Komatsu HYDRAULIC EXCAVATOR PC290LC-11 Shop Manual SEN06507-09 PDF

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Komatsu HYDRAULIC EXCAVATOR PC290LC-11 Shop Manual SEN06507-09 – PDF  DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC290LC-11 Shop Manual SEN06507-09 – PDF  DOWNLOAD

Language : English
Pages :2724
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC290LC-11 Shop Manual SEN06507-09 – PDF  DOWNLOAD

SERIAL NUMBERS 35001 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.
Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effectively.
00 INDEX AND FOREWORD HOW TO READ THE SHOP MANUAL
TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC290LC-11 Shop Manual SEN06507-09 – PDF  DOWNLOAD

SERIAL NUMBERS 35001 and up

COVER 1
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-11 101
WORKING RANGE DRAWINGS 102
WORKING RANGE: PC290LC-11 102
SPECIFICATIONS 103
SPECIFICATIONS: PC290LC-11 103
WEIGHT TABLE 106
WEIGHT TABLE: PC290LC-11 106
TABLE OF FUEL, COOLANT, AND LUBRICANTS 108
10 STRUCTURE AND FUNCTION 109
CONTENTS 110
ABBREVIATION LIST 113
UREA SCR SYSTEM 119
LAYOUT DRAWING OF UREA SCR SYSTEM 120
UREA SCR SYSTEM DIAGRAM 125
FUNCTION OF UREA SCR SYSTEM 126
FUNCTION OF AdBlue/DEF SYSTEM 126
INDUCEMENT STRATEGY 128
COMPONENT PARTS OF UREA SCR SYSTEM 142
AdBlue/DEF MIXING TUBE 142
SCR ASSEMBLY 143
AdBlue/DEF TANK 145
AdBlue/DEF PUMP 147
AdBlue/DEF INJECTOR 148
AdBlue/DEF HOSE 149
AdBlue/DEF TANK HEATING VALVE 150
BOOT-UP SYSTEM 151
LAYOUT DRAWING OF BOOT-UP SYSTEM 151
SYSTEM OPERATING LAMP SYSTEM 153
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 153
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 153
BATTERY DISCONNECT SWITCH 154
FUNCTION OF BATTERY DISCONNECT SWITCH 154
ENGINE SYSTEM 155
LAYOUT DRAWING OF ENGINE SYSTEM 155
SPECIFICATIONS OF ENGINE SYSTEM 156
FUNCTION OF ENGINE SYSTEM 156
ENGINE CONTROL SYSTEM 157
ENGINE CONTROL SYSTEM DIAGRAM 157
FUNCTION OF ENGINE CONTROL SYSTEM 158
AUTO-DECELERATION SYSTEM 160
AUTO-DECELERATION SYSTEM DIAGRAM 160
FUNCTION OF AUTO-DECELERATION SYSTEM 160
OPERATION OF AUTO-DECELERATION SYSTEM 161
ENGINE AUTOMATIC WARM-UP SYSTEM 162
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 162
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 163
OVERHEAT PREVENTION SYSTEM 164
OVERHEAT PREVENTION SYSTEM DIAGRAM 164
FUNCTION OF OVERHEAT PREVENTION SYSTEM 165
TURBOCHARGER PROTECTION SYSTEM 167
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 167
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 168
AUTOMATIC IDLE STOP SYSTEM 169
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 169
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 169
COMPONENT PARTS OF ENGINE SYSTEM 172
VGT 172
EGR SYSTEM 176
EGR VALVE 178
EGR COOLER 180
KCCV SYSTEM 182
KCCV VENTILATOR 184
KDPF 186
COOLING SYSTEM 190
LAYOUT DRAWING OF COOLING SYSTEM 190
SPECIFICATIONS OF COOLING SYSTEM 191
CONTROL SYSTEM 192
LAYOUT DRAWING OF CONTROL SYSTEM 192
MACHINE MONITOR SYSTEM 195
MACHINE MONITOR SYSTEM DIAGRAM 195
KOMTRAX SYSTEM 196
KOMTRAX SYSTEM DIAGRAM 196
FUNCTION OF KOMTRAX SYSTEM 196
COMPONENT PARTS OF CONTROL SYSTEM 197
MACHINE MONITOR 197
KOMTRAX TERMINAL 210
PUMP CONTROLLER 212
RESISTOR FOR PC-EPC VALVE 216
CAN TERMINATING RESISTOR 217
ENGINE CONTROLLER 218
FUEL CONTROL DIAL 225
HYDRAULIC SYSTEM 227
LAYOUT DRAWING OF HYDRAULIC SYSTEM 227
CLSS 233
STRUCTURE OF CLSS 233
OPERATION OF UNLOAD VALVE AND LS PRESSURE 235
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 236
PRESSURE COMPENSATION CONTROL 249
ENGINE AND PUMP COMBINED CONTROL SYSTEM 251
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 251
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 252
PUMP AND VALVE CONTROL SYSTEM 257
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 257
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 258
COMPONENT PARTS OF HYDRAULIC SYSTEM 260
HYDRAULIC TANK 260
MAIN PUMP 262
CONTROL VALVE 287
WORK EQUIPMENT SYSTEM 346
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 346
STRUCTURE OF VALVE CONTROL 351
ONE-TOUCH POWER MAXIMIZING SYSTEM 353
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 353
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 354
PPC LOCK SYSTEM 355
PPC LOCK SYSTEM DIAGRAM 355
FUNCTION OF PPC LOCK SYSTEM 355
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 356
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 356
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 356
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 357
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 358
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 358
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 359
TOOL CONTROL SYSTEM 360
TOOL CONTROL SYSTEM DIAGRAM 360
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 362
WORK EQUIPMENT AND SWING PPC VALVE 362
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 368
2ND-LINE ATTACHMENT PPC VALVE 375
SOLENOID VALVE 377
ANTI-DROP VALVE FOR BOOM 380
ANTI-DROP VALVE FOR ARM 384
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 389
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 391
PILOT CIRCUIT ACCUMULATOR 393
ATTACHMENT CIRCUIT ACCUMULATOR 394
SWING SYSTEM 395
LAYOUT DRAWING OF SWING SYSTEM 395
SWING CONTROL SYSTEM DIAGRAM 399
FUNCTION OF SWING CONTROL SYSTEM 399
COMPONENT PARTS OF SWING SYSTEM 403
SWING MOTOR 403
SWING MACHINERY 414
SWING CIRCLE 416
TRAVEL SYSTEM 417
LAYOUT DRAWING OF TRAVEL SYSTEM 417
TRAVEL CONTROL SYSTEM DIAGRAM 421
FUNCTION OF TRAVEL CONTROL SYSTEM 421
COMPONENT PARTS OF TRAVEL SYSTEM 423
TRAVEL MOTOR 423
FINAL DRIVE 436
TRAVEL PPC VALVE 438
CENTER SWIVEL JOINT 442
UNDERCARRIAGE AND FRAME 444
LAYOUT DRAWING OF UNDERCARRIAGE 444
SPECIFICATIONS OF UNDERCARRIAGE 445
WORK EQUIPMENT 446
STRUCTURE OF WORK EQUIPMENT 446
FUNCTION OF WORK EQUIPMENT 447
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 448
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 448
BUCKET CLEARANCE ADJUSTMENT SHIM 449
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 449
CAB AND ITS ATTACHMENTS 450
ROPS CAB 450
STRUCTURE OF ROPS CAB 450
FUNCTION OF ROPS CAB 450
CAB MOUNT 451
STRUCTURE OF CAB MOUNT 451
FUNCTION OF CAB MOUNT 451
CAB TIPPING STOPPER 452
STRUCTURE OF CAB TIPPING STOPPER 452
FUNCTION OF CAB TIPPING STOPPER 452
20 STANDARD VALUE TABLE 453
CONTENTS 454
ABBREVIATION LIST 455
STANDARD VALUE TABLE FOR ENGINE 461
STANDARD VALUE TABLE FOR ENGINE: PC290LC-11 461
STANDARD VALUE TABLE FOR MACHINE 465
STANDARD VALUE TABLE FOR MACHINE: PC290LC-11 465
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 478
STANDARD VALUE TABLE FOR ELECTRICAL 482
STANDARD VALUE TABLE FOR ELECTRICAL 482
30 TESTING AND ADJUSTING 493
CONTENTS 494
ABBREVIATION LIST 497
RELATED INFORMATION ON TESTING AND ADJUSTING 503
TOOLS FOR TESTING AND ADJUSTING 503
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 509
ENGINE AND COOLING SYSTEM 511
TEST ENGINE SPEED 511
METHOD FOR TESTING ENGINE SPEED 511
TEST BOOST PRESSURE 514
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 514
METHOD FOR TESTING BOOST PRESSURE 515
TEST EXHAUST GAS COLOR 516
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 516
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 517
TEST AND ADJUST VALVE CLEARANCE 519
METHOD FOR TESTING VALVE CLEARANCE 519
METHOD FOR ADJUSTING VALVE CLEARANCE 520
TEST COMPRESSION PRESSURE 521
METHOD FOR TESTING COMPRESSION PRESSURE 521
TEST BLOWBY PRESSURE 526
METHOD FOR TESTING BLOWBY PRESSURE 526
TEST ENGINE OIL PRESSURE 528
METHOD FOR TESTING ENGINE OIL PRESSURE 528
TEST EGR VALVE AND VGT OIL PRESSURE 529
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 529
TEST FUEL PRESSURE 531
METHOD FOR TESTING FUEL PRESSURE 532
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 537
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 538
BLEEDING AIR FROM FUEL SYSTEM 544
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 544
TEST FUEL CIRCUIT FOR LEAKAGE 545
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 545
HANDLE CYLINDER CUT-OUT MODE OPERATION 547
HANDLE NO-INJECTION CRANKING OPERATION 548
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 549
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 549
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 549
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 551
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 551
TEST SCR RELATED FUNCTIONS 552
TEST AdBlue/DEF PUMP RAISED PRESSURE 555
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 558
TEST AdBlue/DEF LINE HEATER RELAY 1 562
TEST AdBlue/DEF LINE HEATER RELAY 2 565
TEST AdBlue/DEF PUMP HEATER RELAY 567
TEST AdBlue/DEF TANK HEATER VALVE 570
TEST DENITRATION EFFICIENCY OF SCR 573
CLEAN AdBlue/DEF TANK 577
METHOD FOR CLEANING AdBlue/DEF TANK 577
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 581
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 581
POWER TRAIN 583
TEST SWING CIRCLE BEARING CLEARANCE 583
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 583
UNDERCARRIAGE AND FRAME 584
TEST AND ADJUST TRACK TENSION 584
METHOD FOR TESTING TRACK TENSION 584
METHOD FOR ADJUSTING TRACK TENSION 584
HYDRAULIC SYSTEM 586
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 586
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 586
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 587
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 588
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 594
TEST OIL PRESSURE OF CONTROL CIRCUIT 597
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 597
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 599
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 599
TEST PC-EPC VALVE OUTLET PRESSURE 600
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 601
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 602
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 602
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL 603
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 606
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 607
METHOD FOR ADJUSTING LS VALVE 608
TEST OUTLET PRESSURE OF SOLENOID VALVE 609
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 609
OPERATING CONDITION OF SOLENOID VALVE 610
TEST PPC VALVE OUTLET PRESSURE 613
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 613
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 615
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 615
TEST PUMP SWASH PLATE SENSOR 616
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 616
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 617
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 617
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 617
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 618
TEST OIL LEAKAGE 619
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 619
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 619
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 620
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 621
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 621
BLEED AIR FROM HYDRAULIC CIRCUIT 622
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 624
TEST AND CHARGE ACCUMULATOR (MANUFACTURED BY NOK) NITROGEN GAS PRESSURE FOR ATTACHMENT (LOW PRESSURE SIDE) 626
TEST ACCUMULATOR (MANUFACTURED BY NOK) NITROGEN GAS PRESSURE FOR ATTACHMENT (LOW PRESSURE SIDE) 626
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH PRESSURE SIDE) 630
TEST ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH PRESSURE SIDE) 630
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ACCUMULATOR PIPING 634
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ACCUMULATOR PIPING 634
CAB AND ITS ATTACHMENTS 641
TEST CAB TIPPING STOPPER 641
METHOD FOR TESTING CAB TIPPING STOPPER 641
METHOD FOR ADJUSTING MIRRORS 642
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 642
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 643
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 644
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 645
ELECTRICAL SYSTEM 647
SET AND OPERATE MACHINE MONITOR 647
OPERATOR MODE 650
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 651
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 651
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 652
CHECKING FUNCTION OF SERVICE METER 652
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 652
SERVICE MODE 655
METHOD FOR OPERATING SERVICE MODE 655
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 657
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 663
ABNORMALITY RECORD MENU 674
METHOD FOR CONFIRMING MAINTENANCE RECORD 678
METHOD FOR OPERATING MAINTENANCE MODE SETTING 679
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 683
DEFAULT MENU 684
DIAGNOSTIC TESTS MENU 695
ADJUSTMENT MENU 704
METHOD FOR PERFORMING NO-INJECTION CRANKING 721
KOMTRAX SETTINGS MENU 722
METHOD FOR DISPLAYING SERVICE MESSAGE 725
METHOD FOR STARTING UP KOMTRAX TERMINAL 727
ADJUST REARVIEW CAMERA ANGLE 732
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 732
ADJUST KomVision CAMERA ANGLE 735
736
SETTING OF KomVision (CAMERA CALIBRATION) 736
KomVision screen – Check 12 m visibility 749
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 752
HANDLE BATTERY DISCONNECT SWITCH 753
TEST DIODES 754
METHOD FOR TESTING DIODE USING DIGITAL TESTER 754
METHOD FOR TESTING DIODE USING ANALOG TESTER 754
Pm CLINIC 755
Pm CLINIC SERVICE 755
Pm CLINIC CHECK SHEET 756
40 TROUBLESHOOTING 767
CONTENTS 768
ABBREVIATION LIST 779
RELATED INFORMATION ON TROUBLESHOOTING 785
GENERAL TROUBLESHOOTING POINTS 785
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 786
SEQUENCE OF EVENTS IN TROUBLESHOOTING 798
CHECKS BEFORE TROUBLESHOOTING 800
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 802
WALK-AROUND CHECK 802
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 804
CHECK FUEL LEVEL AND TYPE 804
CHECK IMPURE INGREDIENT IN FUEL 804
CHECK FUEL PREFILTER 805
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 805
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 806
CHECK MAIN FILTER 807
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 809
CHECK COOLANT LEVEL (RESERVOIR TANK) 810
CHECK CLOGGING OF AIR CLEANER 810
OUTER ELEMENT – CLEAN 811
ELEMENTS – REPLACE 813
CHECK HYDRAULIC OIL LEVEL 814
CHECK HYDRAULIC OIL STRAINER 815
CHECK HYDRAULIC FILTER 816
CHECK OIL LEVEL IN SWING MACHINERY CASE 817
CHECK OIL LEVEL IN DAMPER CASE 818
CHECK OIL LEVEL IN FINAL DRIVE CASE 818
BLEED AIR FROM FUEL SYSTEM 819
BLEED AIR FROM HYDRAULIC SYSTEM 819
ELECTRICAL EQUIPMENT – CHECK METHOD 819
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 827
PROCEDURE FOR TESTING AND TROUBLESHOOTING 837
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 840
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 844
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 846
CONNECTOR LIST AND LAYOUT 849
CONNECTOR CONTACT IDENTIFICATION 862
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 902
FUSE LOCATION TABLE 908
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 910
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 914
FAILURE CODES TABLE 916
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 933
FAILURE CODE [879AKA] 933
FAILURE CODE [879AKB] 934
FAILURE CODE [879BKA] 935
FAILURE CODE [879BKB] 937
FAILURE CODE [879CKA] 939
FAILURE CODE [879CKB] 940
FAILURE CODE [879DKZ] 941
FAILURE CODE [879EMC] 943
FAILURE CODE [879FMC] 944
FAILURE CODE [879GKX] 945
FAILURE CODE [989L00] 947
FAILURE CODE [989M00] 948
FAILURE CODE [989N00] 949
FAILURE CODE [A1U0N3] 950
FAILURE CODE [A1U0N4] 952
FAILURE CODE [A900FR] 954
FAILURE CODE [A900N6] 955
FAILURE CODE [A900NY] 956
FAILURE CODE [AA10NX] 957
FAILURE CODE [AB00KE] 959
FAILURE CODE [AQ10N3] 962
FAILURE CODE [AS00N3] 964
FAILURE CODE [AS00R2] 966
FAILURE CODE [AS00R3] 967
FAILURE CODE [AS00R4] 968
FAILURE CODE [AS00R5] 969
FAILURE CODE [AS00R6] 970
FAILURE CODE [AS00ZK] 971
FAILURE CODE [AS10KM] 972
FAILURE CODE [AS10NR] 973
FAILURE CODE [AS10NT] 974
FAILURE CODE [B@BAZG] 975
FAILURE CODE [B@BAZK] 976
FAILURE CODE [B@BCNS] 978
FAILURE CODE [B@BCQA] 979
FAILURE CODE [B@BCZK] 981
FAILURE CODE [B@HANS] 983
FAILURE CODE [CA115] 984
FAILURE CODE [CA122] 985
FAILURE CODE [CA123] 987
FAILURE CODE [CA131] 989
FAILURE CODE [CA132] 991
FAILURE CODE [CA144] 993
FAILURE CODE [CA145] 995
FAILURE CODE [CA153] 997
FAILURE CODE [CA154]1000
FAILURE CODE [CA187]1002
FAILURE CODE [CA221]1004
FAILURE CODE [CA222]1006
FAILURE CODE [CA227]1008
FAILURE CODE [CA234]1009
FAILURE CODE [CA238]1010
FAILURE CODE [CA239]1012
FAILURE CODE [CA249]1014
FAILURE CODE [CA256]1016
FAILURE CODE [CA271]1018
FAILURE CODE [CA272]1020
FAILURE CODE [CA322]1022
FAILURE CODE [CA323]1024
FAILURE CODE [CA324]1026
FAILURE CODE [CA325]1028
FAILURE CODE [CA331]1030
FAILURE CODE [CA332]1032
FAILURE CODE [CA343]1034
FAILURE CODE [CA351]1035
FAILURE CODE [CA352]1036
FAILURE CODE [CA356]1039
FAILURE CODE [CA357]1041
FAILURE CODE [CA386]1043
FAILURE CODE [CA428]1044
FAILURE CODE [CA429]1046
FAILURE CODE [CA435]1048
FAILURE CODE [CA441]1050
FAILURE CODE [CA442]1052
FAILURE CODE [CA449]1053
FAILURE CODE [CA451]1054
FAILURE CODE [CA452]1056
FAILURE CODE [CA488]1058
FAILURE CODE [CA515]1059
FAILURE CODE [CA516]1061
FAILURE CODE [CA553]1063
FAILURE CODE [CA555]1064
FAILURE CODE [CA556]1065
FAILURE CODE [CA559]1066
FAILURE CODE [CA595]1069
FAILURE CODE [CA687]1070
FAILURE CODE [CA689]1072
FAILURE CODE [CA691]1075
FAILURE CODE [CA692]1077
FAILURE CODE [CA697]1079
FAILURE CODE [CA698]1080
FAILURE CODE [CA731]1081
FAILURE CODE [CA778]1083
FAILURE CODE [CA1117]1088
FAILURE CODE [CA1664]1089
FAILURE CODE [CA1669]1091
FAILURE CODE [CA1673]1092
FAILURE CODE [CA1677]1093
FAILURE CODE [CA1678]1094
FAILURE CODE [CA1682]1095
FAILURE CODE [CA1683]1097
FAILURE CODE [CA1684]1099
FAILURE CODE [CA1686]1101
FAILURE CODE [CA1691]1102
FAILURE CODE [CA1694]1105
FAILURE CODE [CA1695]1108
FAILURE CODE [CA1696]1109
FAILURE CODE [CA1712]1111
FAILURE CODE [CA1713]1114
FAILURE CODE [CA1714]1116
FAILURE CODE [CA1715]1117
FAILURE CODE [CA1776]1118
FAILURE CODE [CA1777]1121
FAILURE CODE [CA1843]1124
FAILURE CODE [CA1844]1126
FAILURE CODE [CA1879]1129
FAILURE CODE [CA1881]1131
FAILURE CODE [CA1883]1133
FAILURE CODE [CA1885]1136
FAILURE CODE [CA1887]1138
FAILURE CODE [CA1921]1140
FAILURE CODE [CA1922]1143
FAILURE CODE [CA1942]1148
FAILURE CODE [CA1993]1149
FAILURE CODE [CA2185]1152
FAILURE CODE [CA2186]1153
FAILURE CODE [CA2249]1155
FAILURE CODE [CA2271]1156
FAILURE CODE [CA2272]1159
FAILURE CODE [CA2288]1162
FAILURE CODE [CA2311]1163
FAILURE CODE [CA2349]1164
FAILURE CODE [CA2353]1167
FAILURE CODE [CA2357]1169
FAILURE CODE [CA2381]1170
FAILURE CODE [CA2382]1173
FAILURE CODE [CA2383]1176
FAILURE CODE [CA2386]1179
FAILURE CODE [CA2387]1181
FAILURE CODE [CA2555]1182
FAILURE CODE [CA2556]1185
FAILURE CODE [CA2637]1188
FAILURE CODE [CA2639]1190
FAILURE CODE [CA2771]1193
FAILURE CODE [CA2777]1199
FAILURE CODE [CA2976]1202
FAILURE CODE [CA3133]1204
FAILURE CODE [CA3134]1207
FAILURE CODE [CA3135]1209
FAILURE CODE [CA3142]1212
FAILURE CODE [CA3143]1213
FAILURE CODE [CA3144]1214
FAILURE CODE [CA3146]1216
FAILURE CODE [CA3147]1217
FAILURE CODE [CA3148]1218
FAILURE CODE [CA3151]1220
FAILURE CODE [CA3165]1226
FAILURE CODE [CA3229]1228
FAILURE CODE [CA3231]1230
FAILURE CODE [CA3232]1232
FAILURE CODE [CA3235]1236
FAILURE CODE [CA3239]1238
FAILURE CODE [CA3241]1241
FAILURE CODE [CA3242]1244
FAILURE CODE [CA3251]1247
FAILURE CODE [CA3253]1249
FAILURE CODE [CA3254]1252
FAILURE CODE [CA3255]1255
FAILURE CODE [CA3256]1259
FAILURE CODE [CA3311]1261
FAILURE CODE [CA3312]1263
FAILURE CODE [CA3313]1266
FAILURE CODE [CA3314]1267
FAILURE CODE [CA3315]1268
FAILURE CODE [CA3316]1270
FAILURE CODE [CA3317]1271
FAILURE CODE [CA3318]1272
FAILURE CODE [CA3319]1274
FAILURE CODE [CA3321]1275
FAILURE CODE [CA3322]1277
FAILURE CODE [CA3419]1279
FAILURE CODE [CA3421]1281
FAILURE CODE [CA3497]1283
FAILURE CODE [CA3498]1284
FAILURE CODE [CA3543]1285
FAILURE CODE [CA3545]1292
FAILURE CODE [CA3547]1294
FAILURE CODE [CA3558]1295
FAILURE CODE [CA3559]1297
FAILURE CODE [CA3562]1299
FAILURE CODE [CA3563]1301
FAILURE CODE [CA3567]1304
FAILURE CODE [CA3568]1307
FAILURE CODE [CA3571]1311
FAILURE CODE [CA3572]1313
FAILURE CODE [CA3574]1315
FAILURE CODE [CA3575]1317
FAILURE CODE [CA3577]1319
FAILURE CODE [CA3578]1321
FAILURE CODE [CA3582]1323
FAILURE CODE [CA3583]1329
FAILURE CODE [CA3596]1331
FAILURE CODE [CA3649]1333
FAILURE CODE [CA3681]1335
FAILURE CODE [CA3682]1340
FAILURE CODE [CA3713]1346
FAILURE CODE [CA3717]1349
FAILURE CODE [CA3718]1350
FAILURE CODE [CA3725]1351
FAILURE CODE [CA3741]1354
FAILURE CODE [CA3748]1355
FAILURE CODE [CA3751]1357
FAILURE CODE [CA3755]1359
FAILURE CODE [CA3866]1361
FAILURE CODE [CA3867]1365
FAILURE CODE [CA3868]1368
FAILURE CODE [CA3899]1372
FAILURE CODE [CA3911]1374
FAILURE CODE [CA3912]1378
FAILURE CODE [CA3932]1380
FAILURE CODE [CA3933]1382
FAILURE CODE [CA3934]1384
FAILURE CODE [CA3935]1387
FAILURE CODE [CA3936]1389
FAILURE CODE [CA4151]1391
FAILURE CODE [CA4152]1395
FAILURE CODE [CA4155]1399
FAILURE CODE [CA4156]1401
FAILURE CODE [CA4157]1404
FAILURE CODE [CA4158]1406
FAILURE CODE [CA4159]1407
FAILURE CODE [CA4161]1408
FAILURE CODE [CA4162]1411
FAILURE CODE [CA4163]1414
FAILURE CODE [CA4164]1415
FAILURE CODE [CA4165]1417
FAILURE CODE [CA4166]1419
FAILURE CODE [CA4168]1420
FAILURE CODE [CA4169]1423
FAILURE CODE [CA4171]1425
FAILURE CODE [CA4249]1428
FAILURE CODE [CA4251]1430
FAILURE CODE [CA4259]1432
FAILURE CODE [CA4261]1435
FAILURE CODE [CA4277]1438
FAILURE CODE [CA4281]1442
FAILURE CODE [CA4459]1445
FAILURE CODE [CA4461]1448
FAILURE CODE [CA4658]1451
FAILURE CODE [CA4731]1455
FAILURE CODE [CA4732]1456
FAILURE CODE [CA4739]1457
FAILURE CODE [CA4768]1458
FAILURE CODE [CA4769]1460
FAILURE CODE [CA4842]1463
FAILURE CODE [CA4952]1467
FAILURE CODE [CA5115]1469
FAILURE CODE [CA5179]1472
FAILURE CODE [CA5181]1474
FAILURE CODE [CA5383]1476
FAILURE CODE [D110KB]1478
FAILURE CODE [D19JKZ]1480
FAILURE CODE [D811MC]1483
FAILURE CODE [D862KA]1484
FAILURE CODE [D8ALKA]1485
FAILURE CODE [D8ALKB]1487
FAILURE CODE [D8AQKR]1489
FAILURE CODE [DA20MC]1491
FAILURE CODE [DA22KK]1492
FAILURE CODE [DA25KP]1495
FAILURE CODE [DA26KP]1498
FAILURE CODE [DA29KQ]1501
FAILURE CODE [DA2LKA]1503
FAILURE CODE [DA2LKB]1505
FAILURE CODE [DA2QKR]1507
FAILURE CODE [DA2RKR]1510
FAILURE CODE [DAF0MB]1511
FAILURE CODE [DAF0MC]1512
FAILURE CODE [DAF8KB]1513
FAILURE CODE [DAF9KQ]1517
FAILURE CODE [DAFGMC]1518
FAILURE CODE [DAFLKA]1519
FAILURE CODE [DAFLKB]1521
FAILURE CODE [DAFQKR]1523
FAILURE CODE [DAZ9KQ]1524
FAILURE CODE [DAZQKR]1525
FAILURE CODE [DB2QKR]1530
FAILURE CODE [DB2RKR]1535
FAILURE CODE [DBP5KB]1540
FAILURE CODE [DBP5KY]1543
FAILURE CODE [DDNRKA]1546
FAILURE CODE [DDNRKY]1548
FAILURE CODE [DDNS00]1550
FAILURE CODE [DGH2KA]1552
FAILURE CODE [DGH2KB]1554
FAILURE CODE [DHA4KA]1556
FAILURE CODE [DHAAMA]1558
FAILURE CODE [DHACMA]1560
FAILURE CODE [DHPAMA]1562
FAILURE CODE [DHPBMA]1565
FAILURE CODE [DHS3MA]1568
FAILURE CODE [DHS4MA]1571
FAILURE CODE [DHS8MA]1574
FAILURE CODE [DHS9MA]1577
FAILURE CODE [DHSAMA]1580
FAILURE CODE [DHSBMA]1583
FAILURE CODE [DHSCMA]1586
FAILURE CODE [DHSDMA]1589
FAILURE CODE [DHSFMA]1592
FAILURE CODE [DHSGMA]1595
FAILURE CODE [DHSHMA]1598
FAILURE CODE [DHSJMA]1601
FAILURE CODE [DHZAMA]1604
FAILURE CODE [DHZCL8]1608
FAILURE CODE [DKR0MA]1609
FAILURE CODE [DKR1MA]1612
FAILURE CODE [DKULKA]1615
FAILURE CODE [DKULKB]1617
FAILURE CODE [DKULKY]1619
FAILURE CODE [DR12KA]1621
FAILURE CODE [DR20KA]1623
FAILURE CODE [DR21KX]1625
FAILURE CODE [DR30KA]1627
FAILURE CODE [DR31KX]1629
FAILURE CODE [DR40KA]1631
FAILURE CODE [DV20KB]1633
FAILURE CODE [DW43KA]1635
FAILURE CODE [DW43KB]1637
FAILURE CODE [DW43KY]1639
FAILURE CODE [DW45KA]1641
FAILURE CODE [DW45KB]1644
FAILURE CODE [DW45KY]1647
FAILURE CODE [DW4CKY]1649
FAILURE CODE [DW91KA]1651
FAILURE CODE [DW91KB]1653
FAILURE CODE [DW91KY]1655
FAILURE CODE [DWA2KA]1657
FAILURE CODE [DWA2KB]1659
FAILURE CODE [DWA2KY]1661
FAILURE CODE [DWK0KA]1663
FAILURE CODE [DWK0KB]1665
FAILURE CODE [DWK0KY]1667
FAILURE CODE [DWK2KA]1669
FAILURE CODE [DWK2KB]1671
FAILURE CODE [DWK2KY]1673
FAILURE CODE [DWK8KA]1675
FAILURE CODE [DWK8KB]1677
FAILURE CODE [DWK8KY]1679
FAILURE CODE [DXA8KA]1681
FAILURE CODE [DXA8KB]1683
FAILURE CODE [DXA9KA]1685
FAILURE CODE [DXA9KB]1687
FAILURE CODE [DXE0KA]1689
FAILURE CODE [DXE0KB]1690
FAILURE CODE [DXE4KA]1692
FAILURE CODE [DXE4KB]1694
FAILURE CODE [DXE4KY]1696
FAILURE CODE [DXE5KA]1698
FAILURE CODE [DXE5KB]1700
FAILURE CODE [DXE6KA]1702
FAILURE CODE [DXE6KB]1704
FAILURE CODE [DXE7KA]1706
FAILURE CODE [DXE7KB]1708
FAILURE CODE [DXE7KY]1710
FAILURE CODE [DXE8KA]1712
FAILURE CODE [DXE8KB]1714
FAILURE CODE [DXE8KY]1716
FAILURE CODE [DXE9KA]1718
FAILURE CODE [DXE9KB]1720
FAILURE CODE [DXE9KY]1722
FAILURE CODE [DXEAKA]1724
FAILURE CODE [DXEAKB]1726
FAILURE CODE [DXEAKY]1728
FAILURE CODE [DXEKKA]1730
FAILURE CODE [DXEKKB]1732
FAILURE CODE [DXEKKY]1734
FAILURE CODE [DXELKA]1736
FAILURE CODE [DXELKB]1738
FAILURE CODE [DXELKY]1740
FAILURE CODE [DY20KA]1742
FAILURE CODE [DY20MA]1744
FAILURE CODE [DY2CKB]1746
FAILURE CODE [DY2DKB]1749
FAILURE CODE [DY2EKB]1751
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1753
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1753
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1759
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1762
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1764
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING1766
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW1769
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW1770
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1771
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1772
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING1773
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1774
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1775
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1776
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1777
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1778
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1779
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1780
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL1782
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1783
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE1784
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1785
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE1787
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED1788
E-24 FUNCTION SWITCH DOES NOT OPERATE1789
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)1790
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF1791
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER1792
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED1793
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED1794
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE1795
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE1796
E-32 ALARM BUZZER CANNOT BE CANCELED1798
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION1799
E-34 SERVICE MODE CANNOT BE SELECTED1800
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE1801
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK1804
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING1806
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE1809
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR1811
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED1814
E-41 ALARM DOES NOT SOUND DURING TRAVEL1815
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED1817
E-43 HORN DOES NOT SOUND1818
E-44 HORN DOES NOT STOP SOUNDING1821
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF1823
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE1824
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE1826
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1827
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1828
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1829
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1830
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1831
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1832
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1833
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1834
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1835
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED1837
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY1838
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1839
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)1839
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS1840
FAILURE MODE AND CAUSE TABLE1842
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK1851
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER1852
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR1855
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP1856
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS1857
H-6 SPEED OR POWER OF BOOM IS LOW1859
H-7 ARM SPEED OR POWER IS LOW1863
H-8 BUCKET SPEED OR POWER IS LOW1868
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION1871
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE1872
H-11 HYDRAULIC DRIFT OF ARM IS LARGE1874
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE1876
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES1877
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE1878
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE1879
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED1880
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED1881
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER1882
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY1883
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW1884
H-21 MACHINE DOES NOT TRAVEL STRAIGHT1885
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW1887
H-23 TRAVEL SPEED IS LOW1890
H-24 ONE OF TRACKS DOES NOT RUN1892
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST1893
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT1894
H-27 SWINGS ONLY IN ONE DIRECTION1895
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)1896
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION1897
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)1898
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)1899
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING1900
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING1901
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)1902
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)1903
TROUBLESHOOTING OF ENGINE (S-MODE)1904
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)1904
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION1905
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT1906
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)1907
S-4 ENGINE STARTABILITY IS POOR1909
S-5 ENGINE DOES NOT PICK UP SMOOTHLY1911
S-6 ENGINE STOPS DURING OPERATION1913
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE1915
S-8 ENGINE LACKS POWER1916
S-9 KDPF GETS CLOGGED IN A SHORT TIME1918
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE1920
S-11 OIL BECOMES CONTAMINATED QUICKLY1921
S-12 FUEL CONSUMPTION IS EXCESSIVE1922
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)1923
S-14 OIL PRESSURE DROPS1924
S-15 FUEL MIXES INTO ENGINE OIL1926
S-16 WATER MIXES INTO ENGINE OIL (MILKY)1927
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)1928
S-18 UNUSUAL NOISE IS HEARD1929
S-19 VIBRATION IS EXCESSIVE1930
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT1931
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY1932
S-22 ACTIVE REGENERATION TAKES TIME1934
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION1935
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE1936
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)1938
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)1939
50 DISASSEMBLY AND ASSEMBLY1941
CONTENTS1942
ABBREVIATION LIST1947
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY1953
HOW TO READ THIS MANUAL1953
COATING MATERIALS LIST1955
SPECIAL TOOLS LIST1959
SKETCHES OF SPECIAL TOOLS1971
ENGINE AND COOLING SYSTEM1977
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY1977
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY1977
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY1980
REMOVE AND INSTALL INJECTOR ASSEMBLY1984
METHOD FOR REMOVING INJECTOR ASSEMBLY1984
METHOD FOR INSTALLING INJECTOR ASSEMBLY1989
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY1997
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY1998
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2007
REMOVE AND INSTALL EGR VALVE ASSEMBLY2023
METHOD FOR REMOVING EGR VALVE ASSEMBLY2023
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2024
REMOVE AND INSTALL EGR COOLER ASSEMBLY2027
METHOD FOR REMOVING EGR COOLER ASSEMBLY2027
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2030
REMOVE AND INSTALL STARTER ASSEMBLY2035
METHOD FOR REMOVING STARTER ASSEMBLY2035
METHOD FOR INSTALLING STARTER ASSEMBLY2037
REMOVE AND INSTALL ALTERNATOR BELT2039
METHOD FOR REMOVING ALTERNATOR BELT2039
METHOD FOR INSTALLING ALTERNATOR BELT2041
REMOVE AND INSTALL RADIATOR ASSEMBLY2043
METHOD FOR REMOVING RADIATOR ASSEMBLY2043
METHOD FOR INSTALLING RADIATOR ASSEMBLY2045
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2047
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2047
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2050
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2053
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2053
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2054
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY2056
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY2057
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY2065
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2076
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2076
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2079
REMOVE AND INSTALL ENGINE REAR OIL SEAL2083
METHOD FOR REMOVING ENGINE REAR OIL SEAL2083
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2084
REMOVE AND INSTALL FUEL COOLER ASSEMBLY2087
METHOD FOR REMOVING FUEL COOLER ASSEMBLY2087
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY2088
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2089
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2089
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2091
REMOVE AND INSTALL FUEL TANK ASSEMBLY2097
METHOD FOR REMOVING FUEL TANK ASSEMBLY2097
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2101
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2105
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2105
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2110
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2116
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2116
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2121
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2127
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2127
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2127
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2129
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2129
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2129
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER2130
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER2130
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER2132
REMOVE AND INSTALL KDPF ASSEMBLY2135
METHOD FOR REMOVING KDPF ASSEMBLY2135
METHOD FOR INSTALLING KDPF ASSEMBLY2137
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2139
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2140
METHOD FOR ASSEMBLING KDPF ASSEMBLY2143
REMOVE AND INSTALL SCR ASSEMBLY2148
METHOD FOR REMOVING SCR ASSEMBLY2148
METHOD FOR INSTALLING SCR ASSEMBLY2150
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2152
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2152
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2158
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET2164
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET2164
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET2172
REMOVE AND INSTALL KCCV ASSEMBLY2181
METHOD FOR REMOVING KCCV ASSEMBLY2181
METHOD FOR INSTALLING KCCV ASSEMBLY2183
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2188
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2188
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2193
REMOVE AND INSTALL AdBlue/DEF INJECTOR2198
METHOD FOR REMOVING AdBlue/DEF INJECTOR2198
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2200
REMOVE AND INSTALL AdBlue/DEF PUMP2202
METHOD FOR REMOVING AdBlue/DEF PUMP2202
METHOD FOR INSTALLING AdBlue/DEF PUMP2204
REMOVE AND INSTALL AdBlue/DEF HOSE2207
METHOD FOR REMOVING AdBlue/DEF HOSE2207
METHOD FOR INSTALLING AdBlue/DEF HOSE2214
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2220
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2220
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2221
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2223
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2223
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2225
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2228
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2228
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2229
POWER TRAIN2230
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2230
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2230
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2231
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY2232
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY2232
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY2236
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY2245
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY2245
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY2247
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY2251
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY2251
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY2255
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY2262
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY2262
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY2262
UNDERCARRIAGE AND FRAME2264
SEPARATION AND CONNECTION OF TRACK ASSEMBLY2264
METHOD FOR SEPARATING TRACK ASSEMBLY2264
METHOD FOR INSTALLING TRACK ASSEMBLY2266
REMOVE AND INSTALL SPROCKET2269
METHOD FOR REMOVING SPROCKET2269
METHOD FOR INSTALLING SPROCKET2269
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY2271
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY2271
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY2272
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2273
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2273
METHOD FOR ASSEMBLING IDLER ASSEMBLY2274
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY2278
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY2279
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY2280
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2281
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2282
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2283
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY2285
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY2285
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY2286
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY2289
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY2289
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY2291
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2293
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2293
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2296
HYDRAULIC SYSTEM2300
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY2300
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY2300
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY2302
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2305
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2306
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2307
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2308
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2308
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2310
REMOVE AND INSTALL MAIN PUMP ASSEMBLY2313
METHOD FOR REMOVING MAIN PUMP ASSEMBLY2313
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY2316
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2319
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2319
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2324
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY2331
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING2331
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY2333
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2337
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2337
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2337
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2339
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY2339
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY2340
WORK EQUIPMENT2342
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2342
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2342
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2346
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM2352
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM2352
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM2354
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM2355
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM2355
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM2357
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY2358
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY2358
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY2358
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2359
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2359
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2362
CAB AND ITS ATTACHMENTS2368
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2368
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY2368
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY2373
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS)2380
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2382
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2382
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY2392
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY2392
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY2395
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY2401
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY2401
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY2408
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2415
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2415
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2420
REMOVE AND INSTALL OPERATOR’S SEAT2426
METHOD FOR REMOVING OPERATOR’S SEAT2426
METHOD FOR INSTALLING OPERATOR’S SEAT2428
REMOVE AND INSTALL SEAT BELT2431
METHOD FOR REMOVING SEAT BELT2431
METHOD FOR INSTALLING SEAT BELT2432
REMOVE AND INSTALL FRONT WIPER ASSEMBLY2433
METHOD FOR REMOVING FRONT WIPER ASSEMBLY2433
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY2438
ELECTRICAL SYSTEM2447
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2447
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2447
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2448
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY2450
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY2450
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY2454
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2459
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2459
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY2462
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR2466
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR2466
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR2467
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2468
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR2468
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR2468
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2470
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR2470
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR2471
REMOVE AND INSTALL SCR TEMPERATURE SENSOR2472
METHOD FOR REMOVING SCR TEMPERATURE SENSOR2472
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR2474
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY2476
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY2476
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY2479
60 MAINTENANCE STANDARD2483
CONTENTS2484
ABBREVIATION LIST2485
ENGINE AND COOLING SYSTEM2491
MAINTENANCE STANDARD OF ENGINE MOUNT2491
MAINTENANCE STANDARD OF COOLING SYSTEM2492
POWER TRAIN2493
MAINTENANCE STANDARD OF SWING CIRCLE2493
MAINTENANCE STANDARD OF SWING MACHINERY2494
MAINTENANCE STANDARD OF FINAL DRIVE2496
MAINTENANCE STANDARD OF SPROCKET2498
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING2499
UNDERCARRIAGE AND FRAME2501
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION2501
MAINTENANCE STANDARD OF IDLER2503
MAINTENANCE STANDARD OF TRACK ROLLER2505
MAINTENANCE STANDARD OF CARRIER ROLLER2507
MAINTENANCE STANDARD OF TRACK SHOE2508
MAINTENANCE STANDARD OF TRIPLE SHOE2511
HYDRAULIC SYSTEM2512
MAINTENANCE STANDARD OF HYDRAULIC TANK2512
MAINTENANCE STANDARD OF MAIN PUMP2513
MAINTENANCE STANDARD OF LS-EPC VALVE2514
MAINTENANCE STANDARD OF PC-EPC VALVE2515
MAINTENANCE STANDARD OF SWING MOTOR2516
MAINTENANCE STANDARD OF TRAVEL MOTOR2519
MAINTENANCE STANDARD OF CONTROL VALVE2522
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM2532
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM2534
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE2536
MAINTENANCE STANDARD OF TRAVEL PPC VALVE2539
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)2542
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE2543
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE2545
MAINTENANCE STANDARD OF SOLENOID VALVE2547
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)2548
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)2549
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT2550
WORK EQUIPMENT2551
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE2551
DIMENSION OF ARM2556
DIMENSIONS OF BUCKET2558
MAINTENANCE STANDARD OF BOOM CYLINDER2560
MAINTENANCE STANDARD OF ARM CYLINDER2561
MAINTENANCE STANDARD OF BUCKET CYLINDER2562
80 APPENDIX2563
CONTENTS2564
ABBREVIATION LIST2566
AIR CONDITIONER SYSTEM2572
PRECAUTIONS FOR REFRIGERANT2572
AIR CONDITIONER COMPONENT2573
SPECIFICATIONS OF AIR CONDITIONER2575
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2576
OUTLINE OF REFRIGERATION CYCLE2577
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2579
AIR CONDITIONER UNIT2579
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2579
FUNCTION OF AIR CONDITIONER UNIT2581
COMPONENT PARTS OF AIR CONDITIONER UNIT2583
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2584
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2584
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT2584
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT2584
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2585
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2585
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2585
FUNCTION OF DUAL PRESSURE SWITCH2586
AIR CONDITIONER CONTROLLER2587
STRUCTURE OF AIR CONDITIONER CONTROLLER2587
COMPRESSOR2588
STRUCTURE OF COMPRESSOR2588
SPECIFICATIONS OF COMPRESSOR2588
FUNCTION OF COMPRESSOR2588
CONDENSER2589
STRUCTURE OF CONDENSER2589
SPECIFICATIONS OF CONDENSER2589
FUNCTION OF CONDENSER2589
SENSORS FOR AIR CONDITIONER SYSTEM2591
STRUCTURE OF SUNLIGHT SENSOR2591
FUNCTION OF SUNLIGHT SENSOR2591
STRUCTURE OF AMBIENT TEMPERATURE SENSOR2591
FUNCTION OF AMBIENT TEMPERATURE SENSOR2591
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2593
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER2595
AIR CONDITIONER SYSTEM DIAGRAM2597
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER2598
FUNCTION OF AIR CONDITIONER CONTROLLER2599
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2600
TESTING AIR LEAKAGE (DUCT)2604
METHOD FOR TESTING AIR LEAKAGE (DUCT)2604
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION2606
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR2607
TEST VENT (MODE) CHANGEOVER2608
METHOD FOR TESTING VENT (MODE) CHANGEOVER2608
TESTING FRESH/RECIRC AIR CHANGEOVER2610
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER2610
TEST SUNLIGHT SENSOR2611
METHOD FOR TESTING SUNLIGHT SENSOR2611
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT2612
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT2612
TEST RELAYS2613
METHOD FOR TESTING RELAYS2613
AIR CONDITIONER TROUBLESHOOTING CHART 12614
AIR CONDITIONER TROUBLESHOOTING CHART 22615
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2618
FAILURE CODE [879AKA]2620
FAILURE CODE [879AKB]2621
FAILURE CODE [879BKA]2622
FAILURE CODE [879BKB]2624
FAILURE CODE [879CKA]2626
FAILURE CODE [879CKB]2627
FAILURE CODE [879DKZ]2628
FAILURE CODE [879EMC]2630
FAILURE CODE [879FMC]2631
FAILURE CODE [879GKX]2632
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)2634
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)2636
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)2639
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER2641
TROUBLESHOOTING USING GAUGE PRESSURE2643
CONNECTION OF SERVICE TOOL2646
METHOD FOR CONNECTING SERVICE TOOL2646
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS2648
HANDLE COMPRESSOR OIL2650
METHOD FOR REPLACING DESICCANT2652
90 CIRCUIT DIAGRAMS2655
CONTENTS2656
ABBREVIATION LIST2657
HYDRAULIC CIRCUIT DIAGRAM2663
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2663
HYDRAULIC CIRCUIT DIAGRAM (1/2)2667
HYDRAULIC CIRCUIT DIAGRAM (2/2)2669
ELECTRICAL CIRCUIT DIAGRAM2671
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM2671
ELECTRICAL CIRCUIT DIAGRAM (1/7)2675
ELECTRICAL CIRCUIT DIAGRAM (2/7)2677
ELECTRICAL CIRCUIT DIAGRAM (3/7)2679
ELECTRICAL CIRCUIT DIAGRAM (4/7)2681
ELECTRICAL CIRCUIT DIAGRAM (5/7)2683
ELECTRICAL CIRCUIT DIAGRAM (6/7)2685
ELECTRICAL CIRCUIT DIAGRAM (7/7)2687
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(1/9)2689
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(2/9)2691
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(3/9)2693
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(4/9)2695
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(5/9)2697
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(6/9)2699
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(7/9)2701
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(8/9)2703
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(9/9)2705
INDEX2707

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S.M 27/12/24