Komatsu HYDRAULIC EXCAVATOR PC490 -11 PC490LC -11 Shop Manual UENBM00304

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Komatsu HYDRAULIC EXCAVATOR PC490 -11 PC490LC -11 Shop Manual UENBM00304 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC490 -11 PC490LC -11 Shop Manual UENBM00304 – PDF DOWNLOAD

Language : English
Pages :2898
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC490 -11 PC490LC -11 Shop Manual UENBM00304 – PDF DOWNLOAD

SERIAL NUMBERS 85006 and up
K70001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC490 -11 PC490LC -11 Shop Manual UENBM00304 – PDF DOWNLOAD

SERIAL NUMBERS 85006 and up
K70001 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
PRECAUTIONS FOR DEF 43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 43
PRECAUTIONS FOR ADDING 43
PRECAUTIONS FOR STORING 43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 43
THE OTHER PRECAUTIONS 43
STORE DEF 44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 58
PRACTICAL USE OF KOMTRAX 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 74
HOW TO READ ELECTRICAL WIRE CODE 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 79
STANDARD TIGHTENING TORQUE TABLE 82
CONVERSION TABLE 89
01 SPECIFICATIONS 95
CONTENTS 96
ABBREVIATION LIST 97
SPECIFICATIONS 103
SPECIFICATION DRAWING 103
SPECIFICATION DRAWING: PC490,PC490LC-11 103
WORKING RANGE DRAWINGS 105
WORKING RANGE: PC490/PC490LC-11 105
SPECIFICATIONS 106
SPECIFICATIONS: PC490/PC490LC-11 106
WEIGHT TABLE 109
WEIGHT TABLE: PC490,PC490LC-11 109
TABLE OF FUEL, COOLANT, AND LUBRICANTS 111
10 STRUCTURE AND FUNCTION 113
CONTENTS 114
ABBREVIATION LIST 118
UREA SCR SYSTEM 124
LAYOUT DRAWING OF UREA SCR SYSTEM 124
UREA SCR SYSTEM DIAGRAM 128
FUNCTION OF UREA SCR SYSTEM 129
FUNCTION OF AdBlue/DEF SYSTEM 129
INDUCEMENT STRATEGY 131
COMPONENT PARTS OF UREA SCR SYSTEM 139
AdBlue/DEF MIXING TUBE 139
SCR ASSEMBLY 139
AdBlue/DEF TANK 142
AdBlue/DEF PUMP 144
AdBlue/DEF INJECTOR 145
AdBlue/DEF HOSE 146
AdBlue/DEF TANK HEATING VALVE 147
BOOT-UP SYSTEM 148
LAYOUT DRAWING OF BOOT-UP SYSTEM 148
SYSTEM OPERATING LAMP SYSTEM 150
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 150
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 150
BATTERY DISCONNECT SWITCH 152
FUNCTION OF BATTERY DISCONNECT SWITCH 152
ENGINE SYSTEM 153
LAYOUT DRAWING OF ENGINE SYSTEM 153
SPECIFICATIONS OF ENGINE SYSTEM 154
FUNCTION OF ENGINE SYSTEM 155
ENGINE CONTROL SYSTEM 156
ENGINE CONTROL SYSTEM DIAGRAM 156
FUNCTION OF ENGINE CONTROL SYSTEM 157
AUTO-DECELERATION SYSTEM 159
AUTO-DECELERATION SYSTEM DIAGRAM 159
FUNCTION OF AUTO-DECELERATION SYSTEM 159
OPERATION OF AUTO-DECELERATION SYSTEM 160
ENGINE AUTOMATIC WARM-UP SYSTEM 161
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 161
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 162
OVERHEAT PREVENTION SYSTEM 163
OVERHEAT PREVENTION SYSTEM DIAGRAM 163
FUNCTION OF OVERHEAT PREVENTION SYSTEM 164
TURBOCHARGER PROTECTION SYSTEM 166
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 166
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 167
AUTOMATIC IDLE STOP SYSTEM 168
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 168
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 168
COMPONENT PARTS OF ENGINE SYSTEM 171
VGT 171
EGR SYSTEM 174
EGR VALVE 176
EGR COOLER 178
KCCV SYSTEM 179
KCCV VENTILATOR 180
KDPF 182
COOLING SYSTEM 187
LAYOUT DRAWING OF COOLING SYSTEM 187
SPECIFICATIONS OF COOLING SYSTEM 188
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 190
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 190
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 191
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 192
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 192
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 193
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 195
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN 195
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 195
COMPONENT PARTS OF COOLING SYSTEM 196
COOLING FAN PUMP 196
COOLING FAN MOTOR 203
CONTROL SYSTEM 210
LAYOUT DRAWING OF CONTROL SYSTEM 210
MACHINE MONITOR SYSTEM 213
MACHINE MONITOR SYSTEM DIAGRAM 213
KomVision SYSTEM 214
LAYOUT DRAWING OF KOMVISION SYSTEM 214
KomVision SYSTEM DIAGRAM 216
FUNCTION OF KomVision SYSTEM 216
KOMTRAX SYSTEM 218
KOMTRAX SYSTEM DIAGRAM 218
FUNCTION OF KOMTRAX SYSTEM 218
PPC LEVERS 219
LH PPC LEVER 219
RH PPC LEVER 220
AUTOMATIC GREASE SYSTEM 221
OUTLINE OF AUTO GREASE SYSTEM 221
COMPONENT PARTS OF CONTROL SYSTEM 236
MACHINE MONITOR 236
KomVision CONTROLLER 249
KomVision CAMERA 253
KOMTRAX TERMINAL 253
PUMP CONTROLLER 256
RESISTOR FOR PC-EPC VALVE 260
CAN TERMINATING RESISTOR 260
ENGINE CONTROLLER 262
FUEL CONTROL DIAL 268
FUEL FEED PUMP 270
FUEL FEED PUMP SWITCH 271
SENSOR 272
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 272
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 272
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 272
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 277
STRUCTURE OF CLSS 277
OPERATION OF UNLOAD VALVE AND LS PRESSURE 279
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 280
PRESSURE COMPENSATION CONTROL 293
ENGINE AND PUMP COMBINED CONTROL SYSTEM 296
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 296
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 298
PUMP AND VALVE CONTROL SYSTEM 303
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 303
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 304
COMPONENT PARTS OF HYDRAULIC SYSTEM 306
HYDRAULIC TANK 306
MAIN PUMP 308
PILOT OIL FILTER 334
CONTROL VALVE 334
WORK EQUIPMENT SYSTEM 396
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 396
STRUCTURE OF VALVE CONTROL 401
ONE-TOUCH POWER MAXIMIZING SYSTEM 402
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 402
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 403
MACHINE PUSH-UP SYSTEM 404
MACHINE PUSH-UP SYSTEM DIAGRAM 404
FUNCTION OF MACHINE PUSH-UP SYSTEM 405
PPC LOCK SYSTEM 406
PPC LOCK SYSTEM DIAGRAM 406
FUNCTION OF PPC LOCK SYSTEM 406
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 407
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 407
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 407
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 408
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 409
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT 409
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 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 421
VARIABLE PRESSURE COMPENSATION VALVE 423
ATTACHMENT CIRCUIT SELECTOR VALVE 424
ATT EPC VALVE ASSEMBLY 427
PILOT CIRCUIT ACCUMULATOR 428
SWING SYSTEM 430
LAYOUT DRAWING OF SWING SYSTEM 430
SWING CONTROL SYSTEM DIAGRAM 436
FUNCTION OF SWING CONTROL SYSTEM 436
COMPONENT PARTS OF SWING SYSTEM 440
SWING MOTOR 440
SWING MACHINERY 451
SWING CIRCLE 453
TRAVEL SYSTEM 455
LAYOUT DRAWING OF TRAVEL SYSTEM 455
TRAVEL CONTROL SYSTEM DIAGRAM 459
FUNCTION OF TRAVEL CONTROL SYSTEM 460
COMPONENT PARTS OF TRAVEL SYSTEM 461
TRAVEL MOTOR 461
FINAL DRIVE 475
TRAVEL PPC VALVE 476
CENTER SWIVEL JOINT 481
UNDERCARRIAGE AND FRAME 483
LAYOUT DRAWING OF UNDERCARRIAGE 483
SPECIFICATIONS OF UNDERCARRIAGE 483
WORK EQUIPMENT 484
STRUCTURE OF WORK EQUIPMENT 484
FUNCTION OF WORK EQUIPMENT 485
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 486
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 486
BUCKET CLEARANCE ADJUSTMENT SHIM 487
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 487
CAB AND ITS ATTACHMENTS 488
ROPS CAB 488
STRUCTURE OF ROPS CAB 488
FUNCTION OF ROPS CAB 488
CAB MOUNT 489
STRUCTURE OF CAB MOUNT 489
FUNCTION OF CAB MOUNT 489
CAB TIPPING STOPPER 490
STRUCTURE OF CAB TIPPING STOPPER 490
FUNCTION OF CAB TIPPING STOPPER 490
20 STANDARD VALUE TABLE 491
CONTENTS 492
ABBREVIATION LIST 493
STANDARD VALUE TABLE FOR ENGINE 499
STANDARD VALUE TABLE FOR ENGINE: PC490LC-11 499
STANDARD VALUE TABLE FOR MACHINE 502
STANDARD VALUE TABLE FOR MACHINE: PC490LC-11 502
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 518
STANDARD VALUE TABLE FOR ELECTRICAL 522
STANDARD VALUE TABLE FOR ELECTRICAL 522
30 TESTING AND ADJUSTING 533
CONTENTS 534
ABBREVIATION LIST 537
RELATED INFORMATION ON TESTING AND ADJUSTING 543
TOOLS FOR TESTING AND ADJUSTING 543
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 550
ENGINE AND COOLING SYSTEM 552
TEST ENGINE SPEED 552
METHOD FOR TESTING ENGINE SPEED 552
TEST BOOST PRESSURE 555
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 555
METHOD FOR TESTING BOOST PRESSURE 556
TEST EXHAUST GAS COLOR 557
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 557
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 558
TEST AND ADJUST VALVE CLEARANCE 559
METHOD FOR TESTING VALVE CLEARANCE 559
METHOD FOR ADJUSTING VALVE CLEARANCE 562
TEST COMPRESSION PRESSURE 563
METHOD FOR TESTING COMPRESSION PRESSURE 563
TEST BLOWBY PRESSURE 566
METHOD FOR TESTING BLOWBY PRESSURE 566
TEST ENGINE OIL PRESSURE 568
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 568
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 568
TEST EGR VALVE AND VGT OIL PRESSURE 570
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 570
TEST FUEL PRESSURE 572
METHOD FOR TESTING FUEL PRESSURE 572
TEST FUEL RETURN RATE AND LEAKAGE 574
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 574
BLEED AIR FROM FUEL SYSTEM 577
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 577
TEST FUEL CIRCUIT FOR LEAKAGE 579
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 579
HANDLE CYLINDER CUT-OUT MODE OPERATION 581
HANDLE NO-INJECTION CRANKING OPERATION 582
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 583
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 583
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 583
CLEAN FUEL DOSER 585
METHOD FOR CLEANING FUEL DOSER 585
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 587
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 587
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 593
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 593
TEST SCR RELATED FUNCTIONS 594
TEST AdBlue/DEF PUMP RAISED PRESSURE 597
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 600
TEST AdBlue/DEF LINE HEATER RELAY 1 604
TEST AdBlue/DEF LINE HEATER RELAY 2 606
TEST AdBlue/DEF PUMP HEATER RELAY 609
TEST AdBlue/DEF TANK HEATER VALVE 612
TEST DENITRATION EFFICIENCY OF SCR 615
CLEAN AdBlue/DEF TANK 619
METHOD FOR CLEANING AdBlue/DEF TANK 619
POWER TRAIN 623
TEST SWING CIRCLE BEARING CLEARANCE 623
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 623
UNDERCARRIAGE AND FRAME 624
TEST AND ADJUST TRACK TENSION 624
METHOD FOR TESTING TRACK TENSION 624
METHOD FOR ADJUSTING TRACK TENSION 624
HYDRAULIC SYSTEM 626
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 626
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 626
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 630
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 632
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 633
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 640
TEST OIL PRESSURE OF CONTROL CIRCUIT 644
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 644
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 646
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 646
TEST PC-EPC VALVE OUTLET PRESSURE 647
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 648
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 650
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 650
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE 651
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 652
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 653
METHOD FOR ADJUSTING LS VALVE 654
TEST OUTLET PRESSURE OF SOLENOID VALVE 655
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 655
OPERATING CONDITION OF SOLENOID VALVE 656
TEST PPC VALVE OUTLET PRESSURE 658
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 658
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 660
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 660
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE 661
TEST PUMP SWASH PLATE SENSOR 663
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 663
TEST COOLING FAN SPEED 664
METHOD FOR TESTING COOLING FAN SPEED 664
TEST OIL PRESSURE IN FAN PUMP CIRCUIT 665
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT 665
TEST FAN PUMP EPC ELECTRIC CURRENT 667
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 667
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 668
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 668
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 670
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 670
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 670
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 671
TEST OIL LEAKAGE 672
TEST OIL LEAKAGE OF BOOM CYLINDER 672
TEST OIL LEAKAGE OF ARM CYLINDER 672
TEST OIL LEAKAGE OF BUCKET CYLINDER 673
METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR 673
METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR 674
BLEED AIR FROM HYDRAULIC CIRCUIT 675
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 677
CAB AND ITS ATTACHMENTS 680
TEST CAB TIPPING STOPPER 680
METHOD FOR TESTING CAB TIPPING STOPPER 680
METHOD FOR ADJUSTING MIRRORS 681
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 681
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 682
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 683
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 684
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 685
ELECTRICAL SYSTEM 687
SET AND OPERATE MACHINE MONITOR 687
OPERATOR MODE 690
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 691
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 691
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 692
CHECKING FUNCTION OF SERVICE METER 692
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 692
SERVICE MODE 695
SERVICE MODE 695
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 697
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 704
METHOD FOR CONFIRMING MAINTENANCE RECORD 720
METHOD FOR OPERATING MAINTENANCE MODE SETTING 721
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 725
METHOD FOR PERFORMING NO-INJECTION CRANKING 768
METHOD FOR CONFIRMING KOMTRAX SETTINGS (TERMINAL STATUS) 769
METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS AND COMMUNICATION STATUS) 770
METHOD FOR CONFIRMING KOMTRAX SETTINGS (MODEM STATUS) 770
METHOD FOR DISPLAYING SERVICE MESSAGE 772
METHOD FOR STARTING UP KOMTRAX TERMINAL 773
ADJUST REARVIEW CAMERA ANGLE 778
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 778
ADJUST KomVision CAMERA ANGLE 781
Angle adjustment method for KomVision camera 782
ADJUST KomVision RELATED ITEMS 786
SETTING OF KomVision (MAIN SETTING) 786
SETTING OF KomVision (CAMERA SETTING) 788
SETTING OF KomVision (CAMERA CALIBRATION) 789
KomVision screen – Check 12 m visibility 802
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 805
HANDLE BATTERY DISCONNECT SWITCH 806
TEST DIODES 807
METHOD FOR TESTING DIODE USING DIGITAL TESTER 807
METHOD FOR TESTING DIODE USING ANALOG TESTER 807
Pm CLINIC 808
Pm CLINIC SERVICE 808
Pm CLINIC CHECK SHEET 809
40 TROUBLESHOOTING 823
CONTENTS 824
ABBREVIATION LIST 835
RELATED INFORMATION ON TROUBLESHOOTING 841
GENERAL TROUBLESHOOTING POINTS 841
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 842
SEQUENCE OF EVENTS IN TROUBLESHOOTING 854
CHECKS BEFORE TROUBLESHOOTING 856
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 858
WALK-AROUND CHECK 858
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 860
CHECK FUEL LEVEL AND TYPE 860
CHECK IMPURE INGREDIENT IN FUEL 861
CHECK FUEL PREFILTER 861
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 861
FUEL PREFILTER CARTRIDGE – REPLACE 862
CHECK MAIN FILTER 863
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 864
CHECK COOLANT LEVEL (RESERVOIR TANK) 866
CHECK CLOGGING OF AIR CLEANER 866
OUTER ELEMENT – CLEAN 867
ELEMENTS – REPLACE 869
CHECK HYDRAULIC OIL LEVEL 870
CHECK HYDRAULIC OIL STRAINER 870
CHECK HYDRAULIC FILTER 871
CHECK OIL LEVEL IN SWING MACHINERY CASE 872
CHECK OIL LEVEL IN DAMPER CASE 873
CHECK OIL LEVEL IN FINAL DRIVE CASE 873
BLEED AIR FROM FUEL SYSTEM 874
BLEED AIR FROM HYDRAULIC SYSTEM 874
ELECTRICAL EQUIPMENT – CHECK METHOD 874
AUTOMATIC GREASE SYSTEM 880
FINDING MALFUNCTIONS 880
MALFUNCTION FINDING PROCEDURES 882
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM 884
PROCEDURE FOR TESTING AND TROUBLESHOOTING 894
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 897
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 901
CONNECTOR LIST AND LAYOUT 903
CONNECTOR CONTACT IDENTIFICATION 916
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 956
FUSE LOCATION TABLE 962
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 965
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 969
FAILURE CODE TABLE 971
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 990
FAILURE CODE [879AKA] 990
FAILURE CODE [879AKB] 991
FAILURE CODE [879BKA] 992
FAILURE CODE [879BKB] 994
FAILURE CODE [879CKA] 996
FAILURE CODE [879CKB] 997
FAILURE CODE [879DKZ] 998
FAILURE CODE [879EMC]1000
FAILURE CODE [879FMC]1001
FAILURE CODE [879GKX]1002
FAILURE CODE [989L00]1004
FAILURE CODE [989M00]1005
FAILURE CODE [989N00]1006
FAILURE CODE [A1U0N3]1007
FAILURE CODE [A1U0N4]1009
FAILURE CODE [A900FR]1011
FAILURE CODE [A900N6]1012
FAILURE CODE [A900NY]1013
FAILURE CODE [AA10NX]1014
FAILURE CODE [AB00KE]1016
FAILURE CODE [AQ10N3]1019
FAILURE CODE [AS00N3]1021
FAILURE CODE [AS00R2]1023
FAILURE CODE [AS00R3]1024
FAILURE CODE [AS00R4]1025
FAILURE CODE [AS00R5]1026
FAILURE CODE [AS00R6]1027
FAILURE CODE [AS00ZK]1028
FAILURE CODE [AS10KM]1029
FAILURE CODE [AS10NR]1030
FAILURE CODE [AS10NT]1031
FAILURE CODE [B@BAZG]1032
FAILURE CODE [B@BAZK]1033
FAILURE CODE [B@BCNS]1035
FAILURE CODE [B@BCQA]1036
FAILURE CODE [B@BCZK]1038
FAILURE CODE [B@HANS]1040
FAILURE CODE [CA115]1041
FAILURE CODE [CA122]1042
FAILURE CODE [CA123]1044
FAILURE CODE [CA131]1046
FAILURE CODE [CA132]1048
FAILURE CODE [CA135]1050
FAILURE CODE [CA141]1052
FAILURE CODE [CA144]1054
FAILURE CODE [CA145]1056
FAILURE CODE [CA153]1058
FAILURE CODE [CA154]1061
FAILURE CODE [CA187]1064
FAILURE CODE [CA221]1066
FAILURE CODE [CA222]1068
FAILURE CODE [CA227]1070
FAILURE CODE [CA234]1071
FAILURE CODE [CA238]1072
FAILURE CODE [CA239]1074
FAILURE CODE [CA249]1076
FAILURE CODE [CA256]1078
FAILURE CODE [CA271]1080
FAILURE CODE [CA272]1082
FAILURE CODE [CA273]1083
FAILURE CODE [CA274]1085
FAILURE CODE [CA322]1086
FAILURE CODE [CA323]1088
FAILURE CODE [CA324]1090
FAILURE CODE [CA325]1092
FAILURE CODE [CA331]1094
FAILURE CODE [CA332]1096
FAILURE CODE [CA343]1098
FAILURE CODE [CA351]1099
FAILURE CODE [CA352]1100
FAILURE CODE [CA356]1103
FAILURE CODE [CA357]1105
FAILURE CODE [CA386]1107
FAILURE CODE [CA441]1108
FAILURE CODE [CA442]1110
FAILURE CODE [CA449]1111
FAILURE CODE [CA451]1112
FAILURE CODE [CA452]1114
FAILURE CODE [CA515]1116
FAILURE CODE [CA516]1118
FAILURE CODE [CA553]1120
FAILURE CODE [CA555]1121
FAILURE CODE [CA556]1122
FAILURE CODE [CA559]1123
FAILURE CODE [CA595]1128
FAILURE CODE [CA687]1129
FAILURE CODE [CA689]1131
FAILURE CODE [CA691]1133
FAILURE CODE [CA692]1135
FAILURE CODE [CA697]1137
FAILURE CODE [CA698]1138
FAILURE CODE [CA731]1139
FAILURE CODE [CA778]1140
FAILURE CODE [CA1117]1143
FAILURE CODE [CA1664]1144
FAILURE CODE [CA1669]1147
FAILURE CODE [CA1673]1148
FAILURE CODE [CA1677]1149
FAILURE CODE [CA1678]1150
FAILURE CODE [CA1682]1151
FAILURE CODE [CA1683]1153
FAILURE CODE [CA1684]1155
FAILURE CODE [CA1686]1157
FAILURE CODE [CA1691]1158
FAILURE CODE [CA1694]1161
FAILURE CODE [CA1695]1163
FAILURE CODE [CA1696]1164
FAILURE CODE [CA1712]1166
FAILURE CODE [CA1713]1169
FAILURE CODE [CA1714]1171
FAILURE CODE [CA1715]1172
FAILURE CODE [CA1776]1173
FAILURE CODE [CA1777]1176
FAILURE CODE [CA1843]1179
FAILURE CODE [CA1844]1181
FAILURE CODE [CA1879]1184
FAILURE CODE [CA1881]1187
FAILURE CODE [CA1883]1189
FAILURE CODE [CA1885]1192
FAILURE CODE [CA1887]1194
FAILURE CODE [CA1921]1196
FAILURE CODE [CA1922]1199
FAILURE CODE [CA1923]1204
FAILURE CODE [CA1924]1206
FAILURE CODE [CA1925]1208
FAILURE CODE [CA1927]1210
FAILURE CODE [CA1928]1212
FAILURE CODE [CA1942]1214
FAILURE CODE [CA1963]1215
FAILURE CODE [CA1977]1218
FAILURE CODE [CA1993]1221
FAILURE CODE [CA2185]1224
FAILURE CODE [CA2186]1226
FAILURE CODE [CA2249]1228
FAILURE CODE [CA2265]1229
FAILURE CODE [CA2266]1231
FAILURE CODE [CA2271]1233
FAILURE CODE [CA2272]1235
FAILURE CODE [CA2349]1237
FAILURE CODE [CA2353]1239
FAILURE CODE [CA2357]1241
FAILURE CODE [CA2381]1242
FAILURE CODE [CA2382]1244
FAILURE CODE [CA2383]1246
FAILURE CODE [CA2386]1248
FAILURE CODE [CA2387]1250
FAILURE CODE [CA2555]1251
FAILURE CODE [CA2556]1254
FAILURE CODE [CA2637]1256
FAILURE CODE [CA2639]1258
FAILURE CODE [CA2732]1261
FAILURE CODE [CA2733]1263
FAILURE CODE [CA2741]1265
FAILURE CODE [CA2765]1266
FAILURE CODE [CA2771]1267
FAILURE CODE [CA2777]1273
FAILURE CODE [CA2878]1276
FAILURE CODE [CA2881]1279
FAILURE CODE [CA2976]1282
FAILURE CODE [CA3133]1284
FAILURE CODE [CA3134]1286
FAILURE CODE [CA3135]1288
FAILURE CODE [CA3142]1291
FAILURE CODE [CA3143]1292
FAILURE CODE [CA3144]1293
FAILURE CODE [CA3146]1295
FAILURE CODE [CA3147]1296
FAILURE CODE [CA3148]1297
FAILURE CODE [CA3151]1299
FAILURE CODE [CA3165]1305
FAILURE CODE [CA3167]1307
FAILURE CODE [CA3229]1310
FAILURE CODE [CA3231]1312
FAILURE CODE [CA3232]1314
FAILURE CODE [CA3235]1318
FAILURE CODE [CA3239]1320
FAILURE CODE [CA3241]1323
FAILURE CODE [CA3242]1326
FAILURE CODE [CA3251]1329
FAILURE CODE [CA3253]1331
FAILURE CODE [CA3254]1334
FAILURE CODE [CA3255]1337
FAILURE CODE [CA3256]1341
FAILURE CODE [CA3311]1343
FAILURE CODE [CA3312]1345
FAILURE CODE [CA3313]1348
FAILURE CODE [CA3314]1349
FAILURE CODE [CA3315]1350
FAILURE CODE [CA3316]1353
FAILURE CODE [CA3317]1354
FAILURE CODE [CA3318]1355
FAILURE CODE [CA3319]1357
FAILURE CODE [CA3321]1358
FAILURE CODE [CA3322]1360
FAILURE CODE [CA3419]1363
FAILURE CODE [CA3421]1365
FAILURE CODE [CA3497]1367
FAILURE CODE [CA3498]1368
FAILURE CODE [CA3543]1369
FAILURE CODE [CA3545]1376
FAILURE CODE [CA3547]1378
FAILURE CODE [CA3558]1379
FAILURE CODE [CA3559]1381
FAILURE CODE [CA3562]1383
FAILURE CODE [CA3563]1385
FAILURE CODE [CA3567]1388
FAILURE CODE [CA3568]1391
FAILURE CODE [CA3571]1395
FAILURE CODE [CA3572]1397
FAILURE CODE [CA3574]1399
FAILURE CODE [CA3575]1401
FAILURE CODE [CA3577]1403
FAILURE CODE [CA3578]1405
FAILURE CODE [CA3582]1407
FAILURE CODE [CA3583]1413
FAILURE CODE [CA3596]1415
FAILURE CODE [CA3649]1417
FAILURE CODE [CA3681]1419
FAILURE CODE [CA3682]1424
FAILURE CODE [CA3713]1430
FAILURE CODE [CA3717]1433
FAILURE CODE [CA3718]1434
FAILURE CODE [CA3725]1435
FAILURE CODE [CA3748]1438
FAILURE CODE [CA3751]1440
FAILURE CODE [CA3755]1442
FAILURE CODE [CA3866]1444
FAILURE CODE [CA3867]1448
FAILURE CODE [CA3868]1451
FAILURE CODE [CA3899]1455
FAILURE CODE [CA3911]1457
FAILURE CODE [CA3912]1461
FAILURE CODE [CA3932]1463
FAILURE CODE [CA3933]1465
FAILURE CODE [CA3934]1467
FAILURE CODE [CA3935]1470
FAILURE CODE [CA3936]1472
FAILURE CODE [CA4151]1474
FAILURE CODE [CA4152]1478
FAILURE CODE [CA4155]1482
FAILURE CODE [CA4156]1484
FAILURE CODE [CA4157]1487
FAILURE CODE [CA4158]1489
FAILURE CODE [CA4159]1490
FAILURE CODE [CA4161]1491
FAILURE CODE [CA4162]1494
FAILURE CODE [CA4163]1497
FAILURE CODE [CA4164]1499
FAILURE CODE [CA4165]1501
FAILURE CODE [CA4166]1503
FAILURE CODE [CA4168]1505
FAILURE CODE [CA4169]1508
FAILURE CODE [CA4171]1510
FAILURE CODE [CA4249]1513
FAILURE CODE [CA4251]1515
FAILURE CODE [CA4259]1517
FAILURE CODE [CA4261]1519
FAILURE CODE [CA4277]1522
FAILURE CODE [CA4281]1526
FAILURE CODE [CA4459]1529
FAILURE CODE [CA4461]1532
FAILURE CODE [CA4658]1535
FAILURE CODE [CA4731]1539
FAILURE CODE [CA4732]1540
FAILURE CODE [CA4739]1541
FAILURE CODE [CA4768]1542
FAILURE CODE [CA4769]1544
FAILURE CODE [CA4842]1547
FAILURE CODE [CA4952]1551
FAILURE CODE [CA5115]1553
FAILURE CODE [CA5179]1556
FAILURE CODE [CA5181]1558
FAILURE CODE [CA5383]1560
FAILURE CODE [D110KB]1562
FAILURE CODE [D19JKZ]1564
FAILURE CODE [D811MC]1567
FAILURE CODE [D862KA]1568
FAILURE CODE [D8ALKA]1569
FAILURE CODE [D8ALKB]1571
FAILURE CODE [D8AQKR]1573
FAILURE CODE [DA20MC]1575
FAILURE CODE [DA22KK]1576
FAILURE CODE [DA25KP]1579
FAILURE CODE [DA29KQ]1582
FAILURE CODE [DA2LKA]1584
FAILURE CODE [DA2LKB]1586
FAILURE CODE [DA2QKR]1588
FAILURE CODE [DA2RKR]1591
FAILURE CODE [DAF0KM]1592
FAILURE CODE [DAF0MB]1593
FAILURE CODE [DAF0MC]1594
FAILURE CODE [DAF8KB]1595
FAILURE CODE [DAF9KQ]1597
FAILURE CODE [DAFGMC]1598
FAILURE CODE [DAFLKA]1599
FAILURE CODE [DAFLKB]1601
FAILURE CODE [DAFQKR]1603
FAILURE CODE [DAZ9KQ]1604
FAILURE CODE [DAZQKR]1605
FAILURE CODE [DB2QKR]1610
FAILURE CODE [DB2RKR]1615
FAILURE CODE [DBP0KM]1619
FAILURE CODE [DBP0KT]1620
FAILURE CODE [DBP5KB]1621
FAILURE CODE [DBP5KY]1624
FAILURE CODE [DBPQKR]1627
FAILURE CODE [DDNRKA]1632
FAILURE CODE [DDNRKY]1634
FAILURE CODE [DDNS00]1636
FAILURE CODE [DFB1KZ]1638
FAILURE CODE [DFB2KZ]1640
FAILURE CODE [DFB3L8]1642
FAILURE CODE [DFB4L8]1644
FAILURE CODE [DFB5KZ]1646
FAILURE CODE [DFB6KZ]1648
FAILURE CODE [DGH2KA]1650
FAILURE CODE [DGH2KB]1652
FAILURE CODE [DHA4KA]1654
FAILURE CODE [DHAAMA]1656
FAILURE CODE [DHACMA]1658
FAILURE CODE [DHPAMA]1660
FAILURE CODE [DHPBMA]1663
FAILURE CODE [DHS3MA]1666
FAILURE CODE [DHS4MA]1669
FAILURE CODE [DHS8MA]1672
FAILURE CODE [DHS9MA]1675
FAILURE CODE [DHSAMA]1678
FAILURE CODE [DHSBMA]1681
FAILURE CODE [DHSCMA]1684
FAILURE CODE [DHSDMA]1687
FAILURE CODE [DHSFMA]1690
FAILURE CODE [DHSGMA]1693
FAILURE CODE [DHSHMA]1696
FAILURE CODE [DHSJMA]1699
FAILURE CODE [DHSVMA]1702
FAILURE CODE [DKR0MA]1705
FAILURE CODE [DKR1MA]1708
FAILURE CODE [DKULKA]1711
FAILURE CODE [DKULKB]1713
FAILURE CODE [DKULKY]1715
FAILURE CODE [DLM3KA]1717
FAILURE CODE [DLM3KB]1719
FAILURE CODE [DLM3MB]1721
FAILURE CODE [DR10KA]1722
FAILURE CODE [DR12KA]1725
FAILURE CODE [DR20KA]1727
FAILURE CODE [DR21KX]1729
FAILURE CODE [DR30KA]1731
FAILURE CODE [DR31KX]1733
FAILURE CODE [DR40KA]1735
FAILURE CODE [DUMBKA]1737
FAILURE CODE [DUMBKB]1739
FAILURE CODE [DV20KB]1741
FAILURE CODE [DW43KA]1743
FAILURE CODE [DW43KB]1745
FAILURE CODE [DW43KY]1747
FAILURE CODE [DW45KA]1749
FAILURE CODE [DW45KB]1752
FAILURE CODE [DW45KY]1755
FAILURE CODE [DW4CKY]1757
FAILURE CODE [DW7BKA]1758
FAILURE CODE [DW7BKB]1760
FAILURE CODE [DW7BKY]1762
FAILURE CODE [DW91KA]1763
FAILURE CODE [DW91KB]1765
FAILURE CODE [DW91KY]1767
FAILURE CODE [DWA2KA]1769
FAILURE CODE [DWA2KB]1771
FAILURE CODE [DWA2KY]1773
FAILURE CODE [DWK0KA]1775
FAILURE CODE [DWK0KB]1777
FAILURE CODE [DWK0KY]1779
FAILURE CODE [DWK2KA]1781
FAILURE CODE [DWK2KB]1783
FAILURE CODE [DWK2KY]1785
FAILURE CODE [DWK8KA]1787
FAILURE CODE [DWK8KB]1789
FAILURE CODE [DWK8KY]1791
FAILURE CODE [DX16KA]1793
FAILURE CODE [DX16KB]1795
FAILURE CODE [DXA8KA]1797
FAILURE CODE [DXA8KB]1799
FAILURE CODE [DXA9KA]1801
FAILURE CODE [DXA9KB]1803
FAILURE CODE [DXE0KA]1805
FAILURE CODE [DXE0KB]1807
FAILURE CODE [DXE4KA]1809
FAILURE CODE [DXE4KB]1811
FAILURE CODE [DXE4KY]1813
FAILURE CODE [DXE5KA]1815
FAILURE CODE [DXE5KB]1817
FAILURE CODE [DXE6KA]1819
FAILURE CODE [DXE6KB]1821
FAILURE CODE [DXE7KA]1823
FAILURE CODE [DXE7KB]1825
FAILURE CODE [DXE7KY]1827
FAILURE CODE [DXE8KA]1829
FAILURE CODE [DXE8KB]1831
FAILURE CODE [DXE8KY]1833
FAILURE CODE [DXE9KA]1835
FAILURE CODE [DXE9KB]1837
FAILURE CODE [DXE9KY]1839
FAILURE CODE [DXEAKA]1841
FAILURE CODE [DXEAKB]1843
FAILURE CODE [DXEAKY]1845
FAILURE CODE [DY20KA]1847
FAILURE CODE [DY20MA]1849
FAILURE CODE [DY2CKB]1851
FAILURE CODE [DY2DKB]1854
FAILURE CODE [DY2EKB]1856
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1858
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1858
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1864
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1867
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1869
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING1871
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW1874
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW1875
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1876
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1877
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING1878
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1879
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1880
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1881
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1882
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1883
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1884
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL1886
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1887
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE1888
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1889
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE1891
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED1892
E-23 FUNCTION SWITCH DOES NOT OPERATE1893
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)1894
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF1895
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER1896
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED1897
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED1898
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE1899
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE1900
E-31 ALARM BUZZER CANNOT BE CANCELED1902
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION1903
E-33 SERVICE MODE CANNOT BE SELECTED1904
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE1905
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK1907
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING1908
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE1911
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR1913
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED1915
E-40 ALARM DOES NOT SOUND DURING TRAVEL1916
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED1918
E-42 HORN DOES NOT SOUND1919
E-43 HORN DOES NOT STOP SOUNDING1923
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF1925
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE1926
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE1928
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1929
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1930
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1931
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1932
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1933
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1934
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1935
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1936
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1937
E-56 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED1939
E-57 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY1940
E-58 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED1941
E-59 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE1943
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1944
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)1944
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS1945
FAILURE MODE AND CAUSE TABLE1947
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK1955
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER1956
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR1958
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP1959
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS1960
H-6 SPEED OR POWER OF BOOM IS LOW1962
H-7 ARM SPEED OR POWER IS LOW1968
H-8 BUCKET SPEED OR POWER IS LOW1973
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION1976
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE1977
H-11 HYDRAULIC DRIFT OF ARM IS LARGE1979
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE1981
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES1982
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE1983
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE1984
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE1985
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED1986
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED1987
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER1988
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY1989
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW1990
H-22 MACHINE DOES NOT TRAVEL STRAIGHT1991
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW1993
H-24 TRAVEL SPEED IS LOW1996
H-25 ONE OF TRACKS DOES NOT RUN1998
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST1999
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT2000
H-28 SWINGS ONLY IN ONE DIRECTION2001
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)2002
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION2003
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)2004
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)2005
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING2006
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING2007
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)2008
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)2009
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)2010
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN2011
TROUBLESHOOTING OF ENGINE (S-MODE)2012
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2012
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2013
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2014
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2015
S-4 ENGINE STARTABILITY IS POOR2016
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2018
S-6 ENGINE STOPS DURING OPERATION2020
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2022
S-8 ENGINE LACKS POWER2023
S-9 KDPF GETS CLOGGED IN A SHORT TIME2025
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2027
S-11 OIL BECOMES CONTAMINATED QUICKLY2028
S-1 FUEL CONSUMPTION IS EXCESSIVE2029
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2030
S-14 OIL PRESSURE DROPS2031
S-15 FUEL MIXES INTO ENGINE OIL2033
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2034
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2035
S-18 UNUSUAL NOISE IS HEARD2036
S-19 VIBRATION IS EXCESSIVE2037
S-2 AIR CANNOT BE BLED FROM FUEL CIRCUIT2038
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2039
S-22 ACTIVE REGENERATION TAKES TIME2041
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2043
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE2044
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)2046
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2047
50 DISASSEMBLY AND ASSEMBLY2049
CONTENTS2050
ABBREVIATION LIST2055
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2061
HOW TO READ THIS MANUAL2061
COATING MATERIALS LIST2063
SPECIAL TOOLS LIST2067
SKETCHES OF SPECIAL TOOLS2079
ENGINE AND COOLING SYSTEM2085
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2085
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2085
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2091
REMOVE AND INSTALL INJECTOR ASSEMBLY2100
METHOD FOR REMOVING INJECTOR ASSEMBLY2100
METHOD FOR INSTALLING INJECTOR ASSEMBLY2106
REMOVE AND INSTALL FUEL DOSER ASSEMBLY2116
METHOD FOR REMOVING FUEL DOSER2116
METHOD FOR INSTALLING FUEL DOSER2117
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2119
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2120
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2128
REMOVE AND INSTALL EGR VALVE ASSEMBLY2142
METHOD FOR REMOVING EGR VALVE ASSEMBLY2142
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2144
REMOVE AND INSTALL EGR COOLER ASSEMBLY2146
METHOD FOR REMOVING EGR COOLER ASSEMBLY2146
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2150
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2155
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY2155
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY2156
REMOVE AND INSTALL ALTERNATOR BELT2158
METHOD FOR REMOVING ALTERNATOR BELT2158
METHOD FOR INSTALLING ALTERNATOR BELT2161
REMOVE AND INSTALL RADIATOR ASSEMBLY2166
METHOD FOR REMOVING RADIATOR ASSEMBLY2166
METHOD FOR INSTALLING RADIATOR ASSEMBLY2168
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2171
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2171
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2175
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2180
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2180
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2182
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2184
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2184
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2186
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY2190
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY2191
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY2209
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2228
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2229
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2231
REMOVE AND INSTALL ENGINE REAR OIL SEAL2235
METHOD FOR REMOVING ENGINE REAR OIL SEAL2236
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2239
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2245
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2245
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2253
REMOVE AND INSTALL FUEL TANK ASSEMBLY2264
METHOD FOR REMOVING FUEL TANK ASSEMBLY2264
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2268
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2272
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2272
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2278
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2283
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2283
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2290
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER2296
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER2296
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER2298
REMOVE AND INSTALL KDPF ASSEMBLY2301
METHOD FOR REMOVING KDPF ASSEMBLY2301
METHOD FOR INSTALLING KDPF ASSEMBLY2305
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2310
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2311
METHOD FOR ASSEMBLING KDPF ASSEMBLY2316
REMOVE AND INSTALL SCR ASSEMBLY2323
METHOD FOR REMOVING SCR ASSEMBLY2323
METHOD FOR INSTALLING SCR ASSEMBLY2326
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2330
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2330
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2335
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET2340
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET2340
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET2344
REMOVE AND INSTALL KCCV ASSEMBLY2354
METHOD FOR REMOVING KCCV ASSEMBLY2354
METHOD FOR INSTALLING KCCV ASSEMBLY2355
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2359
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2359
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2364
REMOVE AND INSTALL AdBlue/DEF INJECTOR2370
METHOD FOR REMOVING AdBlue/DEF INJECTOR2370
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2374
REMOVE AND INSTALL AdBlue/DEF PUMP2379
METHOD FOR REMOVING AdBlue/DEF PUMP2379
METHOD FOR INSTALLING AdBlue/DEF PUMP2381
REMOVE AND INSTALL AdBlue/DEF HOSE2382
METHOD FOR REMOVING AdBlue/DEF HOSE2382
METHOD FOR INSTALLING AdBlue/DEF HOSE2387
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2396
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2396
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2397
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2400
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2400
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2403
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2407
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2407
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2408
POWER TRAIN2410
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2410
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2410
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2411
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY2412
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY2412
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY2417
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY2423
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY2423
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY2424
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY2426
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY2426
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY2430
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY2436
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY2436
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY2436
UNDERCARRIAGE AND FRAME2438
SEPARATION AND CONNECTION OF TRACK ASSEMBLY2438
METHOD FOR SEPARATING TRACK ASSEMBLY2438
METHOD FOR INSTALLING TRACK ASSEMBLY2440
REMOVE AND INSTALL SPROCKET2443
METHOD FOR REMOVING SPROCKET2443
METHOD FOR INSTALLING SPROCKET2443
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY2445
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY2445
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY2446
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2448
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2448
METHOD FOR ASSEMBLING IDLER ASSEMBLY2450
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY2455
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY2456
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY2458
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2461
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2462
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2463
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY2467
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY2467
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY2469
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY2472
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY2472
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY2474
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2477
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2477
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2478
HYDRAULIC SYSTEM2481
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY2481
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY2481
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY2483
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2485
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2486
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2486
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2488
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2488
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2493
REMOVE AND INSTALL MAIN PUMP ASSEMBLY2499
METHOD FOR REMOVING MAIN PUMP ASSEMBLY2499
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY2503
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2509
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2509
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2514
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY2520
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING2521
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY2522
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2527
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2527
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2528
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2530
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY2530
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY2531
REMOVE AND INSTALL QUICK COUPLER VALVE2533
WORK EQUIPMENT2535
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2535
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2536
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2539
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2543
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2543
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2546
CAB AND ITS ATTACHMENTS2550
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2550
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2550
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2557
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS)2564
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2566
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2566
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY2576
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY2576
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY2579
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY2585
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY2585
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY2592
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2600
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2600
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2606
REMOVE AND INSTALL OPERATOR’S SEAT2613
METHOD FOR REMOVING OPERATOR’S SEAT2613
METHOD FOR INSTALLING OPERATOR’S SEAT2615
REMOVE AND INSTALL SEAT BELT2618
METHOD FOR REMOVING SEAT BELT2618
METHOD FOR INSTALLING SEAT BELT2619
REMOVE AND INSTALL FRONT WIPER ASSEMBLY2620
METHOD FOR REMOVING FRONT WIPER ASSEMBLY2620
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY2625
ELECTRICAL SYSTEM2634
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2634
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2634
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2635
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY2637
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY2637
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY2640
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY2645
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY2645
METHOD FOR INSTALLING KomVision CONTROLLER2646
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2647
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2647
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY2650
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR2654
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR2654
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR2655
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2656
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR2656
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR2657
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2659
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR2659
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR2660
REMOVE AND INSTALL SCR TEMPERATURE SENSOR2662
METHOD FOR REMOVING SCR TEMPERATURE SENSOR2662
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR2664
REMOVE AND INSTALL KomVision CAMERA2666
METHOD FOR REMOVING KomVision CAMERA2666
METHOD FOR INSTALLING KomVision CAMERA2667
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY2669
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY2669
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY2672
60 MAINTENANCE STANDARD2675
CONTENTS2676
ABBREVIATION LIST2677
ENGINE AND COOLING SYSTEM2683
MAINTENANCE STANDARD OF ENGINE MOUNT2683
MAINTENANCE STANDARD OF COOLING SYSTEM2684
MAINTENANCE STANDARD OF COOLING FAN PUMP2685
MAINTENANCE STANDARD OF SERVO VALVE2686
MAINTENANCE STANDARD OF COOLING FAN MOTOR2687
POWER TRAIN2688
MAINTENANCE STANDARD OF SWING CIRCLE2688
MAINTENANCE STANDARD OF SWING MACHINERY2689
MAINTENANCE STANDARD OF FINAL DRIVE2691
MAINTENANCE STANDARD OF SPROCKET2693
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING2694
UNDERCARRIAGE AND FRAME2696
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION2696
MAINTENANCE STANDARD OF IDLER2698
MAINTENANCE STANDARD OF TRACK ROLLER2700
MAINTENANCE STANDARD OF CARRIER ROLLER2702
MAINTENANCE STANDARD OF TRACK SHOE2703
MAINTENANCE STANDARD OF TRIPLE SHOE2706
HYDRAULIC SYSTEM2707
MAINTENANCE STANDARD OF MAIN PUMP2707
MAINTENANCE STANDARD OF SWING MOTOR2709
MAINTENANCE STANDARD OF TRAVEL MOTOR2712
MAINTENANCE STANDARD OF CONTROL VALVE2715
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE2726
MAINTENANCE STANDARD OF TRAVEL PPC VALVE2729
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)2732
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE2734
MAINTENANCE STANDARD OF SOLENOID VALVE2735
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE2736
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE2738
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT2739
WORK EQUIPMENT2740
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE2740
DIMENSION OF ARM2745
DIMENSIONS OF BUCKET2747
MAINTENANCE STANDARD OF BOOM CYLINDER2749
MAINTENANCE STANDARD OF ARM CYLINDER2750
MAINTENANCE STANDARD OF BUCKET CYLINDER2751
80 APPENDIX2753
CONTENTS2754
ABBREVIATION LIST2756
AIR CONDITIONER SYSTEM2762
PRECAUTIONS FOR REFRIGERANT2762
AIR CONDITIONER COMPONENT2763
SPECIFICATIONS OF AIR CONDITIONER2765
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2766
OUTLINE OF REFRIGERATION CYCLE2767
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2769
AIR CONDITIONER UNIT2769
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2769
FUNCTION OF AIR CONDITIONER UNIT2771
COMPONENT PARTS OF AIR CONDITIONER UNIT2773
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2774
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2774
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT2774
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT2774
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2775
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2775
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2775
FUNCTION OF DUAL PRESSURE SWITCH2776
AIR CONDITIONER CONTROLLER2777
STRUCTURE OF AIR CONDITIONER CONTROLLER2777
COMPRESSOR2778
STRUCTURE OF COMPRESSOR2778
SPECIFICATIONS OF COMPRESSOR2778
FUNCTION OF COMPRESSOR2778
CONDENSER2779
STRUCTURE OF CONDENSER2779
SPECIFICATIONS OF CONDENSER2779
FUNCTION OF CONDENSER2779
RECEIVER DRIER2780
STRUCTURE OF RECEIVER DRIER2780
SPECIFICATIONS OF RECEIVER DRIER2780
FUNCTION OF RECEIVER DRIER2780
SENSORS FOR AIR CONDITIONER SYSTEM2781
STRUCTURE OF SUNLIGHT SENSOR2781
FUNCTION OF SUNLIGHT SENSOR2781
STRUCTURE OF AMBIENT TEMPERATURE SENSOR2781
FUNCTION OF AMBIENT TEMPERATURE SENSOR2781
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2783
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER2785
AIR CONDITIONER SYSTEM DIAGRAM2787
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER2788
FUNCTION OF AIR CONDITIONER CONTROLLER2789
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2790
TESTING AIR LEAKAGE (DUCT)2794
METHOD FOR TESTING AIR LEAKAGE (DUCT)2794
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION2796
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR2797
TEST VENT (MODE) CHANGEOVER2798
METHOD FOR TESTING VENT (MODE) CHANGEOVER2798
TESTING FRESH/RECIRC AIR CHANGEOVER2800
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER2800
TEST SUNLIGHT SENSOR2801
METHOD FOR TESTING SUNLIGHT SENSOR2801
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT2802
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT2802
TEST RELAYS2803
METHOD FOR TESTING RELAYS2803
AIR CONDITIONER TROUBLESHOOTING CHART 12804
AIR CONDITIONER TROUBLESHOOTING CHART 22805
FAILURE CODE [879AKA]2808
FAILURE CODE [879AKB]2809
FAILURE CODE [879BKA]2810
FAILURE CODE [879BKB]2812
FAILURE CODE [879CKA]2814
FAILURE CODE [879CKB]2815
FAILURE CODE [879DKZ]2816
FAILURE CODE [879EMC]2818
FAILURE CODE [879FMC]2819
FAILURE CODE [879GKX]2820
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)2822
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)2824
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)2827
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER2829
TROUBLESHOOTING USING GAUGE PRESSURE2831
CONNECTION OF SERVICE TOOL2834
METHOD FOR CONNECTING SERVICE TOOL2834
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS2836
HANDLE COMPRESSOR OIL2838
90 CIRCUIT DIAGRAMS2841
CONTENTS2842
ABBREVIATION LIST2843
HYDRAULIC CIRCUIT DIAGRAM2849
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2849
HYDRAULIC CIRCUIT DIAGRAM (1/2)2853
HYDRAULIC CIRCUIT DIAGRAM (2/2)2855
ELECTRICAL CIRCUIT DIAGRAM2857
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM2857
ELECTRICAL CIRCUIT DIAGRAM (1/9)2861
ELECTRICAL CIRCUIT DIAGRAM (2/9)2863
ELECTRICAL CIRCUIT DIAGRAM (3/9)2865
ELECTRICAL CIRCUIT DIAGRAM (4/9)2867
ELECTRICAL CIRCUIT DIAGRAM (5/9)2869
ELECTRICAL CIRCUIT DIAGRAM (6/9)2871
ELECTRICAL CIRCUIT DIAGRAM (7/9)2873
ELECTRICAL CIRCUIT DIAGRAM (8/9)2875
ELECTRICAL CIRCUIT DIAGRAM (9/9)2877
INDEX2879

S.M 31/12/24