
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY2420
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY2427
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY2427
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY2427
UNDERCARRIAGE AND FRAME2429
SEPARATION AND CONNECTION OF TRACK ASSEMBLY2429
METHOD FOR SEPARATING TRACK ASSEMBLY2429
METHOD FOR INSTALLING TRACK ASSEMBLY2431
REMOVE AND INSTALL SPROCKET2434
METHOD FOR REMOVING SPROCKET2434
METHOD FOR INSTALLING SPROCKET2434
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY2436
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY2436
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY2437
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2438
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2438
METHOD FOR ASSEMBLING IDLER ASSEMBLY2439
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY2443
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY2444
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY2445
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2446
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2447
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2448
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY2450
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY2450
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY2451
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY2454
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY2454
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY2456
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2458
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2458
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2461
HYDRAULIC SYSTEM2465
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY2465
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY2465
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY2467
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2470
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2471
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2472
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2473
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2473
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2476
REMOVE AND INSTALL MAIN PUMP ASSEMBLY2480
METHOD FOR REMOVING MAIN PUMP ASSEMBLY2480
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY2483
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2487
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2487
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2494
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY2502
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING2502
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY2504
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2508
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2508
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2508
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2510
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY2510
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY2511
REMOVE AND INSTALL QUICK COUPLER VALVE2513
WORK EQUIPMENT2515
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2515
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2515
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2519
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2525
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2525
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2528
CAB AND ITS ATTACHMENTS2534
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2534
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2534
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2540
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)2547
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2549
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2549
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY2559
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY2559
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY2562
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY2568
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY2568
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY2575
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2582
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2582
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2588
REMOVE AND INSTALL OPERATOR’S SEAT2595
METHOD FOR REMOVING OPERATOR’S SEAT2595
METHOD FOR INSTALLING OPERATOR’S SEAT2597
REMOVE AND INSTALL SEAT BELT2600
METHOD FOR REMOVING SEAT BELT2600
METHOD FOR INSTALLING SEAT BELT2601
REMOVE AND INSTALL FRONT WIPER ASSEMBLY2602
METHOD FOR REMOVING FRONT WIPER ASSEMBLY2602
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY2607
ELECTRICAL SYSTEM2616
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2616
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2616
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2617
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY2619
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY2619
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY2623
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY2628
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY2628
METHOD FOR INSTALLING KomVision CONTROLLER2629
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2631
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2631
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY2634
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR2638
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR2638
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR2639
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2640
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR2640
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR2640
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2642
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR2642
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR2643
REMOVE AND INSTALL SCR TEMPERATURE SENSOR2645
METHOD FOR REMOVING SCR TEMPERATURE SENSOR2645
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR2647
REMOVE AND INSTALL KomVision CAMERA2650
METHOD FOR REMOVING KomVision CAMERA2650
METHOD FOR INSTALLING KomVision CAMERA2653
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY2656
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY2656
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY2659
60 MAINTENANCE STANDARD2663
CONTENTS2664
ABBREVIATION LIST2665
ENGINE AND COOLING SYSTEM2671
MAINTENANCE STANDARD OF ENGINE MOUNT2671
MAINTENANCE STANDARD OF COOLING SYSTEM2672
POWER TRAIN2673
MAINTENANCE STANDARD OF SWING CIRCLE2673
MAINTENANCE STANDARD OF SWING MACHINERY2674
MAINTENANCE STANDARD OF FINAL DRIVE2676
MAINTENANCE STANDARD OF SPROCKET2678
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING2679
UNDERCARRIAGE AND FRAME2681
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION2681
MAINTENANCE STANDARD OF IDLER2683
MAINTENANCE STANDARD OF TRACK ROLLER2685
MAINTENANCE STANDARD OF CARRIER ROLLER2687
MAINTENANCE STANDARD OF TRACK SHOE2688
MAINTENANCE STANDARD OF TRIPLE SHOE2691
HYDRAULIC SYSTEM2692
MAINTENANCE STANDARD OF HYDRAULIC TANK2692
MAINTENANCE STANDARD OF MAIN PUMP2693
MAINTENANCE STANDARD OF LS-EPC VALVE2694
MAINTENANCE STANDARD OF PC-EPC VALVE2695
MAINTENANCE STANDARD OF SWING MOTOR2696
MAINTENANCE STANDARD OF TRAVEL MOTOR2699
MAINTENANCE STANDARD OF CONTROL VALVE2702
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE2712
MAINTENANCE STANDARD OF TRAVEL PPC VALVE2715
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)2718
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE2720
MAINTENANCE STANDARD OF SOLENOID VALVE2721
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)2722
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)2723
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT2724
WORK EQUIPMENT2725
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE2725
DIMENSION OF ARM2730
DIMENSIONS OF BUCKET2732
MAINTENANCE STANDARD OF BOOM CYLINDER2734
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON)2735
MAINTENANCE STANDARD OF ARM CYLINDER2736
MAINTENANCE STANDARD OF BUCKET CYLINDER2737
80 APPENDIX2739
CONTENTS2740
ABBREVIATION LIST2742
AIR CONDITIONER SYSTEM2748
PRECAUTIONS FOR REFRIGERANT2748
AIR CONDITIONER COMPONENT2749
SPECIFICATIONS OF AIR CONDITIONER2751
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2752
OUTLINE OF REFRIGERATION CYCLE2753
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2755
AIR CONDITIONER UNIT2755
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2755
FUNCTION OF AIR CONDITIONER UNIT2757
COMPONENT PARTS OF AIR CONDITIONER UNIT2759
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2760
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2760
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT2760
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT2760
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2761
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2761
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2761
FUNCTION OF DUAL PRESSURE SWITCH2762
AIR CONDITIONER CONTROLLER2763
STRUCTURE OF AIR CONDITIONER CONTROLLER2763
COMPRESSOR2764
STRUCTURE OF COMPRESSOR2764
SPECIFICATIONS OF COMPRESSOR2764
FUNCTION OF COMPRESSOR2764
CONDENSER2765
STRUCTURE OF CONDENSER2765
SPECIFICATIONS OF CONDENSER2765
FUNCTION OF CONDENSER2765
SENSORS FOR AIR CONDITIONER SYSTEM2767
STRUCTURE OF SUNLIGHT SENSOR2767
FUNCTION OF SUNLIGHT SENSOR2767
STRUCTURE OF AMBIENT TEMPERATURE SENSOR2767
FUNCTION OF AMBIENT TEMPERATURE SENSOR2767
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2769
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER2771
AIR CONDITIONER SYSTEM DIAGRAM2773
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER2774
FUNCTION OF AIR CONDITIONER CONTROLLER2775
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2776
TESTING AIR LEAKAGE (DUCT)2780
METHOD FOR TESTING AIR LEAKAGE (DUCT)2780
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION2782
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR2783
TEST VENT (MODE) CHANGEOVER2784
METHOD FOR TESTING VENT (MODE) CHANGEOVER2784
TESTING FRESH/RECIRC AIR CHANGEOVER2786
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER2786
TEST SUNLIGHT SENSOR2787
METHOD FOR TESTING SUNLIGHT SENSOR2787
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT2788
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT2788
TEST RELAYS2789
METHOD FOR TESTING RELAYS2789
AIR CONDITIONER TROUBLESHOOTING CHART 12790
AIR CONDITIONER TROUBLESHOOTING CHART 22791
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2794
FAILURE CODE [879AKA]2796
FAILURE CODE [879AKB]2797
FAILURE CODE [879BKA]2798
FAILURE CODE [879BKB]2800
FAILURE CODE [879CKA]2802
FAILURE CODE [879CKB]2803
FAILURE CODE [879DKZ]2804
FAILURE CODE [879EMC]2806
FAILURE CODE [879FMC]2807
FAILURE CODE [879GKX]2808
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)2810
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)2812
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)2815
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER2817
TROUBLESHOOTING USING GAUGE PRESSURE2819
CONNECTION OF SERVICE TOOL2822
METHOD FOR CONNECTING SERVICE TOOL2822
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS2824
HANDLE COMPRESSOR OIL2826
METHOD FOR REPLACING DESICCANT2828
90 CIRCUIT DIAGRAMS2831
CONTENTS2832
ABBREVIATION LIST2833
HYDRAULIC CIRCUIT DIAGRAM2839
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2839
HYDRAULIC CIRCUIT DIAGRAM (1/2)2843
HYDRAULIC CIRCUIT DIAGRAM (2/2)2845
ELECTRICAL CIRCUIT DIAGRAM2847
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM2847
ELECTRICAL CIRCUIT DIAGRAM (1/10)2851
ELECTRICAL CIRCUIT DIAGRAM (2/10)2853
ELECTRICAL CIRCUIT DIAGRAM (3/10)2855
ELECTRICAL CIRCUIT DIAGRAM (4/10)2857
ELECTRICAL CIRCUIT DIAGRAM (5/10)2859
ELECTRICAL CIRCUIT DIAGRAM (6/10)2861
ELECTRICAL CIRCUIT DIAGRAM (7/10)2863
ELECTRICAL CIRCUIT DIAGRAM (8/10)2865
ELECTRICAL CIRCUIT DIAGRAM (9/10)2867
ELECTRICAL CIRCUIT DIAGRAM (10/10)2869
INDEX2871

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24