Komatsu Hydraulic Excavator PC650LC-11 Shop Manual SEN06603-07 – PDF

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Komatsu Hydraulic Excavator PC650LC-11 Shop Manual SEN06603-07 – PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC650LC-11 Shop Manual SEN06603-07 – PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC650LC-11 Shop Manual SEN06603-07 – PDF DOWNLOAD

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: PC650LC-11. 101
WORKING RANGE DRAWINGS 103
WORKING RANGE: PC650LC-11. 103
SPECIFICATIONS 104
SPECIFICATIONS: PC650LC-11 104
WEIGHT TABLE 107
WEIGHT TABLE: PC650LC-11 107
TABLE OF FUEL, COOLANT, AND LUBRICANTS 109
10 STRUCTURE AND FUNCTION. 111
CONTENTS 112
ABBREVIATION LIST. 115
UREA SCR SYSTEM. 121
LAYOUT DRAWING OF UREA SCR SYSTEM. 121
UREA SCR SYSTEM DIAGRAM. 126
FUNCTION OF UREA SCR SYSTEM. 127
FUNCTION OF AdBlue/DEF SYSTEM. 127
INDUCEMENT STRATEGY. 129
COMPONENT PARTS OF UREA SCR SYSTEM 136
AdBlue/DEF MIXING TUBE 136
SCR ASSEMBLY 137
AdBlue/DEF TANK. 139
AdBlue/DEF PUMP. 141
AdBlue/DEF INJECTOR. 142
AdBlue/DEF HOSE. 143
AdBlue/DEF TANK HEATING VALVE. 144
BOOT-UP SYSTEM 145
LAYOUT DRAWING OF BOOT-UP SYSTEM 145
SYSTEM OPERATING LAMP SYSTEM 146
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 146
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 146
BATTERY DISCONNECT SWITCH. 147
FUNCTION OF BATTERY DISCONNECT SWITCH. 147
ENGINE SYSTEM. 148
LAYOUT DRAWING OF ENGINE SYSTEM. 148
FUNCTION OF ENGINE SYSTEM. 149
ENGINE CONTROL SYSTEM. 150
ENGINE CONTROL SYSTEM DIAGRAM. 150
FUNCTION OF ENGINE CONTROL SYSTEM. 150
AUTO-DECELERATION SYSTEM 153
AUTO-DECELERATION SYSTEM DIAGRAM 153
FUNCTION OF AUTO-DECELERATION SYSTEM 153
OPERATION OF AUTO-DECELERATION SYSTEM. 154
AUTOMATIC LOW IDLE SYSTEM. 155
AUTOMATIC LOW IDLE SYSTEM DIAGRAM. 155
FUNCTION OF AUTOMATIC LOW IDLE SYSTEM. 155
OPERATION OF AUTOMATIC LOW IDLE SYSTEM 156
ENGINE AUTOMATIC WARM-UP SYSTEM. 157
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM. 157
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM. 159
OVERHEAT PREVENTION SYSTEM 160
OVERHEAT PREVENTION SYSTEM DIAGRAM 160
FUNCTION OF OVERHEAT PREVENTION SYSTEM 161
TURBOCHARGER PROTECTION SYSTEM 162
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 162
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 163
AUTOMATIC IDLE STOP SYSTEM 164
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 164
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 164
COMPONENT PARTS OF ENGINE SYSTEM 167
PTO. 167
VGT. 168
EGR SYSTEM 172
EGR VALVE. 174
EGR COOLER 176
KCCV SYSTEM. 177
KCCV VENTILATOR. 179
KDPF 181
COOLING SYSTEM 185
LAYOUT DRAWING OF COOLING SYSTEM 185
SPECIFICATIONS OF COOLING SYSTEM 186
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN. 187
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN. 187
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN. 188
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN. 189
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN. 189
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN. 189
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 191
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN 191
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 191
COMPONENT PARTS OF COOLING SYSTEM. 192
COOLING FAN PUMP 192
COOLING FAN MOTOR. 200
CONTROL SYSTEM 207
LAYOUT DRAWING OF CONTROL SYSTEM 207
MACHINE MONITOR SYSTEM 209
MACHINE MONITOR SYSTEM DIAGRAM 209
FUNCTION OF MACHINE MONITOR SYSTEM 209
KomVision SYSTEM 211
LAYOUT DRAWING OF KOMVISION SYSTEM 211
KomVision SYSTEM DIAGRAM 213
FUNCTION OF KomVision SYSTEM 214
KOMTRAX SYSTEM 216
KOMTRAX SYSTEM DIAGRAM 216
FUNCTION OF KOMTRAX SYSTEM 216
COMPONENT PARTS OF CONTROL SYSTEM. 217
MACHINE MONITOR. 217
KomVision CONTROLLER 232
KomVision CAMERA 236
KOMTRAX TERMINAL 237
PUMP CONTROLLER. 239
RESISTOR FOR TVC VALVE 244
CAN TERMINATING RESISTOR 245
ENGINE CONTROLLER. 246
FUEL CONTROL DIAL. 253
FUEL FEED PUMP 255
FUEL FEED PUMP SWITCH. 256
HYDRAULIC SYSTEM 257
LAYOUT DRAWING OF HYDRAULIC SYSTEM 257
OLSS 260
STRUCTURE OF OLSS. 260
FUNCTION OF OLSS 260
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL. 262
ENGINE AND PUMP COMBINED CONTROL SYSTEM. 273
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM. 273
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM. 275
COMPONENT PARTS OF HYDRAULIC SYSTEM. 278
HYDRAULIC TANK 278
MAIN PUMP. 280
CONTROL VALVE. 308
VARIABLE BACK PRESSURE VALVE 329
WORK EQUIPMENT SYSTEM. 332
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM. 332
ONE-TOUCH POWER MAXIMIZING SYSTEM. 338
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM. 338
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM. 339
MACHINE PUSH-UP SYSTEM 340
MACHINE PUSH-UP SYSTEM DIAGRAM 340
FUNCTION OF MACHINE PUSH-UP SYSTEM 341
BOOM SHOCKLESS CONTROL FUNCTION. 342
BOOM SHOCKLESS CONTROL FUNCTION SYSTEM DIAGRAM 342
OPERATION OF BOOM SHOCKLESS CONTROL FUNCTION 342
PPC LOCK SYSTEM. 343
PPC LOCK SYSTEM DIAGRAM. 343
FUNCTION OF PPC LOCK SYSTEM. 343
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM. 344
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM. 344
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM. 344
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 345
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 346
WORK EQUIPMENT AND SWING PPC VALVE 346
1ST-LINE ATTACHMENT PPC VALVE. 351
PPC SHUTTLE VALVE. 353
SOLENOID VALVE 354
PILOT CIRCUIT ACCUMULATOR. 357
SWING SYSTEM 358
LAYOUT DRAWING OF SWING SYSTEM 358
SWING CONTROL SYSTEM DIAGRAM 361
FUNCTION OF SWING CONTROL SYSTEM 362
COMPONENT PARTS OF SWING SYSTEM. 365
SWING MOTOR. 365
SWING MACHINERY. 377
SWING CIRCLE 379
TRAVEL SYSTEM. 380
LAYOUT DRAWING OF TRAVEL SYSTEM. 380
TRAVEL CONTROL SYSTEM DIAGRAM. 384
FUNCTION OF TRAVEL CONTROL SYSTEM. 386
COMPONENT PARTS OF TRAVEL SYSTEM 387
TRAVEL MOTOR 387
FINAL DRIVE. 400
TRAVEL PPC VALVE 402
CENTER SWIVEL JOINT. 406
UNDERCARRIAGE AND FRAME. 408
LAYOUT DRAWING OF UNDERCARRIAGE. 408
SPECIFICATIONS OF UNDERCARRIAGE. 408
WORK EQUIPMENT 409
STRUCTURE OF WORK EQUIPMENT. 409
FUNCTION OF WORK EQUIPMENT 410
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 411
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 411
BUCKET CLEARANCE ADJUSTMENT SHIM 412
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 412
CAB AND ITS ATTACHMENTS. 413
ROPS CAB 413
STRUCTURE OF ROPS CAB. 413
FUNCTION OF ROPS CAB 413
CAB MOUNT. 414
STRUCTURE OF CAB MOUNT 414
FUNCTION OF CAB MOUNT. 414
CAB TIPPING STOPPER. 415
STRUCTURE OF CAB TIPPING STOPPER 415
FUNCTION OF CAB TIPPING STOPPER. 415
20 STANDARD VALUE TABLE. 417
CONTENTS 418
ABBREVIATION LIST. 419
STANDARD VALUE TABLE FOR ENGINE. 425
STANDARD VALUE TABLE FOR ENGINE: PC650LC-11. 425
STANDARD VALUE TABLE FOR MACHINE 430
STANDARD VALUE TABLE FOR MACHINE: PC650LC-11 430
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE. 447
30 TESTING AND ADJUSTING 451
CONTENTS 452
ABBREVIATION LIST. 455
RELATED INFORMATION ON TESTING AND ADJUSTING 461
TOOLS FOR TESTING AND ADJUSTING. 461
SKETCH OF TOOLS FOR TESTING AND ADJUSTING. 470
ENGINE AND COOLING SYSTEM. 471
TEST ENGINE SPEED. 471
METHOD FOR TESTING ENGINE SPEED. 471
TEST BOOST PRESSURE. 474
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 474
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL. 475
TEST EXHAUST GAS TEMPERATURE 476
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 476
TEST EXHAUST GAS COLOR 478
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER. 478
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER. 479
TEST AND ADJUST VALVE CLEARANCE. 481
METHOD FOR TESTING VALVE CLEARANCE 481
METHOD FOR ADJUSTING VALVE CLEARANCE 482
TEST COMPRESSION PRESSURE. 484
METHOD FOR TESTING COMPRESSION PRESSURE. 484
TEST BLOWBY PRESSURE 487
METHOD FOR TESTING BLOWBY PRESSURE 487
TEST ENGINE OIL PRESSURE 489
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR. 489
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 489
TEST EGR VALVE AND VGT OIL PRESSURE. 491
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE. 491
TEST FUEL PRESSURE 493
METHOD FOR TESTING FUEL PRESSURE 493
TEST FUEL RETURN RATE AND LEAKAGE. 495
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE. 495
BLEED AIR FROM FUEL SYSTEM 498
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 498
TEST FUEL CIRCUIT FOR LEAKAGE. 500
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE. 500
HANDLE CYLINDER CUT-OUT MODE OPERATION 502
HANDLE NO-INJECTION CRANKING OPERATION 503
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION. 504
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT. 504
CLEAN FUEL DOSER 505
METHOD FOR CLEANING FUEL DOSER 505
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 507
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 507
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 513
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER. 513
TEST SCR RELATED FUNCTIONS 514
TEST AdBlue/DEF PUMP RAISED PRESSURE 518
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 521
TEST AdBlue/DEF LINE HEATER RELAY 1. 526
TEST AdBlue/DEF LINE HEATER RELAY 2. 530
TEST AdBlue/DEF PUMP HEATER RELAY. 533
TEST AdBlue/DEF TANK HEATER VALVE. 536
TEST DENITRATION EFFICIENCY OF SCR 539
CLEAN AdBlue/DEF TANK. 543
METHOD FOR CLEANING AdBlue/DEF TANK. 543
POWER TRAIN. 547
TEST SWING CIRCLE BEARING CLEARANCE. 547
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE. 547
UNDERCARRIAGE AND FRAME. 548
TEST AND ADJUST TRACK TENSION. 548
METHOD FOR TESTING TRACK TENSION 548
METHOD FOR ADJUSTING TRACK TENSION 548
HYDRAULIC SYSTEM 550
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 550
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 550
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 559
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT. 559
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 560
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS. 563
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS. 571
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT. 575
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 575
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 576
TEST AND ADJUST PISTON PUMP CONTROL OIL PRESSURE 577
METHOD FOR TESTING TVC VALVE OUTLET PRESSURE 577
METHOD FOR TESTING CO AND NC VALVE OUTLET PRESSURE 578
METHOD FOR TESTING JET SENSOR OUTLET PRESSURE. 579
METHOD FOR ADJUSTING TVC VALVE 581
METHOD FOR ADJUSTING CO AND NC VALVE 582
METHOD FOR ADJUSTING JET SENSOR. 583
TEST SERVO PISTON STROKE 584
METHOD FOR TESTING SERVO PISTON STROKE 584
TEST OUTLET PRESSURE OF SOLENOID VALVE 586
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 586
OPERATING CONDITION OF SOLENOID VALVE. 587
TEST PPC VALVE OUTLET PRESSURE 590
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 590
TEST PPC SHUTTLE VALVE OUTLET PRESSURE 592
METHOD FOR TESTING PPC SHUTTLE VALVE OUTLET PRESSURE 592
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 596
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 596
TEST AND ADJUST TRAVEL DEVIATION 597
METHOD FOR TESTING TRAVEL DEVIATION. 597
METHOD FOR ADJUSTING TRAVEL DEVIATION. 597
TEST COOLING FAN SPEED 599
METHOD FOR TESTING COOLING FAN SPEED 599
TEST OIL PRESSURE IN FAN PUMP CIRCUIT. 600
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT. 600
TEST FAN PUMP EPC ELECTRIC CURRENT 601
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 601
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 602
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 602
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 603
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER. 603
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 603
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE. 604
TEST OIL LEAKAGE 605
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER. 605
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 606
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER. 606
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR. 607
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 607
METHOD FOR TESTING OIL LEAKAGE OF SWIVEL JOINT 608
BLEED AIR FROM HYDRAULIC CIRCUIT 610
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 611
CAB AND ITS ATTACHMENTS. 614
TEST CAB TIPPING STOPPER 614
METHOD FOR TESTING CAB TIPPING STOPPER 614
METHOD FOR ADJUSTING MIRRORS 615
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A). 615
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A). 616
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 617
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 618
ELECTRICAL SYSTEM. 620
SET AND OPERATE MACHINE MONITOR. 620
OPERATOR MODE. 624
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN. 624
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 624
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY). 625
CHECKING FUNCTION OF SERVICE METER 625
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD. 625
SERVICE MODE 628
METHOD FOR OPERATING SERVICE MODE. 628
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 630
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 636
ABNORMALITY RECORD MENU. 648
METHOD FOR CONFIRMING MAINTENANCE RECORD 652
METHOD FOR OPERATING MAINTENANCE MODE SETTING. 653
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING. 657
DEFAULT MENU 659
DIAGNOSTIC TESTS MENU. 665
ADJUSTMENT MENU. 675
METHOD FOR PERFORMING NO-INJECTION CRANKING. 678
KOMTRAX SETTINGS MENU. 680
METHOD FOR DISPLAYING SERVICE MESSAGE. 682
METHOD FOR STARTING UP KOMTRAX TERMINAL. 684
ADJUST REARVIEW CAMERA ANGLE 689
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE. 689
ADJUST KomVision CAMERA ANGLE. 691
METHOD FOR ADJUSTING KomVision CAMERA ANGLE. 692
ADJUST KomVision RELATED ITEMS 694
SETTING OF KomVision (MAIN SETTING). 695
SETTING OF KomVision (CAMERA SETTING). 697
SETTING OF KomVision (CAMERA CALIBRATION). 698
KomVision screen – Check 12 m visibility 711
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER. 714
HANDLE BATTERY DISCONNECT SWITCH 715
TEST DIODES. 716
METHOD FOR TESTING DIODE USING DIGITAL TESTER. 716
METHOD FOR TESTING DIODE USING ANALOG TESTER 716
Pm CLINIC. 717
Pm CLINIC SERVICE. 717
Pm CLINIC CHECK SHEET: PC650LC-11. 721
40 TROUBLESHOOTING 737
CONTENTS 738
ABBREVIATION LIST. 749
RELATED INFORMATION ON TROUBLESHOOTING 755
GENERAL TROUBLESHOOTING POINTS 755
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 756
SEQUENCE OF EVENTS IN TROUBLESHOOTING. 768
CHECKS BEFORE TROUBLESHOOTING. 770
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING. 772
WALK-AROUND CHECK. 772
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 774
CHECK FUEL LEVEL AND TYPE. 774
CHECK IMPURE INGREDIENT IN FUEL. 775
CHECK FUEL PREFILTER 775
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 775
FUEL PREFILTER CARTRIDGE – REPLACE 776
CHECK MAIN FILTER. 777
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 778
CHECK COOLANT LEVEL (RESERVOIR TANK) 780
CHECK CLOGGING OF AIR CLEANER. 780
OUTER ELEMENT – CLEAN. 780
ELEMENTS – REPLACE 783
CHECK HYDRAULIC OIL LEVEL. 783
CHECK HYDRAULIC OIL STRAINER 785
CHECK HYDRAULIC FILTER 785
CHECK OIL LEVEL IN SWING MACHINERY CASE. 786
CHECK OIL LEVEL IN PTO CASE. 787
CHECK PTO LUBRICATION FILTER STRAINER. 787
CHECK OIL LEVEL IN FINAL DRIVE CASE. 788
BLEED AIR FROM FUEL SYSTEM 788
BLEED AIR FROM HYDRAULIC SYSTEM. 789
ELECTRICAL EQUIPMENT – CHECK METHOD. 789
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 795
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 795
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 795
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 795
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL. 795
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK. 796
PROCEDURE FOR TESTING AND TROUBLESHOOTING. 800
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS. 803
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 807
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM. 809
CONNECTOR LIST AND LAYOUT. 812
CONNECTOR CONTACT IDENTIFICATION 826
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE. 866
FUSE LOCATION TABLE. 872
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC). 875
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]). 879
FAILURE CODES TABLE. 881
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE). 898
FAILURE CODE [879AKA]. 898
FAILURE CODE [879AKB]. 899
FAILURE CODE [879BKA]. 900
FAILURE CODE [879BKB]. 902
FAILURE CODE [879CKA]. 904
FAILURE CODE [879CKB]. 905
FAILURE CODE [879DKZ]. 906
FAILURE CODE [879EMC]. 908
FAILURE CODE [879FMC]. 909
FAILURE CODE [879GKX]. 910
FAILURE CODE [989L00]. 912
FAILURE CODE [989M00]. 913
FAILURE CODE [989N00]. 914
FAILURE CODE [A1U0N3]. 915
FAILURE CODE [A1U0N4]. 917
FAILURE CODE [A900FR]. 919
FAILURE CODE [A900N6]. 920
FAILURE CODE [A900NY]. 921
FAILURE CODE [AA10NX]. 922
FAILURE CODE [AB00KE]. 924
FAILURE CODE [AQ10N3]. 926
FAILURE CODE [AS00N3]. 928
FAILURE CODE [AS00R2]. 930
FAILURE CODE [AS00R3]. 931
FAILURE CODE [AS00R4]. 932
FAILURE CODE [AS00R5]. 933
FAILURE CODE [AS00R6]. 934
FAILURE CODE [AS00ZK]. 935
FAILURE CODE [AS10KM]. 936
FAILURE CODE [AS10NR]. 937
FAILURE CODE [AS10NT]. 938
FAILURE CODE [B@BAZG]. 939
FAILURE CODE [B@BAZK]. 940
FAILURE CODE [B@BCNS]. 942
FAILURE CODE [B@BCQA]. 943
FAILURE CODE [B@BCZK]. 945
FAILURE CODE [B@HANS]. 947
FAILURE CODE [CA115] 948
FAILURE CODE [CA122] 949
FAILURE CODE [CA123] 951
FAILURE CODE [CA131] 953
FAILURE CODE [CA132] 955
FAILURE CODE [CA135] 957
FAILURE CODE [CA141] 959
FAILURE CODE [CA144] 961
FAILURE CODE [CA145] 963
FAILURE CODE [CA153] 965
FAILURE CODE [CA154] 968
FAILURE CODE [CA187] 971
FAILURE CODE [CA221] 973
FAILURE CODE [CA222] 975
FAILURE CODE [CA227] 977
FAILURE CODE [CA234] 978
FAILURE CODE [CA238] 979
FAILURE CODE [CA239] 981
FAILURE CODE [CA249] 983
FAILURE CODE [CA256] 985
FAILURE CODE [CA271] 987
FAILURE CODE [CA272] 989
FAILURE CODE [CA273] 990
FAILURE CODE [CA274] 992
FAILURE CODE [CA322] 993
FAILURE CODE [CA323] 995
FAILURE CODE [CA324] 997
FAILURE CODE [CA325] 999
FAILURE CODE [CA331]1001
FAILURE CODE [CA332]1003
FAILURE CODE [CA343]1005
FAILURE CODE [CA351]1006
FAILURE CODE [CA352]1007
FAILURE CODE [CA356]1010
FAILURE CODE [CA357]1012
FAILURE CODE [CA386]1014
FAILURE CODE [CA441]1015
FAILURE CODE [CA442]1017
FAILURE CODE [CA449]1018
FAILURE CODE [CA451]1019
FAILURE CODE [CA452]1021
FAILURE CODE [CA515]1023
FAILURE CODE [CA516]1025
FAILURE CODE [CA553]1027
FAILURE CODE [CA555]1028
FAILURE CODE [CA556]1029
FAILURE CODE [CA559]1030
FAILURE CODE [CA595]1035
FAILURE CODE [CA687]1036
FAILURE CODE [CA689]1038
FAILURE CODE [CA691]1040
FAILURE CODE [CA692]1042
FAILURE CODE [CA697]1044
FAILURE CODE [CA698]1045
FAILURE CODE [CA731]1046
FAILURE CODE [CA778]1047
FAILURE CODE [CA1117].1050
FAILURE CODE [CA1664].1051
FAILURE CODE [CA1669].1055
FAILURE CODE [CA1673].1056
FAILURE CODE [CA1677].1057
FAILURE CODE [CA1678].1058
FAILURE CODE [CA1682].1059
FAILURE CODE [CA1683].1061
FAILURE CODE [CA1684].1063
FAILURE CODE [CA1686].1065
FAILURE CODE [CA1691].1066
FAILURE CODE [CA1694].1069
FAILURE CODE [CA1695].1071
FAILURE CODE [CA1696].1072
FAILURE CODE [CA1712].1074
FAILURE CODE [CA1713].1077
FAILURE CODE [CA1714].1080
FAILURE CODE [CA1715].1081
FAILURE CODE [CA1776].1082
FAILURE CODE [CA1777].1085
FAILURE CODE [CA1843].1088
FAILURE CODE [CA1844].1090
FAILURE CODE [CA1879].1093
FAILURE CODE [CA1881].1096
FAILURE CODE [CA1883].1098
FAILURE CODE [CA1885].1102
FAILURE CODE [CA1887].1104
FAILURE CODE [CA1921].1106
FAILURE CODE [CA1922].1109
FAILURE CODE [CA1923].1115
FAILURE CODE [CA1924].1117
FAILURE CODE [CA1925].1119
FAILURE CODE [CA1927].1121
FAILURE CODE [CA1928].1123
FAILURE CODE [CA1942].1125
FAILURE CODE [CA1963].1126
FAILURE CODE [CA1977].1130
FAILURE CODE [CA1993].1133
FAILURE CODE [CA2185].1136
FAILURE CODE [CA2186].1138
FAILURE CODE [CA2249].1140
FAILURE CODE [CA2265].1141
FAILURE CODE [CA2266].1143
FAILURE CODE [CA2271].1145
FAILURE CODE [CA2272].1147
FAILURE CODE [CA2349].1149
FAILURE CODE [CA2353].1151
FAILURE CODE [CA2357].1153
FAILURE CODE [CA2381].1154
FAILURE CODE [CA2382].1156
FAILURE CODE [CA2383].1158
FAILURE CODE [CA2386].1160
FAILURE CODE [CA2387].1162
FAILURE CODE [CA2555].1163
FAILURE CODE [CA2556].1165
FAILURE CODE [CA2637].1167
FAILURE CODE [CA2639].1169
FAILURE CODE [CA2732].1171
FAILURE CODE [CA2733].1173
FAILURE CODE [CA2741].1175
FAILURE CODE [CA2765].1176
FAILURE CODE [CA2771].1177
FAILURE CODE [CA2777].1183
FAILURE CODE [CA2878].1186
FAILURE CODE [CA2881].1189
FAILURE CODE [CA2976].1192
FAILURE CODE [CA3133].1194
FAILURE CODE [CA3134].1196
FAILURE CODE [CA3135].1198
FAILURE CODE [CA3142].1201
FAILURE CODE [CA3143].1202
FAILURE CODE [CA3144].1203
FAILURE CODE [CA3146].1205
FAILURE CODE [CA3147].1206
FAILURE CODE [CA3148].1207
FAILURE CODE [CA3151].1209
FAILURE CODE [CA3165].1214
FAILURE CODE [CA3167].1216
FAILURE CODE [CA3229].1220
FAILURE CODE [CA3231].1223
FAILURE CODE [CA3232].1226
FAILURE CODE [CA3235].1231
FAILURE CODE [CA3239].1233
FAILURE CODE [CA3241].1236
FAILURE CODE [CA3242].1239
FAILURE CODE [CA3251].1242
FAILURE CODE [CA3253].1246
FAILURE CODE [CA3254].1252
FAILURE CODE [CA3255].1256
FAILURE CODE [CA3256].1259
FAILURE CODE [CA3311].1262
FAILURE CODE [CA3312].1265
FAILURE CODE [CA3313].1268
FAILURE CODE [CA3314].1269
FAILURE CODE [CA3315].1270
FAILURE CODE [CA3316].1273
FAILURE CODE [CA3317].1274
FAILURE CODE [CA3318].1275
FAILURE CODE [CA3319].1278
FAILURE CODE [CA3321].1279
FAILURE CODE [CA3322].1280
FAILURE CODE [CA3419].1283
FAILURE CODE [CA3421].1285
FAILURE CODE [CA3497].1287
FAILURE CODE [CA3498].1288
FAILURE CODE [CA3543].1289
FAILURE CODE [CA3545].1294
FAILURE CODE [CA3547].1296
FAILURE CODE [CA3558].1297
FAILURE CODE [CA3559].1299
FAILURE CODE [CA3562].1301
FAILURE CODE [CA3563].1303
FAILURE CODE [CA3567].1306
FAILURE CODE [CA3568].1309
FAILURE CODE [CA3571].1313
FAILURE CODE [CA3572].1315
FAILURE CODE [CA3574].1317
FAILURE CODE [CA3575].1320
FAILURE CODE [CA3577].1322
FAILURE CODE [CA3578].1324
FAILURE CODE [CA3582].1326
FAILURE CODE [CA3583].1331
FAILURE CODE [CA3596].1333
FAILURE CODE [CA3649].1337
FAILURE CODE [CA3681].1340
FAILURE CODE [CA3682].1345
FAILURE CODE [CA3713].1351
FAILURE CODE [CA3717].1354
FAILURE CODE [CA3718].1355
FAILURE CODE [CA3725].1356
FAILURE CODE [CA3748].1359
FAILURE CODE [CA3751].1361
FAILURE CODE [CA3755].1363
FAILURE CODE [CA3866].1365
FAILURE CODE [CA3867].1369
FAILURE CODE [CA3868].1372
FAILURE CODE [CA3899].1376
FAILURE CODE [CA3911].1379
FAILURE CODE [CA3912].1383
FAILURE CODE [CA3932].1385
FAILURE CODE [CA3933].1387
FAILURE CODE [CA3934].1389
FAILURE CODE [CA3935].1392
FAILURE CODE [CA3936].1394
FAILURE CODE [CA4151].1396
FAILURE CODE [CA4152].1400
FAILURE CODE [CA4155].1404
FAILURE CODE [CA4156].1406
FAILURE CODE [CA4157].1409
FAILURE CODE [CA4158].1411
FAILURE CODE [CA4159].1413
FAILURE CODE [CA4161].1415
FAILURE CODE [CA4162].1418
FAILURE CODE [CA4163].1421
FAILURE CODE [CA4164].1423
FAILURE CODE [CA4165].1426
FAILURE CODE [CA4166].1429
FAILURE CODE [CA4168].1432
FAILURE CODE [CA4169].1437
FAILURE CODE [CA4171].1442
FAILURE CODE [CA4249].1447
FAILURE CODE [CA4251].1451
FAILURE CODE [CA4259].1455
FAILURE CODE [CA4261].1458
FAILURE CODE [CA4277].1461
FAILURE CODE [CA4281].1465
FAILURE CODE [CA4459].1468
FAILURE CODE [CA4461].1471
FAILURE CODE [CA4658].1474
FAILURE CODE [CA4731].1478
FAILURE CODE [CA4732].1479
FAILURE CODE [CA4739].1480
FAILURE CODE [CA4768].1481
FAILURE CODE [CA4769].1483
FAILURE CODE [CA4842].1486
FAILURE CODE [CA4952].1490
FAILURE CODE [CA5115].1492
FAILURE CODE [CA5179].1495
FAILURE CODE [CA5181].1497
FAILURE CODE [CA5383].1499
FAILURE CODE [D110KB].1501
FAILURE CODE [D163KB].1503
FAILURE CODE [D195KA].1505
FAILURE CODE [D195KB].1507
FAILURE CODE [D19JKZ].1509
FAILURE CODE [D811MC].1511
FAILURE CODE [D862KA].1512
FAILURE CODE [D8ALKA].1513
FAILURE CODE [D8ALKB].1515
FAILURE CODE [D8AQKR].1517
FAILURE CODE [DA20MC].1521
FAILURE CODE [DA22KK].1522
FAILURE CODE [DA25KP].1524
FAILURE CODE [DA26KP].1526
FAILURE CODE [DA29KQ].1529
FAILURE CODE [DA2LKA].1531
FAILURE CODE [DA2LKB].1533
FAILURE CODE [DA2QKR].1535
FAILURE CODE [DA2RKR].1540
FAILURE CODE [DAF0KM].1545
FAILURE CODE [DAF0MB].1546
FAILURE CODE [DAF0MC].1547
FAILURE CODE [DAF8KB].1548
FAILURE CODE [DAF9KQ].1549
FAILURE CODE [DAFGMC].1550
FAILURE CODE [DAFLKA].1551
FAILURE CODE [DAFLKB].1553
FAILURE CODE [DAFQKR].1555
FAILURE CODE [DAZ9KQ].1559
FAILURE CODE [DAZQKR].1560
FAILURE CODE [DB2QKR].1564
FAILURE CODE [DB2RKR].1569
FAILURE CODE [DBP0KM].1574
FAILURE CODE [DBP0KT].1575
FAILURE CODE [DBPQKR].1576
FAILURE CODE [DDNRKA].1581
FAILURE CODE [DDNRKY].1583
FAILURE CODE [DDNS00].1585
FAILURE CODE [DGE5KB].1587
FAILURE CODE [DGH2KA].1588
FAILURE CODE [DGH2KB].1590
FAILURE CODE [DHA4KA].1592
FAILURE CODE [DHAAMA].1594
FAILURE CODE [DHACMA].1596
FAILURE CODE [DHPAMA].1598
FAILURE CODE [DHPBMA].1600
FAILURE CODE [DHS3MA].1602
FAILURE CODE [DHS4MA].1605
FAILURE CODE [DHS8MA].1608
FAILURE CODE [DHS9MA].1611
FAILURE CODE [DHSAMA].1614
FAILURE CODE [DHSBMA].1617
FAILURE CODE [DHSCMA].1620
FAILURE CODE [DHSDMA].1623
FAILURE CODE [DHSFMA].1626
FAILURE CODE [DHSGMA].1629
FAILURE CODE [DHSHMA].1632
FAILURE CODE [DHSJMA].1635
FAILURE CODE [DHSVMA].1638
FAILURE CODE [DKULKA].1640
FAILURE CODE [DKULKB].1642
FAILURE CODE [DKULKY].1644
FAILURE CODE [DLM3KA].1646
FAILURE CODE [DLM3KB].1648
FAILURE CODE [DLM3MB].1650
FAILURE CODE [DR10KA].1651
FAILURE CODE [DR21KX].1654
FAILURE CODE [DR31KX].1656
FAILURE CODE [DUMBKA].1658
FAILURE CODE [DUMBKB].1660
FAILURE CODE [DV20KB].1662
FAILURE CODE [DW43KA].1663
FAILURE CODE [DW43KB].1665
FAILURE CODE [DW43KY].1667
FAILURE CODE [DW45KA].1668
FAILURE CODE [DW45KB].1671
FAILURE CODE [DW45KY].1674
FAILURE CODE [DW48KA].1676
FAILURE CODE [DW48KB].1678
FAILURE CODE [DW48KY].1680
FAILURE CODE [DW4CKY].1681
FAILURE CODE [DW4XKA].1683
FAILURE CODE [DW4XKB].1685
FAILURE CODE [DW4XKY].1687
FAILURE CODE [DW7BKA].1688
FAILURE CODE [DW7BKB].1690
FAILURE CODE [DW7BKY].1692
FAILURE CODE [DWK0KA].1693
FAILURE CODE [DWK0KB].1695
FAILURE CODE [DWK0KY].1697
FAILURE CODE [DWK2KA].1698
FAILURE CODE [DWK2KB].1700
FAILURE CODE [DWK2KY].1702
FAILURE CODE [DWK8KA].1703
FAILURE CODE [DWK8KB].1705
FAILURE CODE [DWK8KY].1707
FAILURE CODE [DX16KA].1708
FAILURE CODE [DX16KB].1710
FAILURE CODE [DXA2KA].1711
FAILURE CODE [DXA2KB].1714
FAILURE CODE [DXA3KA].1716
FAILURE CODE [DXA3KB].1719
FAILURE CODE [DY20KA].1721
FAILURE CODE [DY20MA].1723
FAILURE CODE [DY2CKB].1725
FAILURE CODE [DY2DKB].1727
FAILURE CODE [DY2EKB].1729
FAILURE CODE [DY2FMA].1731
FAILURE CODE [DY2GKM].1733
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).1735
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK).1735
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1741
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK.1744
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP.1746
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING.1748
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW1751
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW1752
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING.1753
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1754
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING.1755
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1756
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1757
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1758
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.1759
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.1760
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.1761
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL.1763
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.1764
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE1765
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1766
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE.1768
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED.1769
E-23 FUNCTION SWITCH DOES NOT OPERATE.1770
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER).1771
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF1772
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER1773
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED.1774
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED1775
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE.1776
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE1777
E-31 ALARM BUZZER CANNOT BE CANCELED1778
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION.1779
E-33 SERVICE MODE CANNOT BE SELECTED1780
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE1781
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK.1784
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING.1786
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE.1789
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR.1791
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED.1793
E-40 ALARM DOES NOT SOUND DURING TRAVEL.1794
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED1796
E-42 HORN DOES NOT SOUND1797
E-43 HORN DOES NOT STOP SOUNDING1800
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF.1802
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE.1803
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE1805
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1806
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1807
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.1808
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1809
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.1810
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.1811
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.1812
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1813
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.1814
E-56 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY.1816
E-57 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED1817
E-58 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE1819
E-59 STEP LIGHT DOES NOT LIGHT UP.1820
E-60 STEP LIGHT DOES NOT GO OUT.1822
E-61 BOOM SHOCKLESS FUNCTION CANNOT BE CANCELED.1824
E-62 BOOM SHOCKLESS FUNCTION DOES NOT WORK1826
E-63 ELECTRIC GREASE GUN DOES NOT WORK1827
E-64 ELECTRIC GREASE GUN DOES NOT STOP1829
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).1830
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK1830
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER.1831
H-3 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP.1833
H-4 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS1834
H-5 TRAVEL SPEED OR POWER IS LOW1835
H-6 AUTO-DECELERATION FUNCTION CANNOT BE CANCELED.1836
H-7 SPEED OR POWER OF BOOM IS LOW.1837
H-8 ARM SPEED OR POWER IS LOW.1839
H-9 BUCKET SPEED OR POWER IS LOW1840
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION.1841
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE.1842
H-12 HYDRAULIC DRIFT OF ARM IS LARGE1843
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE.1844
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE1845
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE.1846
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE1847
H-17 MACHINE DOES NOT TRAVEL STRAIGHT.1848
H-18 SPEED OF BOOM AND BUCKET IS SLOW AT COMBINED OPERATION OF ARM, BOOM AND BUCKET.1849
H-19 SPEED OF BOOM, ARM, SWING AND TRAVEL IS SLOW AT COMBINED OPERATION OF BUCKET, BOOM AND ARM.1850
H-20 SWING SPEED IS SLOW AT COMBINED OPERATION OF ARM AND SWING.1851
H-21 TRAVEL DEVIATION IS LARGE AT START OF TRAVELING1852
H-22 TRAVEL DEVIATION IS LARGE AT COMBINED OPERATION1854
H-23 ONE OF TRACKS DOES NOT RUN.1855
H-24 TRAVEL SPEED DOES NOT CHANGE.1857
H-25 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT1858
H-26 SWINGS ONLY IN ONE DIRECTION.1859
H-27 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT).1860
H-28 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION1861
H-29 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)1862
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)1863
H-31 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING.1864
H-32 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING.1865
H-33 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED).1866
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)1867
H-35 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY).1868
H-36 UNUSUAL NOISE IS HEARD FROM AROUND FAN.1869
TROUBLESHOOTING OF ENGINE (S-MODE)1870
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE).1870
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION1871
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT1872
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)1873
S-4 ENGINE STARTABILITY IS POOR.1874
S-5 ENGINE DOES NOT PICK UP SMOOTHLY1876
S-6 ENGINE STOPS DURING OPERATION.1878
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE1880
S-8 ENGINE LACKS POWER1881
S-9 KDPF GETS CLOGGED IN A SHORT TIME.1883
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE1885
S-11 OIL BECOMES CONTAMINATED QUICKLY.1886
S-12 FUEL CONSUMPTION IS EXCESSIVE1887
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)1888
S-14 OIL PRESSURE DROPS.1889
S-15 FUEL MIXES INTO ENGINE OIL.1891
S-16 WATER MIXES INTO ENGINE OIL (MILKY)1892
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING).1893
S-18 UNUSUAL NOISE IS HEARD.1894
S-19 VIBRATION IS EXCESSIVE.1895
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.1896
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY.1897
S-22 ACTIVE REGENERATION TAKES TIME.1899
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION1901
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE1902
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR).1904
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)1905
50 DISASSEMBLY AND ASSEMBLY.1907
CONTENTS1908
ABBREVIATION LIST.1913
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY.1919
HOW TO READ THIS MANUAL.1919
COATING MATERIALS LIST1921
SPECIAL TOOLS LIST1925
SKETCHES OF SPECIAL TOOLS.1942
ENGINE AND COOLING SYSTEM.1949
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY.1949
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY1949
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY1951
REMOVE AND INSTALL INJECTOR ASSEMBLY1956
METHOD FOR REMOVING INJECTOR ASSEMBLY.1956
METHOD FOR INSTALLING INJECTOR ASSEMBLY.1961
REMOVE AND INSTALL FUEL DOSER ASSEMBLY1970
METHOD FOR REMOVING FUEL DOSER ASSEMBLY.1970
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY.1971
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY.1973
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY1974
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY1984
REMOVE AND INSTALL EGR VALVE ASSEMBLY.2001
METHOD FOR REMOVING EGR VALVE ASSEMBLY2001
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2003
REMOVE AND INSTALL EGR COOLER ASSEMBLY2005
METHOD FOR REMOVING EGR COOLER ASSEMBLY.2005
METHOD FOR INSTALLING EGR COOLER ASSEMBLY.2008
REMOVE AND INSTALL STARTER ASSEMBLY.2012
METHOD FOR REMOVING STARTER ASSEMBLY2012
METHOD FOR INSTALLING STARTER ASSEMBLY2012
REMOVE AND INSTALL ALTERNATOR BELT2014
METHOD FOR REMOVING ALTERNATOR BELT.2014
METHOD FOR INSTALLING ALTERNATOR BELT.2015
REMOVE AND INSTALL RADIATOR ASSEMBLY2017
METHOD FOR REMOVING RADIATOR ASSEMBLY.2017
METHOD FOR INSTALLING RADIATOR ASSEMBLY.2020
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2024
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY.2024
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY.2027
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY.2031
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2031
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2033
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY.2036
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY2036
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY2045
REMOVE AND INSTALL ENGINE PTO AND HYDRAULIC ASSEMBLY2054
METHOD FOR REMOVING ENGINE PTO AND HYDRAULIC ASSEMBLY.2054
METHOD FOR INSTALLING ENGINE PTO AND HYDRAULIC ASSEMBLY.2065
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2076
METHOD FOR REMOVING ENGINE FRONT OIL SEAL.2076
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL.2077
REMOVE AND INSTALL ENGINE REAR OIL SEAL.2080
METHOD FOR REMOVING ENGINE REAR OIL SEAL2080
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2082
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY.2089
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2089
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2093
REMOVE AND INSTALL FUEL TANK ASSEMBLY.2099
METHOD FOR REMOVING FUEL TANK ASSEMBLY2099
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2102
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY.2106
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2107
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2113
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.2118
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2118
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2118
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR.2120
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2120
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2120
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER.2122
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2122
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2122
REMOVE AND INSTALL KDPF ASSEMBLY2123
METHOD FOR REMOVING KDPF ASSEMBLY.2123
METHOD FOR INSTALLING KDPF ASSEMBLY.2127
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY.2136
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2137
METHOD FOR ASSEMBLING KDPF ASSEMBLY.2141
REMOVE AND INSTALL SCR ASSEMBLY.2146
METHOD FOR REMOVING SCR ASSEMBLY2146
METHOD FOR INSTALLING SCR ASSEMBLY2148
REMOVE AND INSTALL KDPF, SCR ASSEMBLY.2152
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2153
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2159
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY2171
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY.2171
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY.2173
REMOVE AND INSTALL KCCV ASSEMBLY2181
METHOD FOR REMOVING KCCV ASSEMBLY.2181
METHOD FOR INSTALLING KCCV ASSEMBLY.2182
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE.2184
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2184
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2189
REMOVE AND INSTALL AdBlue/DEF INJECTOR2196
METHOD FOR REMOVING AdBlue/DEF INJECTOR.2196
METHOD FOR INSTALLING AdBlue/DEF INJECTOR.2199
REMOVE AND INSTALL AdBlue/DEF PUMP2203
METHOD FOR REMOVING AdBlue/DEF PUMP.2203
METHOD FOR INSTALLING AdBlue/DEF PUMP.2206
REMOVE AND INSTALL AdBlue/DEF HOSE2209
METHOD FOR REMOVING AdBlue/DEF HOSE.2210
METHOD FOR INSTALLING AdBlue/DEF HOSE.2218
REMOVE AND INSTALL AIR CLEANER ASSEMBLY.2224
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2224
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2225
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2226
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY.2226
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY.2227
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY.2228
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2228
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2229
POWER TRAIN.2230
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY.2230
METHOD FOR DISASSEMBLING PTO ASSEMBLY.2230
METHOD FOR ASSEMBLING PTO ASSEMBLY2231
REMOVE AND INSTALL PTO ASSEMBLY.2234
METHOD FOR REMOVING PTO ASSEMBLY2234
METHOD FOR INSTALLING PTO ASSEMBLY2235
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2238
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.2238
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.2239
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY.2240
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY.2241
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY2246
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.2255
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY2255
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY2256
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY.2258
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY.2258
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY2262
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY2267
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY.2267
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY.2268
UNDERCARRIAGE AND FRAME.2269
DISASSEMBLE AND ASSEMBLE RECOIL SPRING2269
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING.2269
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY2270
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY2272
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY.2272
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY.2273
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY2274
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY.2274
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY.2274
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD.2276
METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD.2278
METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD2279
SEPARATION AND CONNECTION OF TRACK ASSEMBLY.2282
METHOD FOR SEPARATING TRACK ASSEMBLY2282
METHOD FOR INSTALLING TRACK ASSEMBLY2283
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY.2285
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY2285
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY2286
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY.2287
METHOD FOR DISASSEMBLING IDLER ASSEMBLY.2287
METHOD FOR ASSEMBLING IDLER ASSEMBLY2288
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY2291
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY.2291
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY2292
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2294
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2294
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY.2295
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY.2298
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY2298
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY.2299
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY.2301
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY2301
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY2302
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY.2304
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2304
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2304
HYDRAULIC SYSTEM2306
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY.2306
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY2306
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY2306
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY.2308
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY.2309
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2310
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2311
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY.2311
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY.2313
REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY2316
METHOD FOR REMOVING HYDRAULIC PUMP ASSEMBLY.2316
METHOD FOR INSTALLING HYDRAULIC PUMP ASSEMBLY.2318
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY.2324
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2324
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2327
REMOVE AND INSTALL SWING MOTOR ASSEMBLY.2331
METHOD FOR REMOVING SWING MOTOR ASSEMBLY2331
METHOD FOR INSTALLING SWING MOTOR ASSEMBLY2332
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2333
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2333
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY.2334
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2336
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY2336
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY.2337
DISASSEMBLE AND ASSEMBLE GREASE GUN ASSEMBLY2339
METHOD FOR DISASSEMBLING GREASE GUN ASSEMBLY2339
METHOD FOR ASSEMBLING GREASE GUN ASSEMBLY.2339
WORK EQUIPMENT2340
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY.2340
METHOD FOR REMOVING BUCKET CYLINDER ASSEMBLY2340
METHOD FOR INSTALLING BUCKET CYLINDER ASSEMBLY2341
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY2343
METHOD FOR REMOVING ARM CYLINDER ASSEMBLY.2343
METHOD FOR INSTALLING ARM CYLINDER ASSEMBLY.2344
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY.2346
METHOD FOR REMOVING BOOM CYLINDER ASSEMBLY2346
METHOD FOR INSTALLING BOOM CYLINDER ASSEMBLY2347
REMOVE AND INSTALL BUCKET ASSEMBLY2349
METHOD FOR REMOVING BUCKET ASSEMBLY.2349
METHOD FOR INSTALLING BUCKET ASSEMBLY.2350
REMOVE AND INSTALL ARM ASSEMBLY.2351
METHOD FOR REMOVING ARM ASSEMBLY2351
METHOD FOR INSTALLING ARM ASSEMBLY2353
REMOVE AND INSTALL BOOM ASSEMBLY2355
METHOD FOR REMOVING BOOM ASSEMBLY.2355
METHOD FOR INSTALLING BOOM ASSEMBLY.2356
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2358
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY.2358
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY.2360
2361
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY.2361
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY2362
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY.2363
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY.2364
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2366
CAB AND ITS ATTACHMENTS.2371
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2371
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY.2371
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY.2378
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS).2385
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)2387
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)2387
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY2397
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY.2397
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY.2400
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.2406
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY2406
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY2409
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2414
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY.2414
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY.2418
REMOVE AND INSTALL OPERATOR’S SEAT2424
METHOD FOR REMOVING OPERATOR’S SEAT.2424
METHOD FOR INSTALLING OPERATOR’S SEAT.2426
REMOVE AND INSTALL SEAT BELT2429
METHOD FOR REMOVING SEAT BELT.2429
METHOD FOR INSTALLING SEAT BELT.2429
REMOVE AND INSTALL FRONT WIPER ASSEMBLY.2431
METHOD FOR REMOVING FRONT WIPER ASSEMBLY2431
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY2436
ELECTRICAL SYSTEM.2445
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY.2445
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2445
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2446
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.2449
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY2449
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY2451
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY.2454
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2454
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY2456
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR.2460
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR2460
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR2461
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.2462
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR2462
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR2463
REMOVE AND INSTALL SCR TEMPERATURE SENSOR.2465
METHOD FOR REMOVING SCR TEMPERATURE SENSOR2465
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR2467
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY2469
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY.2469
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY.2470
60 MAINTENANCE STANDARD.2473
CONTENTS2474
ABBREVIATION LIST.2475
ENGINE AND COOLING SYSTEM.2481
MAINTENANCE STANDARD OF ENGINE MOUNT2481
MAINTENANCE STANDARD FOR PTO2483
MAINTENANCE STANDARD OF COOLING SYSTEM2484
MAINTENANCE STANDARD OF COOLING FAN PUMP2485
MAINTENANCE STANDARD OF SERVO VALVE.2486
MAINTENANCE STANDARD OF COOLING FAN MOTOR.2487
POWER TRAIN.2488
MAINTENANCE STANDARD OF SWING CIRCLE2488
MAINTENANCE STANDARD OF SWING MACHINERY.2489
MAINTENANCE STANDARD OF FINAL DRIVE.2491
MAINTENANCE STANDARD OF SPROCKET2493
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING.2494
UNDERCARRIAGE AND FRAME.2496
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION.2496
MAINTENANCE STANDARD OF IDLER.2498
MAINTENANCE STANDARD OF TRACK ROLLER2500
MAINTENANCE STANDARD OF CARRIER ROLLER2501
MAINTENANCE STANDARD OF TRACK SHOE2502
MAINTENANCE STANDARD OF DOUBLE SHOE.2505
MAINTENANCE STANDARD OF TRIPLE SHOE.2506
HYDRAULIC SYSTEM2507
MAINTENANCE STANDARD OF MAIN PUMP.2507
MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE.2509
MAINTENANCE STANDARD OF MAIN PUMP TVC VALVE.2511
MAINTENANCE STANDARD OF MAIN PUMP CO AND NC VALVE.2512
MAINTENANCE STANDARD OF SWING MOTOR.2513
MAINTENANCE STANDARD OF TRAVEL MOTOR2514
MAINTENANCE STANDARD OF CONTROL VALVE.2516
MAINTENANCE STANDARD OF TRAVEL SHUTTLE VALVE OF CONTROL VALVE.2523
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE VALVE2524
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE2525
MAINTENANCE STANDARD OF TRAVEL PPC VALVE2528
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE.2531
MAINTENANCE STANDARD OF SOLENOID VALVE2533
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT.2534
WORK EQUIPMENT2535
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE2535
DIMENSION OF ARM2540
DIMENSIONS OF BUCKET2542
MAINTENANCE STANDARD OF BOOM CYLINDER.2544
MAINTENANCE STANDARD OF ARM CYLINDER2545
MAINTENANCE STANDARD OF BUCKET CYLINDER.2546
80 APPENDIX.2547
CONTENTS2548
ABBREVIATION LIST.2550
AIR CONDITIONER SYSTEM2556
PRECAUTIONS FOR REFRIGERANT.2556
AIR CONDITIONER COMPONENT.2557
SPECIFICATIONS OF AIR CONDITIONER.2559
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE.2560
OUTLINE OF REFRIGERATION CYCLE2561
COMPONENT PARTS OF AIR CONDITIONER SYSTEM.2563
AIR CONDITIONER UNIT2563
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT.2563
FUNCTION OF AIR CONDITIONER UNIT2565
COMPONENT PARTS OF AIR CONDITIONER UNIT.2567
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2568
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT.2568
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT.2568
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT.2568
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2569
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT.2569
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT.2569
FUNCTION OF DUAL PRESSURE SWITCH2570
AIR CONDITIONER CONTROLLER2571
STRUCTURE OF AIR CONDITIONER CONTROLLER.2571
COMPRESSOR2572
STRUCTURE OF COMPRESSOR.2572
SPECIFICATIONS OF COMPRESSOR2572
FUNCTION OF COMPRESSOR2572
CONDENSER.2573
STRUCTURE OF CONDENSER2573
SPECIFICATIONS OF CONDENSER.2573
FUNCTION OF CONDENSER.2573
RECEIVER DRIER2574
STRUCTURE OF RECEIVER DRIER.2574
SPECIFICATIONS OF RECEIVER DRIER2574
FUNCTION OF RECEIVER DRIER2574
SENSORS FOR AIR CONDITIONER SYSTEM2575
STRUCTURE OF SUNLIGHT SENSOR2575
FUNCTION OF SUNLIGHT SENSOR.2575
STRUCTURE OF AMBIENT TEMPERATURE SENSOR.2575
FUNCTION OF AMBIENT TEMPERATURE SENSOR2575
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER.2577
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER.2579
AIR CONDITIONER SYSTEM DIAGRAM2581
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER2582
FUNCTION OF AIR CONDITIONER CONTROLLER2583
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS.2584
TESTING AIR LEAKAGE (DUCT)2588
METHOD FOR TESTING AIR LEAKAGE (DUCT).2588
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION.2590
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR2591
TEST VENT (MODE) CHANGEOVER.2592
METHOD FOR TESTING VENT (MODE) CHANGEOVER.2592
TESTING FRESH/RECIRC AIR CHANGEOVER.2594
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER2594
TEST SUNLIGHT SENSOR2595
METHOD FOR TESTING SUNLIGHT SENSOR2595
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.2596
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT.2596
TEST RELAYS.2597
METHOD FOR TESTING RELAYS.2597
AIR CONDITIONER TROUBLESHOOTING CHART 1.2598
AIR CONDITIONER TROUBLESHOOTING CHART 2.2599
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2602
FAILURE CODE [879AKA].2604
FAILURE CODE [879AKB].2605
FAILURE CODE [879BKA].2606
FAILURE CODE [879BKB].2608
FAILURE CODE [879CKA].2610
FAILURE CODE [879CKB].2611
FAILURE CODE [879DKZ].2612
FAILURE CODE [879EMC].2614
FAILURE CODE [879FMC].2615
FAILURE CODE [879GKX].2616
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)2618
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED).2620
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)2623
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER.2625
TROUBLESHOOTING USING GAUGE PRESSURE2627
CONNECTION OF SERVICE TOOL2630
METHOD FOR CONNECTING SERVICE TOOL2630
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS.2632
HANDLE COMPRESSOR OIL.2634
90 CIRCUIT DIAGRAMS.2637
CONTENTS2638
ABBREVIATION LIST.2639
HYDRAULIC CIRCUIT DIAGRAM.2645
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.2645
HYDRAULIC CIRCUIT DIAGRAM.2649
ELECTRICAL CIRCUIT DIAGRAM2651
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM2651
ELECTRICAL CIRCUIT DIAGRAM (1/10).2655
ELECTRICAL CIRCUIT DIAGRAM (2/10).2657
ELECTRICAL CIRCUIT DIAGRAM (3/10).2659
ELECTRICAL CIRCUIT DIAGRAM (4/10).2661
ELECTRICAL CIRCUIT DIAGRAM (5/10).2663
ELECTRICAL CIRCUIT DIAGRAM (6/10).2665
ELECTRICAL CIRCUIT DIAGRAM (7/10).2667
ELECTRICAL CIRCUIT DIAGRAM (8/10).2669
ELECTRICAL CIRCUIT DIAGRAM (9/10).2671
ELECTRICAL CIRCUIT DIAGRAM (10/10)2673
INDEX2675

DESCRIPTION:

Komatsu Hydraulic Excavator PC650LC-11 Shop Manual SEN06603-07 – PDF DOWNLOAD

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

G. B 12/12/24