Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU PC138US-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06662-C2 – PDF DOWNLOAD
$42.95
KOMATSU PC138US-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06662-C2 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU PC138US-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06662-C2 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC138US-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06662-C2 – PDF DOWNLOAD
Language : English
Pages : 3250
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC138US-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06662-C2 – PDF DOWNLOAD
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 AdBlue/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: PC138US-11...................................................................... 103 WORKING RANGE DRAWINGS..................................................................................... 105 WORKING RANGE: PC138US-11.............................................................................. 105 SPECIFICATIONS............................................................................................. 106 SPECIFICATIONS: PC138US-11............................................................................. 106 WEIGHT TABLE............................................................................................... 110 WEIGHT TABLE: PC138US-11............................................................................... 110 TABLE OF FUEL, COOLANT, AND LUBRICANTS..................................................................... 112 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.................................................................................... 126 FUNCTION OF UREA SCR SYSTEM................................................................................ 127 FUNCTION OF AdBlue/DEF SYSTEM.......................................................................... 127 INDUCEMENT STRATEGY.................................................................................... 129 FUNCTION THAT CALLS FOR ATTENTION OF THE OPERATOR FOR UREA SCR SYSTEM TO STAY FUNCTIONAL............... 142 COMPONENT PARTS OF UREA SCR SYSTEM......................................................................... 149 AdBlue/DEF MIXING TUBE................................................................................. 149 SCR ASSEMBLY........................................................................................... 149 AdBlue/DEF TANK........................................................................................ 152 AdBlue/DEF PUMP........................................................................................ 154 AdBlue/DEF INJECTOR.................................................................................... 155 AdBlue/DEF HOSE........................................................................................ 156 AdBlue/DEF TANK HEATING VALVE.......................................................................... 157 BOOT-UP SYSTEM................................................................................................. 158 LAYOUT DRAWING OF BOOT-UP SYSTEM........................................................................... 158 SYSTEM OPERATING LAMP SYSTEM............................................................................... 159 SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL)................................... 159 SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)........................ 159 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL)............................... 159 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER).................... 160 BATTERY DISCONNECT SWITCH.................................................................................. 162 FUNCTION OF BATTERY DISCONNECT SWITCH.................................................................. 162 ENGINE SYSTEM.................................................................................................. 163 LAYOUT DRAWING OF ENGINE SYSTEM............................................................................ 163 ENGINE CONTROL SYSTEM...................................................................................... 165 ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL).......................................... 165 ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................... 166 FUNCTION OF ENGINE CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL)...................................... 167 FUNCTION OF ENGINE CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)........................... 169 AUTO-DECELERATION SYSTEM................................................................................... 171 AUTO-DECELERATION SYSTEM DIAGRAM....................................................................... 171 FUNCTION OF AUTO-DECELERATION SYSTEM................................................................... 171 OPERATION OF AUTO-DECELERATION SYSTEM.................................................................. 172 ENGINE AUTOMATIC WARM-UP SYSTEM............................................................................ 173 ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM................................................................ 173 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM............................................................ 173 OVERHEAT PREVENTION SYSTEM................................................................................. 175 FUNCTION OF OVERHEAT PREVENTION SYSTEM................................................................. 175 TURBOCHARGER PROTECTION SYSTEM............................................................................. 177 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM............................................................. 177 AUTOMATIC IDLE STOP SYSTEM................................................................................. 178 AUTOMATIC IDLE STOP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL)..................................... 178 AUTOMATIC IDLE STOP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER).......................... 179 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM................................................................. 179 COMPONENT PARTS OF ENGINE SYSTEM........................................................................... 182 PTO.................................................................................................... 182 VARIABLE FLOW TURBOCHARGER............................................................................. 182 EGR SYSTEM............................................................................................. 186 EGR VALVE.............................................................................................. 188 EGR COOLER............................................................................................. 189 KCCV SYSTEM............................................................................................ 191 KCCV VENTILATOR........................................................................................ 193 EXHAUST THROTTLE VALVE................................................................................. 195 KDOC................................................................................................... 196 COOLING SYSTEM................................................................................................. 198 LAYOUT DRAWING OF COOLING SYSTEM........................................................................... 198 SPECIFICATIONS OF COOLING SYSTEM....................................................................... 199 CONTROL SYSTEM................................................................................................. 200 LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL)........................................... 200 LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)................................ 202 MACHINE MONITOR SYSTEM..................................................................................... 204 MACHINE MONITOR SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL)......................................... 204 MACHINE MONITOR SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER).............................. 205 FUNCTION OF MACHINE MONITOR SYSTEM..................................................................... 206 KomVision SYSTEM........................................................................................... 207 LAYOUT DRAWING OF KomVision SYSTEM..................................................................... 207 KomVision SYSTEM DIAGRAM............................................................................... 209 FUNCTION OF KomVision SYSTEM........................................................................... 209 KOMTRAX SYSTEM............................................................................................. 211 KOMTRAX SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL)................................................. 211 KOMTRAX SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...................................... 211 FUNCTION OF KOMTRAX SYSTEM............................................................................. 212 COMPONENT PARTS OF CONTROL SYSTEM.......................................................................... 213 MACHINE MONITOR........................................................................................ 213 KomVision CONTROLLER................................................................................... 226 KomVision CAMERA....................................................................................... 230 KOMTRAX TERMINAL....................................................................................... 230 GATEWAY FUNCTION CONTROLLER............................................................................ 232 COMMUNICATION TERMINAL................................................................................. 235 PUMP CONTROLLER........................................................................................ 237 RESISTOR FOR PC-EPC VALVE.............................................................................. 241 CAN TERMINATING RESISTOR............................................................................... 241 ENGINE CONTROLLER...................................................................................... 243 FUEL CONTROL DIAL...................................................................................... 249 HYDRAULIC SYSTEM............................................................................................... 251 LAYOUT DRAWING OF HYDRAULIC SYSTEM......................................................................... 251 CLSS....................................................................................................... 253 STRUCTURE OF CLSS...................................................................................... 253 FUNCTION OF CLSS....................................................................................... 254 ENGINE AND PUMP COMBINED CONTROL SYSTEM.................................................................... 256 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM........................................................ 256 FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM.................................................... 257 COMPONENT PARTS OF HYDRAULIC SYSTEM........................................................................ 261 HYDRAULIC TANK......................................................................................... 261 MAIN PUMP.............................................................................................. 263 CONTROL VALVE.......................................................................................... 287 WORK EQUIPMENT SYSTEM.......................................................................................... 345 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM.................................................................... 345 STRUCTURE OF VALVE CONTROL................................................................................. 348 PPC LOCK SYSTEM............................................................................................ 349 PPC LOCK SYSTEM DIAGRAM................................................................................ 349 FUNCTION OF PPC LOCK SYSTEM............................................................................ 349 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM............................................................ 350 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM................................................ 350 FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM............................................ 350 OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM........................................... 351 OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.................................................................... 352 ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM............................................................ 352 FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.................................................... 353 QUICK COUPLER CONTROL VALVE SYSTEM......................................................................... 354 QUICK COUPLER CONTROL VALVE SYSTEM SYSTEM DIAGRAM...................................................... 354 FUNCTION OF QUICK COUPLER CONTROL VALVE SYSTEM......................................................... 354 OPERATION OF QUICK COUPLER CONTROL VALVE SYSTEM........................................................ 354 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM................................................................... 355 WORK EQUIPMENT AND SWING PPC VALVE..................................................................... 355 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)......................................................... 359 BLADE PPC VALVE........................................................................................ 365 SOLENOID VALVE......................................................................................... 368 VARIABLE BACK PRESSURE SOLENOID VALVE.................................................................. 372 QUICK COUPLER CONTROL VALVE............................................................................ 373 MULTI-CONTROL VALVE.................................................................................... 374 ARM DUMP QUICK RETURN VALVE............................................................................ 375 PILOT CIRCUIT ACCUMULATOR.............................................................................. 378 ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT).............................................. 379 SWING SYSTEM................................................................................................... 380 LAYOUT DRAWING OF SWING SYSTEM............................................................................. 380 SWING CONTROL SYSTEM DIAGRAM............................................................................... 382 FUNCTION OF SWING CONTROL SYSTEM....................................................................... 382 COMPONENT PARTS OF SWING SYSTEM............................................................................ 385 SWING MOTOR............................................................................................ 385 SWING MACHINERY........................................................................................ 394 SWING CIRCLE........................................................................................... 395 TRAVEL SYSTEM.................................................................................................. 397 LAYOUT DRAWING OF TRAVEL SYSTEM............................................................................ 397 TRAVEL CONTROL SYSTEM DIAGRAM.............................................................................. 399 FUNCTION OF TRAVEL CONTROL SYSTEM...................................................................... 399 COMPONENT PARTS OF TRAVEL SYSTEM........................................................................... 403 TRAVEL MOTOR........................................................................................... 403 TRAVEL PPC VALVE....................................................................................... 416 CENTER SWIVEL JOINT.................................................................................... 420 UNDERCARRIAGE AND FRAME........................................................................................ 422 LAYOUT DRAWING OF UNDERCARRIAGE............................................................................ 422 SPECIFICATIONS OF UNDERCARRIAGE........................................................................ 422 IDLER CUSHION.............................................................................................. 423 STRUCTURE OF IDLER CUSHION............................................................................. 423 SPECIFICATIONS OF IDLER CUSHION........................................................................ 423 WORK EQUIPMENT................................................................................................. 424 STRUCTURE OF WORK EQUIPMENT................................................................................ 424 FUNCTION OF WORK EQUIPMENT................................................................................. 425 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM................................................................... 426 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM................................................... 426 BUCKET CLEARANCE ADJUSTMENT SHIM........................................................................... 427 FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM........................................................... 427 CAB AND ITS ATTACHMENTS........................................................................................ 428 ROPS CAB................................................................................................... 428 STRUCTURE OF ROPS CAB (MACHINE WITH KOMTRAX TERMINAL).................................................. 428 STRUCTURE OF ROPS CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER)....................................... 429 FUNCTION OF ROPS CAB................................................................................... 429 CAB MOUNT.................................................................................................. 430 STRUCTURE OF CAB MOUNT................................................................................. 430 FUNCTION OF CAB MOUNT.................................................................................. 430 TAKE WIRING HARNESS OUT OF CAB............................................................................. 432 20 STANDARD VALUE TABLE............................................................................................ 433 CONTENTS....................................................................................................... 434 ABBREVIATION LIST.............................................................................................. 435 STANDARD VALUE TABLE FOR ENGINE................................................................................ 441 STANDARD VALUE TABLE FOR ENGINE:PC138US-11................................................................. 441 STANDARD VALUE TABLE FOR MACHINE............................................................................... 445 STANDARD VALUE TABLE FOR MACHINE:PC138US-11................................................................ 445 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE.................................................... 458 30 TESTING AND ADJUSTING........................................................................................... 463 CONTENTS....................................................................................................... 464 ABBREVIATION LIST.............................................................................................. 467 RELATED INFORMATION ON TESTING AND ADJUSTING................................................................... 473 TOOLS FOR TESTING AND ADJUSTING............................................................................ 473 SKETCH OF TOOLS FOR TESTING AND ADJUSTING.................................................................. 480 ENGINE AND COOLING SYSTEM...................................................................................... 482 TEST ENGINE SPEED.......................................................................................... 482 METHOD FOR TESTING ENGINE SPEED........................................................................ 482 TEST EXHAUST GAS COLOR..................................................................................... 485 METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER............................................ 485 METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER.................................................... 486 TEST THE CLEARANCE OF THE EXHAUST THROTTLE VALVE........................................................... 487 METHOD FOR MEASURING THE CLEARANCE OF THE EXHAUST THROTTLE VALVE....................................... 487 TEST AND ADJUST VALVE CLEARANCE............................................................................ 490 METHOD FOR TESTING VALVE CLEARANCE..................................................................... 490 METHOD FOR ADJUSTING VALVE CLEARANCE................................................................... 491 TEST COMPRESSION PRESSURE.................................................................................. 492 METHOD FOR TESTING COMPRESSION PRESSURE................................................................ 492 TEST BLOWBY PRESSURE....................................................................................... 495 METHOD FOR TESTING BLOWBY PRESSURE..................................................................... 495 TEST ENGINE OIL PRESSURE................................................................................... 497 METHOD FOR TESTING ENGINE OIL PRESSURE................................................................. 497 VISUAL CHECK INSIDE OF EGR VALVE........................................................................... 499 VISUAL CHECK INSIDE OF EGR VALVE....................................................................... 499 CLEAN INSIDE OF EGR VALVE.................................................................................. 501 CLEAN INSIDE OF EGR VALVE.............................................................................. 501 TEST FUEL PRESSURE......................................................................................... 504 METHOD FOR TESTING FUEL PRESSURE....................................................................... 504 TEST FUEL RETURN RATE AND LEAKAGE.......................................................................... 506 METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE........................................................ 507 BLEED AIR FROM FUEL SYSTEM................................................................................. 510 METHOD FOR BLEEDING AIR FROM FUEL SYSTEM............................................................... 510 TEST FUEL CIRCUIT FOR LEAKAGE.............................................................................. 512 METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE............................................................ 512 HANDLE CYLINDER CUT-OUT MODE OPERATION..................................................................... 514 HANDLE NO-INJECTION CRANKING OPERATION..................................................................... 515 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION.................................................... 516 METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT.................................................... 516 METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT................................................... 516 TEST ALTERNATOR BELT....................................................................................... 518 METHOD FOR TESTING ALTERNATOR BELT..................................................................... 518 TEST AUTOMATIC TENSIONER................................................................................... 519 METHOD FOR TESTING AUTOMATIC TENSIONER................................................................. 519 TEST COOLING FAN SPEED..................................................................................... 521 METHOD FOR TESTING COOLING FAN SPEED................................................................... 521 WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER..................................................... 522 METHOD FOR WRITING INJECTOR COMPENSATION VALUE......................................................... 522 TEST SCR RELATED FUNCTIONS................................................................................. 528 TEST AdBlue/DEF PUMP RAISED PRESSURE................................................................... 531 TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR......................................................... 534 TEST AdBlue/DEF LINE HEATER RELAY 1.................................................................... 538 TEST AdBlue/DEF LINE HEATER RELAY 2.................................................................... 541 TEST AdBlue/DEF PUMP HEATER RELAY...................................................................... 544 TEST AdBlue/DEF TANK HEATER VALVE...................................................................... 547 TEST DENITRATION EFFICIENCY OF SCR..................................................................... 551 CLEAN AdBlue/DEF TANK...................................................................................... 554 METHOD FOR CLEANING AdBlue/DEF TANK.................................................................... 554 BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK.......................................................... 559 METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK........................................ 559 CLEAN AdBlue/DEF PUMP...................................................................................... 561 CLEAN AdBlue/DEF PUMP.................................................................................. 561 POWER TRAIN.................................................................................................... 567 TEST SWING CIRCLE BEARING CLEARANCE........................................................................ 567 METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE...................................................... 567 UNDERCARRIAGE AND FRAME........................................................................................ 568 TEST AND ADJUST TRACK TENSION.............................................................................. 568 METHOD FOR TESTING TRACK TENSION....................................................................... 568 METHOD FOR ADJUSTING TRACK TENSION..................................................................... 568 HYDRAULIC SYSTEM............................................................................................... 570 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM........................................................... 570 METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK............................................ 570 METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT.................................. 570 METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT....................................... 572 METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT...................................... 572 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS.......................... 573 METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS................... 573 METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS................. 580 TEST OIL PRESSURE OF CONTROL CIRCUIT....................................................................... 582 METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT..................................................... 582 TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.................................................... 584 METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE).............................. 584 METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE........................................................ 585 METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT........................................... 586 TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.................................................... 588 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR....................................... 588 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE............................................................ 590 METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE).............................. 591 METHOD FOR ADJUSTING LS VALVE.......................................................................... 593 TEST OUTLET PRESSURE OF SOLENOID VALVE..................................................................... 594 METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE................................................... 594 OPERATING CONDITION OF SOLENOID VALVE.................................................................. 595 METHOD FOR TESTING OUTLET PRESSURE OF VARIABLE BACK PRESSURE SOLENOID VALVE............................ 596 OPERATING CONDITION OF VARIABLE BACK PRESSURE SOLENOID VALVE........................................... 598 TEST PPC VALVE OUTLET PRESSURE............................................................................. 599 METHOD FOR TESTING PPC VALVE OUTLET PRESSURE........................................................... 599 ADJUST WORK EQUIPMENT AND SWING PPC VALVES................................................................. 601 METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES....................................... 601 TEST AND ADJUST TRAVEL DEVIATION........................................................................... 602 METHOD FOR TESTING TRAVEL DEVIATION.................................................................... 602 METHOD FOR ADJUSTING TRAVEL DEVIATION.................................................................. 602 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT................................................... 605 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER.............. 605 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER................................... 605 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE...................................... 606 TEST OIL LEAKAGE........................................................................................... 607 METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER...................................................... 607 METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER....................................................... 608 METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER.................................................... 608 METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER..................................................... 609 METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR........................................................ 609 METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR....................................................... 610 BLEED AIR FROM HYDRAULIC CIRCUIT........................................................................... 612 METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT......................................................... 613 CAB AND ITS ATTACHMENTS........................................................................................ 616 TEST CAB TIPPING STOPPER................................................................................... 616 METHOD FOR TESTING CAB TIPPING STOPPER................................................................. 616 METHOD FOR ADJUSTING MIRRORS............................................................................... 617 PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A).................................................. 617 PROCEDURE FOR ADJUSTING MACHINE REAR MIRROR (B)........................................................ 617 ELECTRICAL SYSTEM.............................................................................................. 619 SET AND OPERATE MACHINE MONITOR............................................................................ 619 OPERATOR MODE.......................................................................................... 622 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN............................................ 622 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN............................................... 622 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)...................................................... 623 CHECKING FUNCTION OF SERVICE METER..................................................................... 624 SERVICE MODE........................................................................................... 624 METHOD FOR OPERATING SERVICE MODE...................................................................... 624 METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION................................................. 627 METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION................................................. 633 ABNORMALITY RECORD MENU................................................................................ 644 METHOD FOR CONFIRMING MAINTENANCE RECORD............................................................... 648 METHOD FOR OPERATING MAINTENANCE MODE SETTING.......................................................... 649 METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING........................................................ 652 DEFAULT MENU........................................................................................... 653 DIAGNOSTIC TESTS MENU.................................................................................. 661 ADJUSTMENT MENU........................................................................................ 670 METHOD FOR PERFORMING NO-INJECTION CRANKING............................................................ 683 KOMTRAX SETTINGS MENU.................................................................................. 684 METHOD FOR DISPLAYING SERVICE MESSAGE.................................................................. 689 START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL).................................................. 691 STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL)............................................. 696 START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)......................................... 698 STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER).................................... 704 ADJUST REARVIEW CAMERA ANGLE............................................................................... 706 METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE............................................................ 706 ADJUST KomVision CAMERA ANGLE.............................................................................. 709 METHOD FOR ADJUSTING KomVision CAMERA ANGLE............................................................ 710 ADJUST KomVision RELATED ITEMS............................................................................. 712 SETTING OF KomVision (MAIN SETTING).................................................................... 712 SETTING OF KomVision (CAMERA SETTING).................................................................. 715 SETTING OF KomVision (CAMERA CALIBRATION).............................................................. 717 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER................................................................ 730 BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL).................................................. 731 BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER)....................................... 732 TEST DIODES................................................................................................ 733 METHOD FOR TESTING DIODE USING DIGITAL TESTER.......................................................... 733 METHOD FOR TESTING DIODE USING ANALOG TESTER........................................................... 733 Pm CLINIC...................................................................................................... 734 Pm CLINIC SERVICE.......................................................................................... 734 Pm CLINIC CHECK SHEET:PC138US-11....................................................................... 735 40 TROUBLESHOOTING................................................................................................. 745 CONTENTS....................................................................................................... 746 ABBREVIATION LIST.............................................................................................. 756 RELATED INFORMATION ON TROUBLESHOOTING......................................................................... 762 GENERAL TROUBLESHOOTING POINTS............................................................................. 762 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM................................................................. 763 SEQUENCE OF EVENTS IN TROUBLESHOOTING...................................................................... 775 CHECKS BEFORE TROUBLESHOOTING.............................................................................. 777 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING................................................................ 779 WALK-AROUND CHECK...................................................................................... 779 TESTING IN ACCORDANCE WITH TESTING PROCEDURE............................................................... 781 CHECK FUEL PREFILTER................................................................................... 781 WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT..................................................... 781 METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE.......................................................... 781 CHECK MAIN FILTER...................................................................................... 783 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)......................................................... 784 CHECK OIL LEVEL IN PTO GEAR CASE....................................................................... 785 CHECK COOLANT LEVEL (RESERVOIR TANK)................................................................... 786 CHECK CLOGGING OF AIR CLEANER.......................................................................... 786 OUTER ELEMENT - CLEAN.................................................................................. 787 ELEMENTS - REPLACE..................................................................................... 789 CHECK HYDRAULIC OIL LEVEL.............................................................................. 790 CHECK HYDRAULIC OIL STRAINER........................................................................... 792 CHECK HYDRAULIC FILTER................................................................................. 792 CHECK OIL LEVEL IN SWING MACHINERY CASE................................................................ 793 CHECK OIL LEVEL IN FINAL DRIVE CASE.................................................................... 794 BLEED AIR FROM FUEL SYSTEM............................................................................. 795 BLEED AIR FROM HYDRAULIC SYSTEM........................................................................ 795 METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod........................................................... 795 PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM....................................................... 800 PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR..................................................... 800 PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER................................................... 800 PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER..................................................... 801 PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL.................................................... 801 PREPARATION FOR TROUBLESHOOTING OF GATEWAY FUNCTION CONTROLLER......................................... 802 DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK................................................... 802 PROCEDURE FOR TESTING AND TROUBLESHOOTING.................................................................. 807 SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS............................................................ 810 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE............................................................. 815 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM........................ 817 CONNECTOR LIST AND LAYOUT(MACHINE WITH KOMTRAX TERMINAL)................................................... 820 CONNECTOR LIST AND LAYOUT(MACHINE WITH GATEWAY FUNCTION CONTROLLER)........................................ 833 CONNECTOR CONTACT IDENTIFICATION........................................................................... 846 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE.................................................................... 886 FUSE LOCATION TABLE (MACHINE WITH KOMTRAX TERMINAL)........................................................ 892 FUSE LOCATION TABLE (MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................. 895 PRECAUTIONS FOR REPLACING KDOC............................................................................. 898 FAILURE CODES TABLE........................................................................................ 899 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE).............................................................. 915 FAILURE CODE [879AKA]...................................................................................... 915 FAILURE CODE [879AKB]...................................................................................... 917 FAILURE CODE [879BKA]...................................................................................... 919 FAILURE CODE [879BKB]...................................................................................... 921 FAILURE CODE [879CKA]...................................................................................... 923 FAILURE CODE [879CKB]...................................................................................... 924 FAILURE CODE [879DKZ]...................................................................................... 925 FAILURE CODE [879EMC]...................................................................................... 928 FAILURE CODE [879FMC]...................................................................................... 929 FAILURE CODE [879GKX]...................................................................................... 930 FAILURE CODE [989L00]...................................................................................... 932 FAILURE CODE [989M00]...................................................................................... 933 FAILURE CODE [989N00]...................................................................................... 934 FAILURE CODE [A1U0N3]...................................................................................... 935 FAILURE CODE [A1U0N4]...................................................................................... 938 FAILURE CODE [A900FR]...................................................................................... 941 FAILURE CODE [A900N6]...................................................................................... 942 FAILURE CODE [A900NY]...................................................................................... 943 FAILURE CODE [AA10NX]...................................................................................... 944 FAILURE CODE [AB00KE]...................................................................................... 946 FAILURE CODE [AQ10MB]...................................................................................... 949 FAILURE CODE [AQ10N3]...................................................................................... 951 FAILURE CODE [AS00R2]...................................................................................... 953 FAILURE CODE [AS00R3]...................................................................................... 954 FAILURE CODE [AS00R4]...................................................................................... 955 FAILURE CODE [AS00R5]...................................................................................... 956 FAILURE CODE [AS00R6]...................................................................................... 957 FAILURE CODE [AS00ZK]...................................................................................... 958 FAILURE CODE [AS10KM]...................................................................................... 960 FAILURE CODE [AS10NR]...................................................................................... 961 FAILURE CODE [AS10NT]...................................................................................... 963 FAILURE CODE [AU10QA]...................................................................................... 964 FAILURE CODE [B@BAZG]...................................................................................... 965 FAILURE CODE [B@BAZK]...................................................................................... 966 FAILURE CODE [B@BCNS]...................................................................................... 968 FAILURE CODE [B@HANS]...................................................................................... 969 FAILURE CODE [CA115]....................................................................................... 971 FAILURE CODE [CA122]....................................................................................... 973 FAILURE CODE [CA123]....................................................................................... 977 FAILURE CODE [CA131]....................................................................................... 981 FAILURE CODE [CA132]....................................................................................... 984 FAILURE CODE [CA144]....................................................................................... 987 FAILURE CODE [CA145]....................................................................................... 991 FAILURE CODE [CA153]....................................................................................... 994 FAILURE CODE [CA154]....................................................................................... 998 FAILURE CODE [CA187].......................................................................................1002 FAILURE CODE [CA221].......................................................................................1004 FAILURE CODE [CA222].......................................................................................1008 FAILURE CODE [CA227].......................................................................................1011 FAILURE CODE [CA234].......................................................................................1012 FAILURE CODE [CA238].......................................................................................1014 FAILURE CODE [CA239].......................................................................................1016 FAILURE CODE [CA249].......................................................................................1018 FAILURE CODE [CA256].......................................................................................1021 FAILURE CODE [CA271].......................................................................................1024 FAILURE CODE [CA272].......................................................................................1027 FAILURE CODE [CA322].......................................................................................1029 FAILURE CODE [CA324].......................................................................................1033 FAILURE CODE [CA331].......................................................................................1037 FAILURE CODE [CA332].......................................................................................1041 FAILURE CODE [CA343].......................................................................................1045 FAILURE CODE [CA351].......................................................................................1046 FAILURE CODE [CA352].......................................................................................1047 FAILURE CODE [CA356].......................................................................................1050 FAILURE CODE [CA357].......................................................................................1053 FAILURE CODE [CA386].......................................................................................1057 FAILURE CODE [CA435].......................................................................................1058 FAILURE CODE [CA441].......................................................................................1060 FAILURE CODE [CA442].......................................................................................1063 FAILURE CODE [CA449].......................................................................................1064 FAILURE CODE [CA451].......................................................................................1065 FAILURE CODE [CA452].......................................................................................1068 FAILURE CODE [CA515].......................................................................................1071 FAILURE CODE [CA516].......................................................................................1073 FAILURE CODE [CA553].......................................................................................1076 FAILURE CODE [CA555].......................................................................................1078 FAILURE CODE [CA556].......................................................................................1080 FAILURE CODE [CA559].......................................................................................1082 FAILURE CODE [CA689].......................................................................................1088 FAILURE CODE [CA691].......................................................................................1093 FAILURE CODE [CA692].......................................................................................1096 FAILURE CODE [CA697].......................................................................................1099 FAILURE CODE [CA698].......................................................................................1100 FAILURE CODE [CA731].......................................................................................1101 FAILURE CODE [CA778].......................................................................................1104 FAILURE CODE [CA1117]......................................................................................1111 FAILURE CODE [CA1664]......................................................................................1113 FAILURE CODE [CA1669]......................................................................................1116 FAILURE CODE [CA1673]......................................................................................1118 FAILURE CODE [CA1677]......................................................................................1120 FAILURE CODE [CA1678]......................................................................................1122 FAILURE CODE [CA1682]......................................................................................1124 FAILURE CODE [CA1683]......................................................................................1133 FAILURE CODE [CA1684]......................................................................................1136 FAILURE CODE [CA1686]......................................................................................1139 FAILURE CODE [CA1691]......................................................................................1141 FAILURE CODE [CA1694]......................................................................................1145 FAILURE CODE [CA1695]......................................................................................1150 FAILURE CODE [CA1696]......................................................................................1151 FAILURE CODE [CA1712]......................................................................................1154 FAILURE CODE [CA1713]......................................................................................1158 FAILURE CODE [CA1714]......................................................................................1161 FAILURE CODE [CA1715]......................................................................................1163 FAILURE CODE [CA1776]......................................................................................1165 FAILURE CODE [CA1777]......................................................................................1168 FAILURE CODE [CA1843]......................................................................................1172 FAILURE CODE [CA1844]......................................................................................1175 FAILURE CODE [CA1885]......................................................................................1179 FAILURE CODE [CA1887]......................................................................................1182 FAILURE CODE [CA1896]......................................................................................1185 FAILURE CODE [CA1938]......................................................................................1187 FAILURE CODE [CA1942]......................................................................................1190 FAILURE CODE [CA1961]......................................................................................1192 FAILURE CODE [CA2185]......................................................................................1193 FAILURE CODE [CA2186]......................................................................................1195 FAILURE CODE [CA2249]......................................................................................1197 FAILURE CODE [CA2272]......................................................................................1198 FAILURE CODE [CA2311]......................................................................................1202 FAILURE CODE [CA2349]......................................................................................1203 FAILURE CODE [CA2353]......................................................................................1206 FAILURE CODE [CA2357]......................................................................................1209 FAILURE CODE [CA2636]......................................................................................1211 FAILURE CODE [CA2637]......................................................................................1215 FAILURE CODE [CA2765]......................................................................................1218 FAILURE CODE [CA2771]......................................................................................1219 FAILURE CODE [CA2976]......................................................................................1227 FAILURE CODE [CA3142]......................................................................................1231 FAILURE CODE [CA3143]......................................................................................1232 FAILURE CODE [CA3144]......................................................................................1233 FAILURE CODE [CA3146]......................................................................................1237 FAILURE CODE [CA3147]......................................................................................1238 FAILURE CODE [CA3148]......................................................................................1239 FAILURE CODE [CA3151]......................................................................................1243 FAILURE CODE [CA3165]......................................................................................1251 FAILURE CODE [CA3229]......................................................................................1255 FAILURE CODE [CA3231]......................................................................................1259 FAILURE CODE [CA3232]......................................................................................1263 FAILURE CODE [CA3235]......................................................................................1268 FAILURE CODE [CA3239]......................................................................................1272 FAILURE CODE [CA3241]......................................................................................1276 FAILURE CODE [CA3242]......................................................................................1280 FAILURE CODE [CA3251]......................................................................................1284 FAILURE CODE [CA3313]......................................................................................1288 FAILURE CODE [CA3314]......................................................................................1290 FAILURE CODE [CA3315]......................................................................................1291 FAILURE CODE [CA3419]......................................................................................1295 FAILURE CODE [CA3421]......................................................................................1297 FAILURE CODE [CA3497]......................................................................................1299 FAILURE CODE [CA3498]......................................................................................1301 FAILURE CODE [CA3543]......................................................................................1303 FAILURE CODE [CA3545]......................................................................................1311 FAILURE CODE [CA3547]......................................................................................1314 FAILURE CODE [CA3558]......................................................................................1316 FAILURE CODE [CA3559]......................................................................................1319 FAILURE CODE [CA3562]......................................................................................1322 FAILURE CODE [CA3563]......................................................................................1325 FAILURE CODE [CA3567]......................................................................................1330 FAILURE CODE [CA3568]......................................................................................1334 FAILURE CODE [CA3571]......................................................................................1342 FAILURE CODE [CA3572]......................................................................................1345 FAILURE CODE [CA3574]......................................................................................1348 FAILURE CODE [CA3575]......................................................................................1354 FAILURE CODE [CA3577]......................................................................................1357 FAILURE CODE [CA3578]......................................................................................1360 FAILURE CODE [CA3582]......................................................................................1363 FAILURE CODE [CA3583]......................................................................................1375 FAILURE CODE [CA3596]......................................................................................1378 FAILURE CODE [CA3649]......................................................................................1385 FAILURE CODE [CA3681]......................................................................................1388 FAILURE CODE [CA3682]......................................................................................1395 FAILURE CODE [CA3713]......................................................................................1402 FAILURE CODE [CA3717]......................................................................................1406 FAILURE CODE [CA3718]......................................................................................1408 FAILURE CODE [CA3724]......................................................................................1410 FAILURE CODE [CA3725]......................................................................................1411 FAILURE CODE [CA3748]......................................................................................1414 FAILURE CODE [CA3755]......................................................................................1418 FAILURE CODE [CA3866]......................................................................................1422 FAILURE CODE [CA3867]......................................................................................1427 FAILURE CODE [CA3868]......................................................................................1431 FAILURE CODE [CA3899]......................................................................................1436 FAILURE CODE [CA3911]......................................................................................1439 FAILURE CODE [CA3912]......................................................................................1444 FAILURE CODE [CA3918]......................................................................................1447 FAILURE CODE [CA3921]......................................................................................1450 FAILURE CODE [CA3928]......................................................................................1452 FAILURE CODE [CA3932]......................................................................................1453 FAILURE CODE [CA3933]......................................................................................1456 FAILURE CODE [CA3934]......................................................................................1459 FAILURE CODE [CA3935]......................................................................................1463 FAILURE CODE [CA3936]......................................................................................1466 FAILURE CODE [CA4152]......................................................................................1468 FAILURE CODE [CA4155]......................................................................................1473 FAILURE CODE [CA4156]......................................................................................1476 FAILURE CODE [CA4157]......................................................................................1480 FAILURE CODE [CA4159]......................................................................................1483 FAILURE CODE [CA4164]......................................................................................1485 FAILURE CODE [CA4165]......................................................................................1488 FAILURE CODE [CA4166]......................................................................................1491 FAILURE CODE [CA4168]......................................................................................1493 FAILURE CODE [CA4169]......................................................................................1496 FAILURE CODE [CA4171]......................................................................................1499 FAILURE CODE [CA4249]......................................................................................1503 FAILURE CODE [CA4251]......................................................................................1506 FAILURE CODE [CA4261]......................................................................................1509 FAILURE CODE [CA4277]......................................................................................1513 FAILURE CODE [CA4281]......................................................................................1518 FAILURE CODE [CA4459]......................................................................................1524 FAILURE CODE [CA4461]......................................................................................1527 FAILURE CODE [CA4533]......................................................................................1532 FAILURE CODE [CA4534]......................................................................................1533 FAILURE CODE [CA4731]......................................................................................1535 FAILURE CODE [CA4732]......................................................................................1537 FAILURE CODE [CA4739]......................................................................................1539 FAILURE CODE [CA4768]......................................................................................1541 FAILURE CODE [CA4769]......................................................................................1544 FAILURE CODE [CA4842]......................................................................................1547 FAILURE CODE [CA4952](MACHINE WITH KOMTRAX TERMINAL).......................................................1552 FAILURE CODE [CA4952](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1554 FAILURE CODE [CA5115]......................................................................................1556 FAILURE CODE [CA5179]......................................................................................1560 FAILURE CODE [CA5181]......................................................................................1563 FAILURE CODE [CA5271]......................................................................................1566 FAILURE CODE [CA5272]......................................................................................1569 FAILURE CODE [CA5273]......................................................................................1572 FAILURE CODE [CA5274]......................................................................................1575 FAILURE CODE [CA5275]......................................................................................1577 FAILURE CODE [CA5276]......................................................................................1580 FAILURE CODE [CA5277]......................................................................................1583 FAILURE CODE [CA5387]......................................................................................1585 FAILURE CODE [CA5388]......................................................................................1589 FAILURE CODE [CA5389]......................................................................................1592 FAILURE CODE [CA5391]......................................................................................1597 FAILURE CODE [CA5392]......................................................................................1603 FAILURE CODE [CA5393]......................................................................................1605 FAILURE CODE [CA5394]......................................................................................1608 FAILURE CODE [CA5395]......................................................................................1611 FAILURE CODE [CA5396]......................................................................................1614 FAILURE CODE [CA5631]......................................................................................1616 FAILURE CODE [CA5938]......................................................................................1618 FAILURE CODE [D110KB]......................................................................................1620 FAILURE CODE [D19JKZ]......................................................................................1622 FAILURE CODE [D811MC](MACHINE WITH KOMTRAX TERMINAL).......................................................1625 FAILURE CODE [D811MC](MACHINE WITH GATEWAY FUNCTION CONTROLLER )...........................................1626 FAILURE CODE [D862KA](MACHINE WITH KOMTRAX TERMINAL).......................................................1627 FAILURE CODE [D862KA](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1628 FAILURE CODE [D8ALKA](MACHINE WITH KOMTRAX TERMINAL).......................................................1630 FAILURE CODE [D8ALKA](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1633 FAILURE CODE [D8ALKB](MACHINE WITH KOMTRAX TERMINAL).......................................................1636 FAILURE CODE [D8ALKB](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1638 FAILURE CODE [D8AQKR](MACHINE WITH KOMTRAX TERMINAL).......................................................1640 FAILURE CODE [D8AQKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1645 FAILURE CODE [D8G1KT]......................................................................................1650 FAILURE CODE [D8G6KT]......................................................................................1651 FAILURE CODE [DA20MC]......................................................................................1652 FAILURE CODE [DA22KK]......................................................................................1653 FAILURE CODE [DA25KP]......................................................................................1657 FAILURE CODE [DA26KP]......................................................................................1662 FAILURE CODE [DA29KQ]......................................................................................1664 FAILURE CODE [DA2LKA](MACHINE WITH KOMTRAX TERMINAL).......................................................1667 FAILURE CODE [DA2LKA](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1670 FAILURE CODE [DA2LKB](MACHINE WITH KOMTRAX TERMINAL).......................................................1673 FAILURE CODE [DA2LKB](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1675 FAILURE CODE [DA2QKR](MACHINE WITH KOMTRAX TERMINAL).......................................................1677 FAILURE CODE [DA2QKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1684 FAILURE CODE [DA2RKR](MACHINE WITH KOMTRAX TERMINAL).......................................................1691 FAILURE CODE [DA2RKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1698 FAILURE CODE [DAF0KM]......................................................................................1705 FAILURE CODE [DAF0MB]......................................................................................1706 FAILURE CODE [DAF0MC]......................................................................................1707 FAILURE CODE [DAF8KB]......................................................................................1708 FAILURE CODE [DAF9KQ]......................................................................................1710 FAILURE CODE [DAFGMC]......................................................................................1712 FAILURE CODE [DAFLKA](MACHINE WITH KOMTRAX TERMINAL).......................................................1713 FAILURE CODE [DAFLKA](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1716 FAILURE CODE [DAFLKB](MACHINE WITH KOMTRAX TERMINAL).......................................................1719 FAILURE CODE [DAFLKB](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1721 FAILURE CODE [DAFQKR](MACHINE WITH KOMTRAX TERMINAL).......................................................1723 FAILURE CODE [DAFQKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1729 FAILURE CODE [DAZ9KQ]......................................................................................1735 FAILURE CODE [DAZQKR](MACHINE WITH KOMTRAX TERMINAL).......................................................1737 FAILURE CODE [DAZQKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1742 FAILURE CODE [DB2QKR](MACHINE WITH KOMTRAX TERMINAL).......................................................1747 FAILURE CODE [DB2QKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1754 FAILURE CODE [DB2RKR](MACHINE WITH KOMTRAX TERMINAL).......................................................1761 FAILURE CODE [DB2RKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1769 FAILURE CODE [DB90MC]......................................................................................1777 FAILURE CODE [DBP0KM]......................................................................................1778 FAILURE CODE [DBP0KT]......................................................................................1779 FAILURE CODE [DBPQKR](MACHINE WITH KOMTRAX TERMINAL).......................................................1780 FAILURE CODE [DBPQKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1786 FAILURE CODE [DDNRKA]......................................................................................1792 FAILURE CODE [DDNRKY]......................................................................................1795 FAILURE CODE [DDNS00]......................................................................................1798 FAILURE CODE [DFB1KZ]......................................................................................1800 FAILURE CODE [DFB2KZ]......................................................................................1803 FAILURE CODE [DFB3L8]......................................................................................1806 FAILURE CODE [DFB4L8]......................................................................................1808 FAILURE CODE [DFB5KZ]......................................................................................1810 FAILURE CODE [DFB6KZ]......................................................................................1813 FAILURE CODE [DGH2KA]......................................................................................1816 FAILURE CODE [DGH2KB]......................................................................................1818 FAILURE CODE [DHA4KA]......................................................................................1820 FAILURE CODE [DHPAMA]......................................................................................1822 FAILURE CODE [DHS3MA]......................................................................................1825 FAILURE CODE [DHS4MA]......................................................................................1828 FAILURE CODE [DHS8MA]......................................................................................1831 FAILURE CODE [DHS9MA]......................................................................................1834 FAILURE CODE [DHSAMA]......................................................................................1837 FAILURE CODE [DHSBMA]......................................................................................1840 FAILURE CODE [DHSCMA]......................................................................................1843 FAILURE CODE [DHSDMA]......................................................................................1846 FAILURE CODE [DHSFMA]......................................................................................1849 FAILURE CODE [DHSGMA]......................................................................................1852 FAILURE CODE [DHSHMA]......................................................................................1855 FAILURE CODE [DHSJMA]......................................................................................1858 FAILURE CODE [DHSKMA]......................................................................................1861 FAILURE CODE [DHSLMA]......................................................................................1863 FAILURE CODE [DKULKA]......................................................................................1865 FAILURE CODE [DKULKB]......................................................................................1867 FAILURE CODE [DKULKY]......................................................................................1869 FAILURE CODE [DLM5KA]......................................................................................1871 FAILURE CODE [DLM5MB]......................................................................................1875 FAILURE CODE [DR10KA]......................................................................................1877 FAILURE CODE [DR21KX]......................................................................................1881 FAILURE CODE [DUMBKA](MACHINE WITH KOMTRAX TERMINAL).......................................................1884 FAILURE CODE [DUMBKA](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1887 FAILURE CODE [DUMBKB](MACHINE WITH KOMTRAX TERMINAL).......................................................1890 FAILURE CODE [DUMBKB](MACHINE WITH GATEWAY FUNCTION CONTROLLER)............................................1892 FAILURE CODE [DV20KB]......................................................................................1894 FAILURE CODE [DW43KA]......................................................................................1896 FAILURE CODE [DW43KB]......................................................................................1898 FAILURE CODE [DW43KY]......................................................................................1900 FAILURE CODE [DW45KA]......................................................................................1902 FAILURE CODE [DW45KB]......................................................................................1906 FAILURE CODE [DW45KY]......................................................................................1910 FAILURE CODE [DW4CKY]......................................................................................1912 FAILURE CODE [DW91KA]......................................................................................1914 FAILURE CODE [DW91KB]......................................................................................1917 FAILURE CODE [DW91KY]......................................................................................1919 FAILURE CODE [DWA2KA]......................................................................................1921 FAILURE CODE [DWA2KB]......................................................................................1924 FAILURE CODE [DWA2KY]......................................................................................1926 FAILURE CODE [DWJ0KA]......................................................................................1928 FAILURE CODE [DWJ0KB]......................................................................................1931 FAILURE CODE [DWJ0KY]......................................................................................1934 FAILURE CODE [DWK2KA]......................................................................................1936 FAILURE CODE [DWK2KB]......................................................................................1939 FAILURE CODE [DWK2KY]......................................................................................1941 FAILURE CODE [DWN5KA]......................................................................................1943 FAILURE CODE [DWN5KB]......................................................................................1946 FAILURE CODE [DWN5KY]......................................................................................1949 FAILURE CODE [DWNSKA]......................................................................................1951 FAILURE CODE [DWNSKB]......................................................................................1953 FAILURE CODE [DWNSKY]......................................................................................1955 FAILURE CODE [DXA8KA]......................................................................................1957 FAILURE CODE [DXA8KB]......................................................................................1961 FAILURE CODE [DXE4KA]......................................................................................1963 FAILURE CODE [DXE4KB]......................................................................................1966 FAILURE CODE [DXE4KY]......................................................................................1968 FAILURE CODE [DY20KA]......................................................................................1970 FAILURE CODE [DY20MA]......................................................................................1973 FAILURE CODE [DY2CKB]......................................................................................1976 FAILURE CODE [DY2DKB]......................................................................................1980 FAILURE CODE [DY2EKB]......................................................................................1983 FAILURE CODE [F313KA]......................................................................................1986 FAILURE CODE [F313KB]......................................................................................1988 FAILURE CODE [F318KB]......................................................................................1990 FAILURE CODE [F318KY]......................................................................................1992 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)..................................................................1994 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)..............................................................1994 MANUAL PREHEATING SYSTEM DOES NOT WORK.....................................................................2000 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP..........................................2003 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING............................2005 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING..............................2008 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...............................2009 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...................................2010 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............................................2011 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................2012 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................2013 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.......................................2014 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.................................2015 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...................................................2016 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL.......................................................2018 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.............................2019 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE........................2020 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY.................................................................2021 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM..............................2024 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE.............................2026 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED.....................................................2027 FUNCTION SWITCH DOES NOT OPERATE...........................................................................2028 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)...................................................2029 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF....2030 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER....................................................2031 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED.......................2033 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED..........................2034 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE.................................2035 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE................................2036 ALARM BUZZER CANNOT BE CANCELED............................................................................2037 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...................................2038 SERVICE MODE CANNOT BE SELECTED............................................................................2039 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE............................................2040 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK.............................................2043 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING.............................2045 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE.............2047 WORK EQUIPMENT DOES NOT OPERATE WHILE LOCK LEVER AUTOMATIC RELEASE SWITCH IS IN RELEASE POSITION...........2049 ALARM DOES NOT SOUND DURING TRAVEL.........................................................................2051 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED......................................................2053 HORN DOES NOT SOUND........................................................................................2054 HORN DOES NOT STOP SOUNDING................................................................................2056 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF...................................2057 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...........................................2058 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE......................................2060 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................2061 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................2062 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................2063 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................2064 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................2065 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................2066 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.........................................2067 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................2068 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................2069 BLADE RAISE ON IS NOT DISPLAYED CORRECTLY WITH MONITORING..................................................2072 BLADE LOWER ON IS NOT DISPLAYED CORRECTLY WITH MONITORING..................................................2073 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...................................................................2074 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)..................................................2075 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)....................................................2075 FAILURE MODE AND CAUSE TABLE...............................................................................2076 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK...........................................................2085 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER..................................................2086 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR...............................................................2088 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP..........................................................2089 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS.................................................................2090 SPEED OR POWER OF BOOM IS LOW..............................................................................2092 ARM SPEED OR POWER IS LOW..................................................................................2095 BUCKET SPEED OR POWER IS LOW...............................................................................2098 BLADE SPEED OR POWER IS LOW................................................................................2101 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION...........................................................2103 HYDRAULIC DRIFT OF BOOM IS LARGE...........................................................................2104 HYDRAULIC DRIFT OF ARM IS LARGE............................................................................2105 HYDRAULIC DRIFT OF BUCKET IS LARGE.........................................................................2106 HYDRAULIC DRIFT OF BLADE IS LARGE..........................................................................2107 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...........................2109 TIME LAG OF WORK EQUIPMENT IS LARGE........................................................................2110 ATTACHMENT CIRCUIT CANNOT BE CHANGED.......................................................................2111 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED...........................................................2112 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER........................2113 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY......................................2114 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW....................................2115 MACHINE DOES NOT TRAVEL STRAIGHT...........................................................................2116 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.......................................................2119 TRAVEL SPEED IS LOW........................................................................................2121 ONE OF TRACKS DOES NOT RUN.................................................................................2123 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST..........................................2125 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT..................................................2126 SWINGS ONLY IN ONE DIRECTION...............................................................................2127 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)...............................2128 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION........................2129 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)..........................2130 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)......2131 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING.........................................................2132 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING...........................................2133 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED).....................................2134 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)....................................2135 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY).....................................................2136 UNUSUAL NOISE IS HEARD FROM AROUND FAN.....................................................................2137 TROUBLESHOOTING OF ENGINE (S-MODE).............................................................................2138 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)....................................................2138 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.....................................2139 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT.................................................................2140 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START).............2141 ENGINE STARTABILITY IS POOR................................................................................2142 ENGINE DOES NOT PICK UP SMOOTHLY...........................................................................2144 ENGINE STOPS DURING OPERATION..............................................................................2146 ENGINE RUNS ROUGH OR IS UNSTABLE...........................................................................2148 ENGINE LACKS POWER.........................................................................................2149 EXHAUST SMOKE IS BLACK.....................................................................................2151 ENGINE OIL CONSUMPTION IS EXCESSIVE........................................................................2153 OIL BECOMES CONTAMINATED QUICKLY...........................................................................2154 FUEL CONSUMPTION IS EXCESSIVE..............................................................................2155 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)......................................2156 OIL PRESSURE DROPS.........................................................................................2157 FUEL MIXES INTO ENGINE OIL.................................................................................2158 WATER MIXES INTO ENGINE OIL (MILKY)........................................................................2159 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...........................................................2160 UNUSUAL NOISE IS HEARD.....................................................................................2161 VIBRATION IS EXCESSIVE.....................................................................................2163 AIR CANNOT BE BLED FROM FUEL CIRCUIT.......................................................................2164 ACTIVE REGENERATION IS EXECUTED FREQUENTLY.................................................................2165 ACTIVE REGENERATION TAKES TIME.............................................................................2166 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION........................................................2167 AdBlue/DEF CONSUMPTION IS EXCESSIVE........................................................................2168 THERE IS UNUSUAL SMELL (IRRITATING ODOR)...................................................................2170 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)..................................................2171 50 DISASSEMBLY AND ASSEMBLY........................................................................................2173 CONTENTS.......................................................................................................2174 ABBREVIATION LIST..............................................................................................2179 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY................................................................2185 HOW TO READ THIS MANUAL....................................................................................2185 COATING MATERIALS LIST.....................................................................................2187 SPECIAL TOOLS LIST.........................................................................................2191 SKETCHES OF SPECIAL TOOLS..................................................................................2207 ENGINE AND COOLING SYSTEM......................................................................................2210 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS NOT REMOVED).......................2210 REMOVE SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS NOT REMOVED)...............................2211 INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS NOT REMOVED)..............................2217 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS REMOVED)...........................2224 REMOVE SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS REMOVED)...................................2224 INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS REMOVED)..................................2227 REMOVE AND INSTALL INJECTOR ASSEMBLY.......................................................................2231 METHOD FOR REMOVING INJECTOR ASSEMBLY..................................................................2232 METHOD FOR INSTALLING INJECTOR ASSEMBLY................................................................2239 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY..................................................................2252 METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY.............................................................2253 METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY...........................................................2269 REMOVE AND INSTALL EGR VALVE ASSEMBLY......................................................................2293 METHOD FOR REMOVING EGR VALVE ASSEMBLY.................................................................2293 METHOD FOR INSTALLING EGR VALVE ASSEMBLY...............................................................2295 REMOVE AND INSTALL EGR COOLER ASSEMBLY.....................................................................2298 METHOD FOR REMOVING EGR COOLER ASSEMBLY................................................................2298 METHOD FOR INSTALLING EGR COOLER ASSEMBLY..............................................................2301 REMOVE AND INSTALL STARTING MOTOR ASSEMBLY.................................................................2305 METHOD FOR REMOVING STARTING MOTOR ASSEMBLY............................................................2305 METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY..........................................................2310 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT.........................................................2315 METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT....................................................2315 METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT..................................................2316 REMOVE AND INSTALL ALTERNATOR BELT.........................................................................2318 METHOD FOR REMOVING ALTERNATOR BELT....................................................................2318 METHOD FOR INSTALLING ALTERNATOR BELT..................................................................2320 REMOVE AND INSTALL AUTOMATIC TENSIONER.....................................................................2322 METHOD FOR REMOVING AUTOMATIC TENSIONER................................................................2322 METHOD FOR INSTALLING AUTOMATIC TENSIONER..............................................................2322 REMOVE AND INSTALL RADIATOR ASSEMBLY.......................................................................2324 METHOD FOR REMOVING RADIATOR ASSEMBLY..................................................................2324 METHOD FOR INSTALLING RADIATOR ASSEMBLY................................................................2327 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY...........................................................2331 METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY......................................................2331 METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY....................................................2337 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY....................................................................2342 METHOD FOR REMOVING AFTERCOOLER ASSEMBLY...............................................................2342 METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY.............................................................2344 REMOVE AND INSTALL FAN CLUTCH ASSEMBLY.....................................................................2346 METHOD FOR REMOVING FAN CLUTCH ASSEMBLY................................................................2347 METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY..............................................................2353 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY...........................................................2362 METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY......................................................2364 METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY....................................................2375 REMOVE AND INSTALL ENGINE FRONT OIL SEAL...................................................................2391 METHOD FOR REMOVING ENGINE FRONT OIL SEAL..............................................................2391 METHOD FOR INSTALLING ENGINE FRONT OIL SEAL............................................................2392 REMOVE AND INSTALL ENGINE REAR OIL SEAL....................................................................2394 METHOD FOR REMOVING ENGINE REAR OIL SEAL...............................................................2394 METHOD FOR INSTALLING ENGINE REAR OIL SEAL.............................................................2395 REMOVE AND INSTALL FUEL COOLER ASSEMBLY....................................................................2399 METHOD FOR REMOVING FUEL COOLER ASSEMBLY...............................................................2399 METHOD FOR INSTALLING FUEL COOLER ASSEMBLY.............................................................2401 REMOVE AND INSTALL KDOC ASSEMBLY...........................................................................2403 METHOD FOR REMOVING KDOC ASSEMBLY......................................................................2403 METHOD FOR INSTALLING KDOC ASSEMBLY....................................................................2408 REMOVE AND INSTALL KDOC AND SCR ASSEMBLY...................................................................2412 METHOD FOR REMOVING KDOC AND SCR ASSEMBLY..............................................................2413 METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY............................................................2420 REMOVE AND INSTALL FUEL TANK ASSEMBLY......................................................................2428 METHOD FOR REMOVING FUEL TANK ASSEMBLY.................................................................2429 METHOD FOR INSTALLING FUEL TANK ASSEMBLY...............................................................2436 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY................................................................2445 METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY...........................................................2446 METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY.........................................................2451 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..................................................2458 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.............................................2459 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...........................................2464 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR..................................................................2471 REMOVE AdBlue/DEF TANK SENSOR..........................................................................2471 INSTALL AdBlue/DEF TANK SENSOR.........................................................................2472 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER................................................................2479 METHOD FOR REMOVING AdBlue/DEF TANK STRAINER...........................................................2479 METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER.........................................................2479 REMOVE AND INSTALL SCR ASSEMBLY............................................................................2481 METHOD FOR REMOVING SCR ASSEMBLY.......................................................................2481 METHOD FOR INSTALLING SCR ASSEMBLY.....................................................................2486 REMOVE AND INSTALL KDOC AND SCR ASSEMBLY BRACKET...........................................................2491 METHOD FOR REMOVING KDOC AND SCR ASSEMBLY BRACKET......................................................2491 METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY BRACKET....................................................2495 REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY...................................................................2500 METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY..............................................................2501 METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY............................................................2503 REMOVE AND INSTALL KCCV ASSEMBLY...........................................................................2507 METHOD FOR REMOVING KCCV ASSEMBLY......................................................................2507 METHOD FOR INSTALLING KCCV ASSEMBLY....................................................................2509 REMOVE AND INSTALL EXHAUST THROTTLE VALVE..................................................................2511 METHOD FOR REMOVING EXHAUST THROTTLE VALVE.............................................................2512 METHOD FOR INSTALLING EXHAUST THROTTLE VALVE...........................................................2518 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE..................................................................2525 METHOD FOR REMOVING AdBlue/DEF MIXING TUBE.............................................................2526 METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE...........................................................2531 REMOVE AND INSTALL AdBlue/DEF INJECTOR.....................................................................2535 METHOD FOR REMOVING AdBlue/DEF INJECTOR................................................................2536 METHOD FOR INSTALLING AdBlue/DEF INJECTOR..............................................................2540 REMOVE AND INSTALL AdBlue/DEF PUMP.........................................................................2545 METHOD FOR REMOVING AdBlue/DEF PUMP....................................................................2546 METHOD FOR INSTALLING AdBlue/DEF PUMP..................................................................2549 REMOVE AND INSTALL AdBlue/DEF HOSE.........................................................................2553 METHOD FOR REMOVING AdBlue/DEF HOSE....................................................................2553 METHOD FOR INSTALLING AdBlue/DEF HOSE..................................................................2564 REMOVE AND INSTALL AIR CLEANER ASSEMBLY....................................................................2574 METHOD FOR REMOVING AIR CLEANER ASSEMBLY...............................................................2574 METHOD FOR INSTALLING AIR CLEANER ASSEMBLY.............................................................2576 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY.....................................................2580 METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY................................................2580 METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY..............................................2583 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY......................................................2586 METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY.................................................2586 METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY...............................................2588 POWER TRAIN....................................................................................................2590 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...................................................2590 METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY..............................................2591 METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY............................................2593 DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE MACHINE:50001～54383)............2597 METHOD FOR DISASSEMBLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE MACHINE:50001～54383)........2608 METHOD FOR ASSEMBLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE MACHINE:50001～54383)...........2625 DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE MACHINE:54384～).................2642 DISASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE MACHINE:54834～)..........................2654 ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE MACHINE:54384～).............................2672 REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY................................................2693 METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY...........................................2694 METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY.........................................2697 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY..........................................................2700 METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY......................................................2701 METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY.........................................................2704 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY...................................................................2710 METHOD FOR REMOVING SWING CIRCLE ASSEMBLY..............................................................2710 METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY............................................................2711 UNDERCARRIAGE AND FRAME........................................................................................2712 SEPARATION AND CONNECTION OF TRACK ASSEMBLY................................................................2712 METHOD FOR SEPARATING TRACK ASSEMBLY...................................................................2713 METHOD FOR INSTALLING TRACK ASSEMBLY...................................................................2715 REMOVE AND INSTALL SPROCKET................................................................................2718 METHOD FOR REMOVING SPROCKET...........................................................................2718 METHOD FOR INSTALLING SPROCKET.........................................................................2719 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY........................................................2720 METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY...................................................2720 METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY.................................................2721 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY....................................................................2722 METHOD FOR DISASSEMBLING IDLER ASSEMBLY................................................................2723 METHOD FOR ASSEMBLING IDLER ASSEMBLY...................................................................2724 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY.........................................................2728 METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY........................................................2728 METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY...........................................................2730 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY.............................................................2733 METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY.........................................................2733 METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY............................................................2735 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY................................................................2738 METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY...........................................................2739 METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY.........................................................2742 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY..................................................................2745 METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY.............................................................2746 METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY...........................................................2751 HYDRAULIC SYSTEM...............................................................................................2758 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY............................................................2758 METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY.......................................................2759 METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY.....................................................2762 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY......................................................2767 METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY..................................................2768 METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY.....................................................2769 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY.................................................................2770 METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY............................................................2771 METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY..........................................................2776 REMOVE AND INSTALL MAIN PUMP ASSEMBLY......................................................................2782 METHOD FOR REMOVING MAIN PUMP ASSEMBLY.................................................................2783 METHOD FOR INSTALLING MAIN PUMP ASSEMBLY...............................................................2788 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY..................................................................2795 METHOD FOR REMOVING CONTROL VALVE ASSEMBLY.............................................................2796 METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY...........................................................2806 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY............................................................2818 METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY...........................................................2818 METHOD FOR REPLACING PRESSURE REDUCING VALVE CARTRIDGE ASSEMBLY........................................2821 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY.................................................2824 METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY.............................................2824 METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY................................................2825 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY.........................................................2827 METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY.....................................................2827 METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY........................................................2827 WORK EQUIPMENT.................................................................................................2830 REMOVE AND INSTALL BLADE ASSEMBLY..........................................................................2830 METHOD FOR REMOVING BLADE ASSEMBLY.....................................................................2830 METHOD FOR INSTALLING BLADE ASSEMBLY...................................................................2831 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY.................................................................2834 METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY............................................................2835 METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY..........................................................2841 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY..................................................2847 METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY..............................................2848 METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY.................................................2850 CAB AND ITS ATTACHMENTS........................................................................................2857 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY(MACHINE WITH KOMTRAX TERMINAL)..................................2857 REMOVE OPERATOR CAB ASSEMBLY(MACHINE WITH KOMTRAX TERMINAL)............................................2857 INSTALL OPERATOR CAB ASSEMBLY(MACHINE WITH KOMTRAX TERMINAL)...........................................2861 REMOVE AND INSTALL OPERATOR'S CAB DOOR.....................................................................2866 METHOD FOR INSTALLING OPERATOR'S CAB DOOR..............................................................2867 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)......................................................2871 METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS).................................................2872 METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)...............................................2873 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY...................................................................2882 METHOD FOR REMOVING FRONT WINDOW ASSEMBLY..............................................................2882 METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY............................................................2885 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY....................................................................2886 METHOD FOR REMOVING FLOOR FRAME ASSEMBLY...............................................................2887 METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY.............................................................2897 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY...........................................................2908 METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY......................................................2908 METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY....................................................2914 REMOVE AND INSTALL OPERATOR'S SEAT.........................................................................2921 METHOD FOR REMOVING OPERATOR'S SEAT....................................................................2921 METHOD FOR INSTALLING OPERATOR'S SEAT..................................................................2922 REMOVE AND INSTALL SEAT BELT...............................................................................2923 METHOD FOR REMOVING SEAT BELT..........................................................................2923 METHOD FOR INSTALLING SEAT BELT........................................................................2924 REMOVE AND INSTALL FRONT WIPER ASSEMBLY....................................................................2925 METHOD FOR REMOVING FRONT WIPER ASSEMBLY...............................................................2925 METHOD FOR INSTALLING FRONT WIPER ASSEMBLY.............................................................2930 ELECTRICAL SYSTEM..............................................................................................2938 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY..............................................................2938 METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY.........................................................2938 METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY.......................................................2940 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY................................................................2941 METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY...........................................................2941 METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY.........................................................2944 REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY...........................................................2947 METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY......................................................2947 METHOD FOR INSTALLING KomVision CONTROLLER ASSEMBLY....................................................2949 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY................................................................2951 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY...........................................................2951 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY.........................................................2954 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR....................................................2958 METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR...............................................2958 METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR.............................................2959 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR..........................................................2961 METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR.....................................................2961 METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR...................................................2963 REMOVE AND INSTALL SCR TEMPERATURE SENSOR..................................................................2966 METHOD FOR REMOVING SCR TEMPERATURE SENSOR.............................................................2966 METHOD FOR INSTALLING SCR TEMPERATURE SENSOR...........................................................2967 REMOVE AND INSTALL REARVIEW CAMERA.........................................................................2969 METHOD FOR REMOVING REARVIEW CAMERA....................................................................2969 METHOD FOR INSTALLING REARVIEW CAMERA..................................................................2971 REMOVE AND INSTALL KomVision CAMERA........................................................................2973 METHOD FOR REMOVING KomVision CAMERA...................................................................2974 METHOD FOR INSTALLING KomVision CAMERA.................................................................2976 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY...............................................................2978 METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY..........................................................2978 METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY........................................................2980 REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY....................................................2982 REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY............................................................2982 INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY...........................................................2984 REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS...................................................2987 REMOVE COMMUNICATION TERMINAL WIRING HARNESS...........................................................2988 INSTALL COMMUNICATION TERMINAL WIRING HARNESS..........................................................2991 REMOVE AND INSTALL COMMUNICATION TERMINAL..................................................................2996 REMOVE COMMUNICATION TERMINAL..........................................................................2996 INSTALL COMMUNICATION TERMINAL.........................................................................2997 60 MAINTENANCE STANDARD............................................................................................2999 CONTENTS.......................................................................................................3000 ABBREVIATION LIST..............................................................................................3001 ENGINE AND COOLING SYSTEM......................................................................................3007 MAINTENANCE STANDARD OF ENGINE MOUNT.......................................................................3007 MAINTENANCE STANDARD FOR PTO...............................................................................3008 MAINTENANCE STANDARD OF COOLING SYSTEM.....................................................................3009 POWER TRAIN....................................................................................................3010 MAINTENANCE STANDARD OF SWING CIRCLE.......................................................................3010 MAINTENANCE STANDARD OF SWING MACHINERY....................................................................3011 MAINTENANCE STANDARD OF SPROCKET...........................................................................3013 UNDERCARRIAGE AND FRAME........................................................................................3014 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION......................................................3014 MAINTENANCE STANDARD OF IDLER..............................................................................3016 MAINTENANCE STANDARD OF TRACK ROLLER.......................................................................3017 MAINTENANCE STANDARD OF CARRIER ROLLER.....................................................................3018 MAINTENANCE STANDARD OF TRACK SHOE.........................................................................3019 MAINTENANCE STANDARD OF TRIPLE SHOE........................................................................3022 MAINTENANCE STANDARD OF ROAD LINER.........................................................................3023 HYDRAULIC SYSTEM...............................................................................................3024 MAINTENANCE STANDARD OF HYDRAULIC TANK.....................................................................3024 MAINTENANCE STANDARD OF MAIN PUMP..........................................................................3025 MAINTENANCE STANDARD OF PC-EPC VALVE.......................................................................3029 MAINTENANCE STANDARD OF SWING MOTOR........................................................................3030 MAINTENANCE STANDARD OF TRAVEL MOTOR (APPLICABLE MACHINE:50001～54383)......................................3033 MAINTENANCE STANDARD OF TRAVEL MOTOR (APPLICABLE MACHINE:54384～)...........................................3034 MAINTENANCE STANDARD OF CONTROL VALVE......................................................................3035 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE.................................................3046 MAINTENANCE STANDARD OF BLADE PPC VALVE....................................................................3049 MAINTENANCE STANDARD OF TRAVEL PPC VALVE...................................................................3051 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE).....................................3054 MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE.....................................3056 MAINTENANCE STANDARD OF SOLENOID VALVE.....................................................................3057 MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE SOLENOID VALVE..............................................3060 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)..............................3061 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)...............................3062 MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT).........................3063 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT................................................................3064 WORK EQUIPMENT.................................................................................................3065 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE.............................................................3065 DIMENSION OF ARM.......................................................................................3070 DIMENSIONS OF BUCKET...................................................................................3072 MAINTENANCE STANDARD OF BOOM CYLINDER......................................................................3074 MAINTENANCE STANDARD OF ARM CYLINDER.......................................................................3075 MAINTENANCE STANDARD OF BUCKET CYLINDER....................................................................3076 MAINTENANCE STANDARD OF BLADE CYLINDER.....................................................................3077 CAB AND ITS ATTACHMENTS........................................................................................3078 MAINTENANCE STANDARD OF CAB MOUNT..........................................................................3078 80 APPENDIX........................................................................................................3079 CONTENTS.......................................................................................................3080 ABBREVIATION LIST..............................................................................................3082 AIR CONDITIONER SYSTEM.........................................................................................3088 PRECAUTIONS FOR REFRIGERANT................................................................................3088 AIR CONDITIONER COMPONENT..................................................................................3089 SPECIFICATIONS OF AIR CONDITIONER..........................................................................3091 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE..........................................................3092 OUTLINE OF REFRIGERATION CYCLE.............................................................................3093 COMPONENT PARTS OF AIR CONDITIONER SYSTEM......................................................................3095 AIR CONDITIONER UNIT.......................................................................................3095 CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT..........................................................3095 FUNCTION OF AIR CONDITIONER UNIT.......................................................................3097 COMPONENT PARTS OF AIR CONDITIONER UNIT....................................................................3098 FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT...............................................3098 FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT..............................................3098 FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT............................3098 FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT..............................................3099 STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT.........................................3100 FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT..........................................3100 OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT..............................................3100 FUNCTION OF DUAL PRESSURE SWITCH.......................................................................3101 AIR CONDITIONER CONTROLLER.................................................................................3102 STRUCTURE OF AIR CONDITIONER CONTROLLER................................................................3102 COMPRESSOR.................................................................................................3103 STRUCTURE OF COMPRESSOR................................................................................3103 SPECIFICATIONS OF COMPRESSOR...........................................................................3103 FUNCTION OF COMPRESSOR.................................................................................3103 CONDENSER..................................................................................................3104 STRUCTURE OF CONDENSER.................................................................................3104 SPECIFICATIONS OF CONDENSER............................................................................3104 FUNCTION OF CONDENSER..................................................................................3104 SENSORS FOR AIR CONDITIONER SYSTEM.........................................................................3106 STRUCTURE OF SUNLIGHT SENSOR...........................................................................3106 FUNCTION OF SUNLIGHT SENSOR............................................................................3106 STRUCTURE OF AMBIENT TEMPERATURE SENSOR................................................................3106 FUNCTION OF AMBIENT TEMPERATURE SENSOR.................................................................3106 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER....................................3108 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER..........................................3110 AIR CONDITIONER SYSTEM DIAGRAM.................................................................................3112 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER.....................................................3113 FUNCTION OF AIR CONDITIONER CONTROLLER.................................................................3114 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS..................................3115 TESTING AIR LEAKAGE (DUCT).....................................................................................3124 METHOD FOR TESTING AIR LEAKAGE (DUCT)......................................................................3124 TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION..........................................................3126 HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR.............3127 TEST VENT (MODE) CHANGEOVER....................................................................................3128 METHOD FOR TESTING VENT (MODE) CHANGEOVER..................................................................3128 TESTING FRESH/RECIRC AIR CHANGEOVER............................................................................3129 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER.............................................................3129 TEST SUNLIGHT SENSOR...........................................................................................3130 METHOD FOR TESTING SUNLIGHT SENSOR.........................................................................3130 TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT....................................................................3131 METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT..................................................3131 TEST RELAYS....................................................................................................3133 METHOD FOR TESTING RELAYS..................................................................................3133 AIR CONDITIONER TROUBLESHOOTING CHART 1........................................................................3134 AIR CONDITIONER TROUBLESHOOTING CHART 2........................................................................3135 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................................3138 FAILURE CODE [879AKA]..........................................................................................3140 FAILURE CODE [879AKB]..........................................................................................3141 FAILURE CODE [879BKA]..........................................................................................3142 FAILURE CODE [879BKB]..........................................................................................3144 FAILURE CODE [879CKA]..........................................................................................3146 FAILURE CODE [879CKB]..........................................................................................3147 FAILURE CODE [879DKZ]..........................................................................................3148 FAILURE CODE [879EMC]..........................................................................................3150 FAILURE CODE [879FMC]..........................................................................................3151 FAILURE CODE [879GKX]..........................................................................................3152 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE).....................................3154 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)......................................3156 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL).............................3159 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER................................................................3161 TROUBLESHOOTING USING GAUGE PRESSURE...........................................................................3163 CONNECTION OF SERVICE TOOL.....................................................................................3165 METHOD FOR CONNECTING SERVICE TOOL.........................................................................3165 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS........................3167 HANDLE COMPRESSOR OIL..........................................................................................3169 METHOD FOR REPLACING DESICCANT.................................................................................3171 90 CIRCUIT DIAGRAMS................................................................................................3173 CONTENTS.......................................................................................................3174 ABBREVIATION LIST..............................................................................................3175 HYDRAULIC CIRCUIT DIAGRAM......................................................................................3181 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM..................................................................3181 HYDRAULIC CIRCUIT DIAGRAM..................................................................................3185 ELECTRICAL CIRCUIT DIAGRAM.....................................................................................3187 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM.................................................................3187 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (1/9)...........................................3191 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (2/9)...........................................3193 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (3/9)...........................................3195 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (4/9)...........................................3197 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (5/9)...........................................3199 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (6/9)...........................................3201 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (7/9)...........................................3203 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (8/9)...........................................3205 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (9/9)...........................................3207 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/11)...............................3209 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/11)...............................3211 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/11)...............................3213 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/11)...............................3215 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/11)...............................3217 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/11)...............................3219 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/11)...............................3221 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/11)...............................3223 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/11)...............................3225 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (10/11)..............................3227 ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (11/11)..............................3229 INDEX...............................................................................................................3231
DESCRIPTION:
KOMATSU PC138US-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06662-C2 – PDF DOWNLOAD
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.
S.S 30/12/24
