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KOMATSU PC138US-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL WENBM00310 – PDF DOWNLOAD
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KOMATSU PC138US-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL WENBM00310 – PDF DOWNLOAD
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KOMATSU PC138US-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL WENBM00310 – PDF DOWNLOAD
Language : English
Pages : 3434
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC138US-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL WENBM00310 – PDF DOWNLOAD
WENBM00310 PC138US-11E0..................................................................................................... 1 00 INDEX AND FOREWORD.................................................................................................. 3 INDEX.............................................................................................................. 4 FOREWORD, SAFETY, BASIC INFORMATION................................................................................ 22 HOW TO READ THE SHOP MANUAL.................................................................................... 22 SAFETY NOTICE FOR OPERATION.................................................................................... 24 PRECAUTIONS TO PREVENT FIRE.................................................................................... 32 ACTIONS IF FIRE OCCURS......................................................................................... 34 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS................................................................... 35 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS.................................................................. 36 PRECAUTIONS FOR DEF............................................................................................ 37 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING............................................................. 37 PRECAUTIONS FOR ADDING..................................................................................... 37 PRECAUTIONS FOR STORING.................................................................................... 37 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE.................................................................... 37 THE OTHER PRECAUTIONS...................................................................................... 37 STORE AdBlue/DEF............................................................................................... 38 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT................................................................... 39 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS........................................................ 42 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT.................................................................. 49 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT................................................................. 51 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT............................................................... 52 PRACTICAL USE OF KOMTRAX....................................................................................... 53 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER.................................................................. 54 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER...................................... 54 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER...................................... 55 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER...................................... 56 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS..................................................... 58 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR...................................................... 62 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR.............................................. 63 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL............................................ 65 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH............................................ 66 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE....................................... 68 HOW TO READ ELECTRICAL WIRE CODE............................................................................... 69 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................................. 73 STANDARD TIGHTENING TORQUE TABLE............................................................................... 76 CONVERSION TABLE............................................................................................... 83 ABBREVIATION LIST.............................................................................................. 88 01 SPECIFICATIONS...................................................................................................... 91 CONTENTS........................................................................................................... 92 SPECIFICATIONS..................................................................................................... 93 SPECIFICATION DRAWING.......................................................................................... 93 SPECIFICATION DRAWING: PC138US-11E0........................................................................ 93 WORKING RANGE DRAWINGS......................................................................................... 95 WORKING RANGE DRAWINGS: PC138US-11E0....................................................................... 95 SPECIFICATIONS................................................................................................. 96 SPECIFICATIONS: PC138US-11E0............................................................................... 96 WEIGHT TABLE................................................................................................... 100 WEIGHT TABLE: PC138US-11E0................................................................................. 100 FUEL, COOLANT, LUBRICANT....................................................................................... 102 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.......................................... 102 10 STRUCTURE AND FUNCTION.............................................................................................. 105 CONTENTS........................................................................................................... 106 UREA SCR SYSTEM.................................................................................................... 109 LAYOUT DRAWING OF UREA SCR SYSTEM.............................................................................. 109 UREA SCR SYSTEM DIAGRAM........................................................................................ 111 FUNCTION OF UREA SCR SYSTEM.................................................................................... 112 FUNCTION OF AdBlue/DEF SYSTEM.............................................................................. 112 INDUCEMENT STRATEGY........................................................................................ 115 COMPONENT PARTS OF UREA SCR SYSTEM............................................................................. 123 AdBlue/DEF MIXING TUBE..................................................................................... 123 SCR ASSEMBLY............................................................................................... 124 AdBlue/DEF TANK............................................................................................ 126 AdBlue/DEF PUMP............................................................................................ 128 AdBlue/DEF INJECTOR........................................................................................ 129 AdBlue/DEF HOSE............................................................................................ 130 AdBlue/DEF TANK HEATING VALVE.............................................................................. 131 BOOT-UP SYSTEM..................................................................................................... 132 LAYOUT DRAWING OF BOOT-UP SYSTEM............................................................................... 132 SYSTEM OPERATING LAMP SYSTEM................................................................................... 133 SYSTEM DIAGRAM OF SYSTEM OPERATING LAMP SYSTEM............................................................. 133 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM................................................................... 133 BATTERY DISCONNECT SWITCH...................................................................................... 134 FUNCTION OF BATTERY DISCONNECT SWITCH...................................................................... 134 ENGINE SYSTEM...................................................................................................... 135 LAYOUT DRAWING OF ENGINE SYSTEM................................................................................ 135 ENGINE CONTROL SYSTEM.......................................................................................... 137 SYSTEM DIAGRAM OF ENGINE CONTROL SYSTEM.................................................................... 137 FUNCTION OF ENGINE CONTROL SYSTEM.......................................................................... 138 AUTO-DECELERATION SYSTEM....................................................................................... 140 AUTO-DECELERATION SYSTEM DIAGRAM........................................................................... 140 FUNCTION OF AUTO-DECELERATION SYSTEM....................................................................... 140 OPERATION OF AUTO-DECELERATION SYSTEM...................................................................... 141 ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................ 142 ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM.................................................................... 142 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM................................................................ 143 OVERHEAT PREVENTION SYSTEM..................................................................................... 144 FUNCTION OF OVERHEAT PREVENTION SYSTEM..................................................................... 144 TURBOCHARGER PROTECTION SYSTEM................................................................................. 146 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM................................................................. 146 AUTOMATIC IDLE STOP SYSTEM..................................................................................... 147 AUTOMATIC IDLE STOP SYSTEM DIAGRAM......................................................................... 147 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM..................................................................... 147 COMPONENT PARTS OF ENGINE SYSTEM............................................................................... 150 PTO........................................................................................................ 150 VARIABLE FLOW TURBOCHARGER................................................................................. 151 EGR SYSTEM................................................................................................. 154 EGR VALVE.................................................................................................. 157 EGR COOLER................................................................................................. 160 KCCV SYSTEM................................................................................................ 162 KCCV VENTILATOR............................................................................................ 165 EXHAUST THROTTLE VALVE..................................................................................... 167 KDPF....................................................................................................... 168 COOLING SYSTEM..................................................................................................... 172 LAYOUT DRAWING OF COOLING SYSTEM............................................................................... 172 SPECIFICATIONS OF COOLING SYSTEM........................................................................... 173 FAN SPEED CONTROL SYSTEM OF FAN CLUTCH......................................................................... 174 FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH............................................................. 174 FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH......................................................... 175 ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH..................................................................... 176 ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH......................................................... 176 FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH..................................................... 176 COMPONENT PARTS OF COOLING SYSTEM.............................................................................. 178 FAN CLUTCH................................................................................................. 178 CONTROL SYSTEM..................................................................................................... 179 LAYOUT DRAWING OF CONTROL SYSTEM............................................................................... 179 MACHINE MONITOR SYSTEM......................................................................................... 181 SYSTEM DIAGRAM OF MACHINE MONITOR.......................................................................... 181 FUNCTION OF MACHINE MONITOR SYSTEM......................................................................... 181 KomVision SYSTEM............................................................................................... 183 LAYOUT DRAWING OF KomVision SYSTEM......................................................................... 183 KomVision SYSTEM DIAGRAM................................................................................... 185 FUNCTION OF KomVision SYSTEM............................................................................... 185 KOMTRAX SYSTEM................................................................................................. 187 SYSTEM DIAGRAM OF KOMTRAX SYSTEM........................................................................... 187 FUNCTION OF KOMTRAX SYSTEM................................................................................. 187 COMPONENT PARTS OF CONTROL SYSTEM.............................................................................. 188 MACHINE MONITOR............................................................................................ 188 KomVision CONTROLLER....................................................................................... 205 KomVision CAMERA........................................................................................... 209 GATEWAY FUNCTION CONTROLLER................................................................................ 210 COMMUNICATION TERMINAL..................................................................................... 213 PUMP CONTROLLER............................................................................................ 214 RESISTOR FOR PC-EPC VALVE.................................................................................. 218 CAN TERMINATING RESISTOR................................................................................... 219 ENGINE CONTROLLER.......................................................................................... 220 FUEL CONTROL DIAL.......................................................................................... 227 HYDRAULIC SYSTEM................................................................................................... 229 LAYOUT DRAWING OF HYDRAULIC SYSTEM............................................................................. 229 CLSS........................................................................................................... 231 STRUCTURE OF CLSS.......................................................................................... 231 FUNCTION OF CLSS........................................................................................... 232 ENGINE AND PUMP COMBINED CONTROL SYSTEM........................................................................ 234 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM............................................................ 234 FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM........................................................ 235 COMPONENT PARTS OF HYDRAULIC SYSTEM............................................................................ 239 HYDRAULIC TANK............................................................................................. 239 MAIN PUMP.................................................................................................. 241 CONTROL VALVE.............................................................................................. 268 WORK EQUIPMENT SYSTEM.............................................................................................. 328 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM........................................................................ 328 STRUCTURE OF VALVE CONTROL..................................................................................... 331 PPC LOCK SYSTEM................................................................................................ 332 PPC LOCK SYSTEM DIAGRAM.................................................................................... 332 FUNCTION OF PPC LOCK SYSTEM................................................................................ 332 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................ 333 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM.................................................... 333 FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................ 333 OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM............................................... 334 OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT........................................................................ 335 ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM................................................................ 335 FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT........................................................ 336 TOOL CONTROL SYSTEM............................................................................................ 337 TOOL CONTROL SYSTEM DIAGRAM................................................................................ 337 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM....................................................................... 339 WORK EQUIPMENT AND SWING PPC VALVE......................................................................... 339 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)............................................................. 344 BLADE PPC VALVE............................................................................................ 352 SOLENOID VALVE............................................................................................. 354 VARIABLE BACK PRESSURE SOLENOID VALVE...................................................................... 357 MULTI-CONTROL VALVE........................................................................................ 358 ARM DUMP QUICK RETURN VALVE................................................................................ 359 1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE.................................................................. 361 PILOT CIRCUIT ACCUMULATOR.................................................................................. 364 ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT).................................................. 365 SWING SYSTEM....................................................................................................... 366 LAYOUT DRAWING OF SWING SYSTEM................................................................................. 366 SWING CONTROL SYSTEM DIAGRAM................................................................................... 368 FUNCTION OF SWING CONTROL SYSTEM........................................................................... 369 COMPONENT PARTS OF SWING SYSTEM................................................................................ 371 SWING MOTOR................................................................................................ 371 SWING MACHINERY............................................................................................ 381 SWING CIRCLE............................................................................................... 383 TRAVEL SYSTEM...................................................................................................... 384 LAYOUT DRAWING OF TRAVEL SYSTEM................................................................................ 384 TRAVEL CONTROL SYSTEM DIAGRAM.................................................................................. 386 FUNCTION OF TRAVEL CONTROL SYSTEM.......................................................................... 387 COMPONENT PARTS OF TRAVEL SYSTEM............................................................................... 390 TRAVEL MOTOR............................................................................................... 390 TRAVEL PPC VALVE........................................................................................... 400 CENTER SWIVEL JOINT........................................................................................ 404 UNDERCARRIAGE AND FRAME............................................................................................ 406 LAYOUT DRAWING OF UNDERCARRIAGE................................................................................ 406 SPECIFICATIONS OF UNDERCARRIAGE............................................................................ 406 IDLER CUSHION.................................................................................................. 407 STRUCTURE OF IDLER CUSHION................................................................................. 407 SPECIFICATIONS OF IDLER CUSHION............................................................................ 407 WORK EQUIPMENT..................................................................................................... 408 STRUCTURE OF WORK EQUIPMENT.................................................................................... 408 FUNCTION OF WORK EQUIPMENT..................................................................................... 409 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM....................................................................... 410 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM....................................................... 410 BUCKET CLEARANCE ADJUSTMENT SHIM............................................................................... 411 FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM............................................................... 411 CAB AND ITS ATTACHMENTS............................................................................................ 412 ROPS CAB....................................................................................................... 412 STRUCTURE OF ROPS CAB...................................................................................... 412 FUNCTION OF ROPS CAB....................................................................................... 412 CAB MOUNT...................................................................................................... 413 STRUCTURE OF CAB MOUNT..................................................................................... 413 FUNCTION OF CAB MOUNT...................................................................................... 413 TAKE WIRING HARNESS OUT OF CAB................................................................................. 415 20 STANDARD VALUE TABLE................................................................................................ 417 CONTENTS........................................................................................................... 418 STANDARD VALUE TABLE FOR ENGINE.................................................................................... 419 STANDARD VALUE TABLE FOR ENGINE:PC138US-11E0................................................................... 419 STANDARD VALUE TABLE FOR MACHINE................................................................................... 423 STANDARD VALUE TABLE FOR MACHINE:PC138US-11E0.................................................................. 423 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE........................................................ 437 30 TESTING AND ADJUSTING............................................................................................... 441 CONTENTS........................................................................................................... 442 RELATED INFORMATION ON TESTING AND ADJUSTING....................................................................... 446 TOOLS FOR TESTING AND ADJUSTING................................................................................ 446 SKETCH OF TOOLS FOR TESTING AND ADJUSTING...................................................................... 453 ENGINE AND COOLING SYSTEM.......................................................................................... 455 TEST ENGINE SPEED.............................................................................................. 455 METHOD FOR TESTING ENGINE SPEED............................................................................ 455 TEST EXHAUST GAS COLOR......................................................................................... 458 TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER.............................................................. 458 TEST EXHAUST GAS COLOR BY SMOKE METER...................................................................... 459 TEST THE CLEARANCE OF THE EXHAUST THROTTLE VALVE............................................................... 461 MEASURE CLEARANCE OF THE EXHAUST THROTTLE VALVE............................................................ 461 TEST AND ADJUST VALVE CLEARANCE................................................................................ 464 METHOD FOR TESTING VALVE CLEARANCE......................................................................... 464 METHOD FOR ADJUSTING VALVE CLEARANCE....................................................................... 465 TEST COMPRESSION PRESSURE...................................................................................... 466 METHOD FOR TESTING COMPRESSION PRESSURE.................................................................... 466 TEST BLOWBY PRESSURE........................................................................................... 469 METHOD FOR TESTING BLOWBY PRESSURE......................................................................... 469 TEST ENGINE OIL PRESSURE....................................................................................... 471 TEST ENGINE OIL PRESSURE................................................................................... 471 VISUAL CHECK INSIDE OF EGR VALVE............................................................................... 473 VISUAL CHECK INSIDE OF EGR VALVE........................................................................... 473 CLEAN INSIDE OF EGR VALVE...................................................................................... 475 CLEAN INSIDE OF EGR VALVE.................................................................................. 475 TEST FUEL PRESSURE............................................................................................. 478 TEST FUEL PRESSURE......................................................................................... 478 TEST FUEL RETURN RATE AND LEAKAGE.............................................................................. 480 METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE............................................................ 481 BLEED AIR FROM FUEL SYSTEM..................................................................................... 484 BLEED AIR FROM FUEL SYSTEM................................................................................. 484 TEST FUEL CIRCUIT FOR LEAKAGE.................................................................................. 486 METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE................................................................ 486 HANDLE CYLINDER CUT-OUT MODE OPERATION......................................................................... 488 HANDLE NO-INJECTION CRANKING OPERATION......................................................................... 489 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION........................................................ 490 CHECK AIR CONDITIONER COMPRESSOR BELT...................................................................... 490 ADJUST AIR CONDITIONER COMPRESSOR BELT..................................................................... 490 TEST ALTERNATOR BELT........................................................................................... 492 METHOD FOR TESTING ALTERNATOR BELT......................................................................... 492 TEST AUTOMATIC TENSIONER....................................................................................... 493 METHOD FOR TESTING AUTOMATIC TENSIONER..................................................................... 493 TEST COOLING FAN SPEED......................................................................................... 495 METHOD FOR TESTING COOLING FAN SPEED....................................................................... 495 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER................................................. 496 METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER................................ 496 WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER......................................................... 497 METHOD FOR WRITING INJECTOR COMPENSATION VALUE............................................................. 497 TEST SCR RELATED FUNCTIONS..................................................................................... 503 TEST AdBlue/DEF PUMP RAISED PRESSURE....................................................................... 507 TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR............................................................. 510 TEST AdBlue/DEF LINE HEATER RELAY 1........................................................................ 515 TEST AdBlue/DEF LINE HEATER RELAY 2........................................................................ 519 TEST AdBlue/DEF PUMP HEATER RELAY.......................................................................... 522 TEST AdBlue/DEF TANK HEATER VALVE.......................................................................... 526 TEST DENITRATION EFFICIENCY OF SCR......................................................................... 530 CLEAN AdBlue/DEF TANK.......................................................................................... 533 METHOD FOR CLEANING AdBlue/DEF TANK........................................................................ 533 BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK.............................................................. 538 METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK............................................ 538 CLEAN AdBlue/DEF PUMP.......................................................................................... 540 CLEAN AdBlue/DEF PUMP...................................................................................... 540 POWER TRAIN........................................................................................................ 546 TEST SWING CIRCLE BEARING CLEARANCE............................................................................ 546 METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE.......................................................... 546 UNDERCARRIAGE AND FRAME............................................................................................ 547 TEST AND ADJUST TRACK TENSION.................................................................................. 547 METHOD FOR TESTING TRACK TENSION........................................................................... 547 METHOD FOR ADJUSTING TRACK TENSION......................................................................... 547 HYDRAULIC SYSTEM................................................................................................... 549 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................................... 549 RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK............................................................. 549 RELEASE REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT................................................... 549 METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT........................................... 550 RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT....................................................... 551 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS.............................. 552 METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS....................... 552 METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS..................... 559 TEST OIL PRESSURE OF CONTROL CIRCUIT........................................................................... 561 METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT......................................................... 561 TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT........................................................ 563 METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE).................................. 563 METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE............................................................ 564 METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT............................................... 565 TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT........................................................ 567 TEST LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR......................................................... 567 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE................................................................ 569 METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE).................................. 570 METHOD FOR ADJUSTING LS VALVE.............................................................................. 572 TEST OUTLET PRESSURE OF SOLENOID VALVE......................................................................... 573 METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE....................................................... 573 OPERATING CONDITION OF SOLENOID VALVE...................................................................... 574 METHOD FOR TESTING OUTLET PRESSURE OF VARIABLE BACK PRESSURE SOLENOID VALVE................................ 575 OPERATING CONDITION OF VARIABLE BACK PRESSURE SOLENOID VALVE............................................... 577 TEST PPC VALVE OUTLET PRESSURE................................................................................. 578 METHOD FOR TESTING PPC VALVE OUTLET PRESSURE............................................................... 578 TEST ATTACHMENT CIRCUIT OIL PRESSURE........................................................................... 580 METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE......................................................... 580 ADJUST WORK EQUIPMENT AND SWING PPC VALVES..................................................................... 581 METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES........................................... 581 TEST AND ADJUST TRAVEL DEVIATION............................................................................... 582 METHOD FOR TESTING TRAVEL DEVIATION........................................................................ 582 METHOD FOR ADJUSTING TRAVEL DEVIATION...................................................................... 582 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT....................................................... 585 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER.................. 585 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER....................................... 585 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE.......................................... 586 TEST OIL LEAKAGE............................................................................................... 587 METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER.......................................................... 587 METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER........................................................... 588 METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER........................................................ 588 METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER......................................................... 589 METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR............................................................ 589 METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR........................................................... 590 BLEED AIR FROM HYDRAULIC CIRCUIT............................................................................... 592 METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT............................................................. 593 TEST AND CHARGE ACCUMULATOR (MANUFACTURED BY EAGLE INDUSTRY CO., LTD.) NITROGEN GAS PRESSURE FOR ATTACHMENT.... 596 TEST ACCUMULATOR (MANUFACTURED BY EAGLE INDUSTRY CO., LTD.) NITROGEN GAS PRESSURE FOR ATTACHMENT........... 596 CAB AND ITS ATTACHMENTS............................................................................................ 600 TEST CAB TIPPING STOPPER....................................................................................... 600 METHOD FOR TESTING CAB TIPPING STOPPER..................................................................... 600 ADJUST MIRRORS................................................................................................. 601 ADJUST MACHINE LEFT FRONT MIRROR (A)....................................................................... 601 ADJUST MACHINE REAR MIRROR (B)............................................................................. 602 ELECTRICAL SYSTEM.................................................................................................. 603 SET AND OPERATE MACHINE MONITOR................................................................................ 603 OPERATOR MODE.............................................................................................. 608 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN................................................ 608 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN................................................... 608 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY).......................................................... 609 CHECKING FUNCTION OF SERVICE METER......................................................................... 609 METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD.................................................. 609 SERVICE MODE............................................................................................... 613 OPERATE SERVICE MODE....................................................................................... 613 METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION..................................................... 616 METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION..................................................... 622 ABNORMALITY RECORD MENU.................................................................................... 633 CHECK MAINTENANCE RECORD................................................................................... 637 MAINTENANCE MODE SETTING................................................................................... 638 METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING............................................................ 642 DEFAULT MENU............................................................................................... 644 DIAGNOSTIC TESTS MENU...................................................................................... 657 ADJUSTMENT MENU............................................................................................ 668 METHOD FOR PERFORMING NO-INJECTION CRANKING................................................................ 692 KOMTRAX SETTINGS MENU...................................................................................... 694 METHOD FOR DISPLAYING SERVICE MESSAGE...................................................................... 696 START UP KOMTRAX SYSTEM........................................................................................ 698 STOP USING OF KOMTRAX SYSTEM................................................................................... 704 ADJUST KomVision CAMERA ANGLE.................................................................................. 706 ADJUST KomVision CAMERA ANGLE.............................................................................. 707 ADJUST KomVision CAMERA ANGLE (RIGHT REAR CAMERA).......................................................... 708 ADJUST KomVision RELATED ITEMS................................................................................. 710 SETTING OF KomVision (MAIN SETTING)........................................................................ 711 SETTING OF KomVision (CAMERA SETTING)...................................................................... 714 SETTING OF KomVision (CAMERA CALIBRATION).................................................................. 716 SET REGION OF Bluetooth(R) COMPATIBLE RADIO.................................................................... 729 SET REGION OF Bluetooth(R) COMPATIBLE RADIO................................................................ 729 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER.................................................................... 731 BATTERY DISCONNECT SWITCH...................................................................................... 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-11E0........................................................................ 735 40 TROUBLESHOOTING..................................................................................................... 745 CONTENTS........................................................................................................... 746 RELATED INFORMATION ON TROUBLESHOOTING............................................................................. 757 GENERAL TROUBLESHOOTING POINTS................................................................................. 757 TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEM............................................................... 758 SEQUENCE OF EVENTS IN TROUBLESHOOTING.......................................................................... 770 CHECKS BEFORE TROUBLESHOOTING.................................................................................. 772 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING.................................................................... 774 WALK-AROUND CHECK.......................................................................................... 774 TESTING IN ACCORDANCE WITH TESTING PROCEDURE................................................................... 776 CHECK FUEL LEVEL AND TYPE.................................................................................. 776 CHECK FUEL PREFILTER....................................................................................... 777 WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT......................................................... 777 METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE.............................................................. 777 CHECK MAIN FILTER.......................................................................................... 779 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)............................................................. 780 CHECK OIL LEVEL IN PTO GEAR CASE........................................................................... 781 CHECK COOLANT LEVEL (RESERVOIR TANK)....................................................................... 782 CHECK CLOGGING OF AIR CLEANER.............................................................................. 782 OUTER ELEMENT - CLEAN...................................................................................... 783 ELEMENTS - REPLACE......................................................................................... 785 CHECK HYDRAULIC OIL LEVEL.................................................................................. 786 CHECK HYDRAULIC OIL STRAINER............................................................................... 788 CHECK HYDRAULIC FILTER..................................................................................... 788 CHECK OIL LEVEL IN SWING MACHINERY CASE.................................................................... 789 CHECK OIL LEVEL IN FINAL DRIVE CASE........................................................................ 790 BLEED AIR FROM FUEL SYSTEM................................................................................. 790 BLEED AIR FROM HYDRAULIC SYSTEM............................................................................ 790 METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod............................................................... 791 PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM........................................................... 796 PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR......................................................... 796 PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER....................................................... 796 PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER......................................................... 797 PREPARATION FOR TROUBLESHOOTING OF GATEWAY FUNCTION CONTROLLER............................................. 797 DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK....................................................... 798 PROCEDURE FOR TESTING AND TROUBLESHOOTING...................................................................... 803 SYMPTOM AND TROUBLESHOOTING NUMBERS............................................................................ 806 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE................................................................. 811 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM............................ 813 CONNECTOR LIST AND LAYOUT...................................................................................... 816 CONNECTOR CONTACT IDENTIFICATION............................................................................... 830 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE........................................................................ 870 FUSE LOCATION TABLE............................................................................................ 876 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC).................................................... 879 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]).................... 883 FAILURE CODE TABLE............................................................................................. 885 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE).................................................................. 903 FAILURE CODE [6AZ0ZG].......................................................................................... 903 FAILURE CODE [879AKA].......................................................................................... 905 FAILURE CODE [879AKB].......................................................................................... 907 FAILURE CODE [879BKA].......................................................................................... 909 FAILURE CODE [879BKB].......................................................................................... 911 FAILURE CODE [879CKA].......................................................................................... 913 FAILURE CODE [879CKB].......................................................................................... 914 FAILURE CODE [879DKZ].......................................................................................... 915 FAILURE CODE [879EMC].......................................................................................... 918 FAILURE CODE [879FMC].......................................................................................... 919 FAILURE CODE [879GKX].......................................................................................... 920 FAILURE CODE [989L00].......................................................................................... 922 FAILURE CODE [989M00].......................................................................................... 923 FAILURE CODE [989N00].......................................................................................... 924 FAILURE CODE [A1U0N3].......................................................................................... 925 FAILURE CODE [A1U0N4].......................................................................................... 927 FAILURE CODE [A900FR].......................................................................................... 929 FAILURE CODE [A900N6].......................................................................................... 930 FAILURE CODE [A900NY].......................................................................................... 931 FAILURE CODE [AA10NX].......................................................................................... 932 FAILURE CODE [AB00KE].......................................................................................... 934 FAILURE CODE [AQ10MB].......................................................................................... 937 FAILURE CODE [AQ10N3].......................................................................................... 939 FAILURE CODE [AS00R2].......................................................................................... 941 FAILURE CODE [AS00R3].......................................................................................... 942 FAILURE CODE [AS00R4].......................................................................................... 943 FAILURE CODE [AS00R6].......................................................................................... 944 FAILURE CODE [AS10KM].......................................................................................... 945 FAILURE CODE [AS10NR].......................................................................................... 946 FAILURE CODE [AS10NT].......................................................................................... 947 FAILURE CODE [AU10QA].......................................................................................... 948 FAILURE CODE [B@BAZG].......................................................................................... 949 FAILURE CODE [B@BAZK].......................................................................................... 950 FAILURE CODE [B@BCNS].......................................................................................... 952 FAILURE CODE [B@BCQA].......................................................................................... 953 FAILURE CODE [B@BCZK].......................................................................................... 955 FAILURE CODE [B@HANS].......................................................................................... 957 FAILURE CODE [CA115]........................................................................................... 959 FAILURE CODE [CA122]........................................................................................... 961 FAILURE CODE [CA123]........................................................................................... 965 FAILURE CODE [CA131]........................................................................................... 969 FAILURE CODE [CA132]........................................................................................... 972 FAILURE CODE [CA144]........................................................................................... 975 FAILURE CODE [CA145]........................................................................................... 979 FAILURE CODE [CA153]........................................................................................... 982 FAILURE CODE [CA154]........................................................................................... 986 FAILURE CODE [CA187]........................................................................................... 990 FAILURE CODE [CA221]........................................................................................... 992 FAILURE CODE [CA222]........................................................................................... 996 FAILURE CODE [CA227]........................................................................................... 999 FAILURE CODE [CA234]...........................................................................................1000 FAILURE CODE [CA238]...........................................................................................1002 FAILURE CODE [CA239]...........................................................................................1004 FAILURE CODE [CA249]...........................................................................................1006 FAILURE CODE [CA256]...........................................................................................1009 FAILURE CODE [CA271]...........................................................................................1012 FAILURE CODE [CA272]...........................................................................................1015 FAILURE CODE [CA322]...........................................................................................1017 FAILURE CODE [CA324]...........................................................................................1021 FAILURE CODE [CA331]...........................................................................................1025 FAILURE CODE [CA332]...........................................................................................1029 FAILURE CODE [CA343]...........................................................................................1033 FAILURE CODE [CA351]...........................................................................................1034 FAILURE CODE [CA352]...........................................................................................1035 FAILURE CODE [CA356]...........................................................................................1038 FAILURE CODE [CA357]...........................................................................................1041 FAILURE CODE [CA386]...........................................................................................1045 FAILURE CODE [CA435]...........................................................................................1046 FAILURE CODE [CA441]...........................................................................................1048 FAILURE CODE [CA442]...........................................................................................1051 FAILURE CODE [CA449]...........................................................................................1052 FAILURE CODE [CA451]...........................................................................................1053 FAILURE CODE [CA452]...........................................................................................1056 FAILURE CODE [CA515]...........................................................................................1059 FAILURE CODE [CA516]...........................................................................................1061 FAILURE CODE [CA553]...........................................................................................1064 FAILURE CODE [CA555]...........................................................................................1066 FAILURE CODE [CA556]...........................................................................................1068 FAILURE CODE [CA559]...........................................................................................1070 FAILURE CODE [CA689]...........................................................................................1076 FAILURE CODE [CA691]...........................................................................................1081 FAILURE CODE [CA692]...........................................................................................1084 FAILURE CODE [CA697]...........................................................................................1087 FAILURE CODE [CA698]...........................................................................................1088 FAILURE CODE [CA731]...........................................................................................1089 FAILURE CODE [CA778]...........................................................................................1092 FAILURE CODE [CA1117]..........................................................................................1099 FAILURE CODE [CA1664]..........................................................................................1101 FAILURE CODE [CA1669]..........................................................................................1104 FAILURE CODE [CA1673]..........................................................................................1106 FAILURE CODE [CA1677]..........................................................................................1108 FAILURE CODE [CA1678]..........................................................................................1110 FAILURE CODE [CA1682]..........................................................................................1112 FAILURE CODE [CA1683]..........................................................................................1115 FAILURE CODE [CA1684]..........................................................................................1118 FAILURE CODE [CA1686]..........................................................................................1121 FAILURE CODE [CA1691]..........................................................................................1123 FAILURE CODE [CA1694]..........................................................................................1126 FAILURE CODE [CA1695]..........................................................................................1128 FAILURE CODE [CA1696]..........................................................................................1129 FAILURE CODE [CA1712]..........................................................................................1132 FAILURE CODE [CA1713]..........................................................................................1135 FAILURE CODE [CA1714]..........................................................................................1138 FAILURE CODE [CA1715]..........................................................................................1140 FAILURE CODE [CA1776]..........................................................................................1142 FAILURE CODE [CA1777]..........................................................................................1145 FAILURE CODE [CA1843]..........................................................................................1149 FAILURE CODE [CA1844]..........................................................................................1152 FAILURE CODE [CA1883]..........................................................................................1156 FAILURE CODE [CA1885]..........................................................................................1161 FAILURE CODE [CA1887]..........................................................................................1164 FAILURE CODE [CA1896]..........................................................................................1167 FAILURE CODE [CA1921]..........................................................................................1171 FAILURE CODE [CA1922]..........................................................................................1175 FAILURE CODE [CA1938]..........................................................................................1180 FAILURE CODE [CA1942]..........................................................................................1183 FAILURE CODE [CA1961]..........................................................................................1185 FAILURE CODE [CA1993]..........................................................................................1186 FAILURE CODE [CA2185]..........................................................................................1191 FAILURE CODE [CA2186]..........................................................................................1193 FAILURE CODE [CA2249]..........................................................................................1195 FAILURE CODE [CA2272]..........................................................................................1196 FAILURE CODE [CA2311]..........................................................................................1200 FAILURE CODE [CA2349]..........................................................................................1201 FAILURE CODE [CA2353]..........................................................................................1204 FAILURE CODE [CA2357]..........................................................................................1207 FAILURE CODE [CA2636]..........................................................................................1208 FAILURE CODE [CA2637]..........................................................................................1212 FAILURE CODE [CA2639]..........................................................................................1214 FAILURE CODE [CA2765]..........................................................................................1216 FAILURE CODE [CA2771]..........................................................................................1217 FAILURE CODE [CA2777]..........................................................................................1225 FAILURE CODE [CA2976]..........................................................................................1228 FAILURE CODE [CA3135]..........................................................................................1232 FAILURE CODE [CA3142]..........................................................................................1235 FAILURE CODE [CA3143]..........................................................................................1236 FAILURE CODE [CA3144]..........................................................................................1237 FAILURE CODE [CA3146]..........................................................................................1240 FAILURE CODE [CA3147]..........................................................................................1241 FAILURE CODE [CA3148]..........................................................................................1242 FAILURE CODE [CA3151]..........................................................................................1245 FAILURE CODE [CA3165]..........................................................................................1251 FAILURE CODE [CA3229]..........................................................................................1254 FAILURE CODE [CA3231]..........................................................................................1257 FAILURE CODE [CA3232]..........................................................................................1259 FAILURE CODE [CA3235]..........................................................................................1264 FAILURE CODE [CA3239]..........................................................................................1267 FAILURE CODE [CA3241]..........................................................................................1271 FAILURE CODE [CA3242]..........................................................................................1275 FAILURE CODE [CA3251]..........................................................................................1278 FAILURE CODE [CA3255]..........................................................................................1281 FAILURE CODE [CA3256]..........................................................................................1284 FAILURE CODE [CA3312]..........................................................................................1286 FAILURE CODE [CA3313]..........................................................................................1289 FAILURE CODE [CA3314]..........................................................................................1291 FAILURE CODE [CA3315]..........................................................................................1292 FAILURE CODE [CA3318]..........................................................................................1294 FAILURE CODE [CA3322]..........................................................................................1296 FAILURE CODE [CA3419]..........................................................................................1298 FAILURE CODE [CA3421]..........................................................................................1300 FAILURE CODE [CA3497]..........................................................................................1302 FAILURE CODE [CA3498]..........................................................................................1304 FAILURE CODE [CA3545]..........................................................................................1306 FAILURE CODE [CA3547]..........................................................................................1309 FAILURE CODE [CA3558]..........................................................................................1311 FAILURE CODE [CA3559]..........................................................................................1314 FAILURE CODE [CA3562]..........................................................................................1317 FAILURE CODE [CA3563]..........................................................................................1320 FAILURE CODE [CA3567]..........................................................................................1325 FAILURE CODE [CA3568]..........................................................................................1329 FAILURE CODE [CA3571]..........................................................................................1333 FAILURE CODE [CA3572]..........................................................................................1336 FAILURE CODE [CA3574]..........................................................................................1339 FAILURE CODE [CA3575]..........................................................................................1342 FAILURE CODE [CA3577]..........................................................................................1344 FAILURE CODE [CA3578]..........................................................................................1347 FAILURE CODE [CA3582]..........................................................................................1350 FAILURE CODE [CA3583]..........................................................................................1356 FAILURE CODE [CA3596]..........................................................................................1359 FAILURE CODE [CA3649]..........................................................................................1362 FAILURE CODE [CA3681]..........................................................................................1365 FAILURE CODE [CA3682]..........................................................................................1372 FAILURE CODE [CA3713]..........................................................................................1379 FAILURE CODE [CA3717]..........................................................................................1383 FAILURE CODE [CA3718]..........................................................................................1385 FAILURE CODE [CA3724]..........................................................................................1387 FAILURE CODE [CA3725]..........................................................................................1388 FAILURE CODE [CA3748]..........................................................................................1391 FAILURE CODE [CA3755]..........................................................................................1393 FAILURE CODE [CA3866]..........................................................................................1395 FAILURE CODE [CA3867]..........................................................................................1400 FAILURE CODE [CA3868]..........................................................................................1404 FAILURE CODE [CA3899]..........................................................................................1409 FAILURE CODE [CA3911]..........................................................................................1412 FAILURE CODE [CA3912]..........................................................................................1417 FAILURE CODE [CA3918]..........................................................................................1420 FAILURE CODE [CA3921]..........................................................................................1423 FAILURE CODE [CA3928]..........................................................................................1428 FAILURE CODE [CA3932]..........................................................................................1429 FAILURE CODE [CA3933]..........................................................................................1432 FAILURE CODE [CA3934]..........................................................................................1435 FAILURE CODE [CA3935]..........................................................................................1439 FAILURE CODE [CA3936]..........................................................................................1442 FAILURE CODE [CA4152]..........................................................................................1444 FAILURE CODE [CA4155]..........................................................................................1449 FAILURE CODE [CA4156]..........................................................................................1452 FAILURE CODE [CA4157]..........................................................................................1456 FAILURE CODE [CA4159]..........................................................................................1458 FAILURE CODE [CA4164]..........................................................................................1460 FAILURE CODE [CA4165]..........................................................................................1463 FAILURE CODE [CA4166]..........................................................................................1466 FAILURE CODE [CA4168]..........................................................................................1468 FAILURE CODE [CA4169]..........................................................................................1471 FAILURE CODE [CA4171]..........................................................................................1473 FAILURE CODE [CA4249]..........................................................................................1476 FAILURE CODE [CA4251]..........................................................................................1478 FAILURE CODE [CA4261]..........................................................................................1480 FAILURE CODE [CA4277]..........................................................................................1484 FAILURE CODE [CA4281]..........................................................................................1489 FAILURE CODE [CA4459]..........................................................................................1492 FAILURE CODE [CA4461]..........................................................................................1495 FAILURE CODE [CA4533]..........................................................................................1500 FAILURE CODE [CA4534]..........................................................................................1501 FAILURE CODE [CA4731]..........................................................................................1503 FAILURE CODE [CA4732]..........................................................................................1505 FAILURE CODE [CA4739]..........................................................................................1507 FAILURE CODE [CA4768]..........................................................................................1509 FAILURE CODE [CA4769]..........................................................................................1512 FAILURE CODE [CA4842]..........................................................................................1515 FAILURE CODE [CA4952]..........................................................................................1520 FAILURE CODE [CA5115]..........................................................................................1522 FAILURE CODE [CA5179]..........................................................................................1526 FAILURE CODE [CA5181]..........................................................................................1529 FAILURE CODE [CA5271]..........................................................................................1532 FAILURE CODE [CA5272]..........................................................................................1535 FAILURE CODE [CA5273]..........................................................................................1538 FAILURE CODE [CA5274]..........................................................................................1541 FAILURE CODE [CA5275]..........................................................................................1543 FAILURE CODE [CA5276]..........................................................................................1546 FAILURE CODE [CA5277]..........................................................................................1549 FAILURE CODE [CA5383]..........................................................................................1551 FAILURE CODE [CA5387]..........................................................................................1553 FAILURE CODE [CA5388]..........................................................................................1555 FAILURE CODE [CA5389]..........................................................................................1558 FAILURE CODE [CA5391]..........................................................................................1560 FAILURE CODE [CA5392]..........................................................................................1566 FAILURE CODE [CA5393]..........................................................................................1568 FAILURE CODE [CA5394]..........................................................................................1571 FAILURE CODE [CA5395]..........................................................................................1574 FAILURE CODE [CA5396]..........................................................................................1577 FAILURE CODE [CA5631]..........................................................................................1579 FAILURE CODE [CA5938]..........................................................................................1581 FAILURE CODE [D110KB]..........................................................................................1583 FAILURE CODE [D19JKZ]..........................................................................................1585 FAILURE CODE [D811MC]..........................................................................................1588 FAILURE CODE [D862KA]..........................................................................................1589 FAILURE CODE [D8ALKA]..........................................................................................1591 FAILURE CODE [D8ALKB]..........................................................................................1594 FAILURE CODE [D8AQKR]..........................................................................................1596 FAILURE CODE [D8ARKR]..........................................................................................1601 FAILURE CODE [D8G1KT]..........................................................................................1606 FAILURE CODE [D8G6KT]..........................................................................................1607 FAILURE CODE [DA20MC]..........................................................................................1608 FAILURE CODE [DA22KK]..........................................................................................1609 FAILURE CODE [DA22KT]..........................................................................................1613 FAILURE CODE [DA25KP]..........................................................................................1616 FAILURE CODE [DA26KP]..........................................................................................1621 FAILURE CODE [DA29KQ]..........................................................................................1624 FAILURE CODE [DA2JKT]..........................................................................................1627 FAILURE CODE [DA2JKY]..........................................................................................1628 FAILURE CODE [DA2LKA]..........................................................................................1629 FAILURE CODE [DA2LKB]..........................................................................................1632 FAILURE CODE [DA2QKR]..........................................................................................1634 FAILURE CODE [DA2RKR]..........................................................................................1641 FAILURE CODE [DAF0KM]..........................................................................................1648 FAILURE CODE [DAF0MB]..........................................................................................1649 FAILURE CODE [DAF0MC]..........................................................................................1650 FAILURE CODE [DAF8KB]..........................................................................................1651 FAILURE CODE [DAF9KQ]..........................................................................................1653 FAILURE CODE [DAFGMC]..........................................................................................1655 FAILURE CODE [DAFLKA]..........................................................................................1656 FAILURE CODE [DAFLKB]..........................................................................................1659 FAILURE CODE [DAFQKR]..........................................................................................1661 FAILURE CODE [DAZ9KQ]..........................................................................................1667 FAILURE CODE [DAZQKR]..........................................................................................1669 FAILURE CODE [DB2QKR]..........................................................................................1674 FAILURE CODE [DB2RKR]..........................................................................................1681 FAILURE CODE [DBP0KM]..........................................................................................1689 FAILURE CODE [DBP0KT]..........................................................................................1690 FAILURE CODE [DBP5KB]..........................................................................................1691 FAILURE CODE [DBP5KY]..........................................................................................1694 FAILURE CODE [DBPQKR]..........................................................................................1697 FAILURE CODE [DDNRKA]..........................................................................................1703 FAILURE CODE [DDNRKY]..........................................................................................1706 FAILURE CODE [DDNS00]..........................................................................................1709 FAILURE CODE [DFB1KZ]..........................................................................................1712 FAILURE CODE [DFB2KZ]..........................................................................................1715 FAILURE CODE [DFB3L8]..........................................................................................1718 FAILURE CODE [DFB4L8]..........................................................................................1720 FAILURE CODE [DFB5KZ]..........................................................................................1722 FAILURE CODE [DFB6KZ]..........................................................................................1725 FAILURE CODE [DGH2KA]..........................................................................................1728 FAILURE CODE [DGH2KB]..........................................................................................1730 FAILURE CODE [DHA4KA]..........................................................................................1732 FAILURE CODE [DHAAMA]..........................................................................................1734 FAILURE CODE [DHACMA]..........................................................................................1736 FAILURE CODE [DHPAMA]..........................................................................................1738 FAILURE CODE [DHS3MA]..........................................................................................1741 FAILURE CODE [DHS4MA]..........................................................................................1744 FAILURE CODE [DHS8MA]..........................................................................................1747 FAILURE CODE [DHS9MA]..........................................................................................1750 FAILURE CODE [DHSAMA]..........................................................................................1753 FAILURE CODE [DHSBMA]..........................................................................................1756 FAILURE CODE [DHSCMA]..........................................................................................1759 FAILURE CODE [DHSDMA]..........................................................................................1762 FAILURE CODE [DHSFMA]..........................................................................................1765 FAILURE CODE [DHSGMA]..........................................................................................1768 FAILURE CODE [DHSHMA]..........................................................................................1771 FAILURE CODE [DHSJMA]..........................................................................................1774 FAILURE CODE [DHSKMA]..........................................................................................1777 FAILURE CODE [DHSLMA]..........................................................................................1779 FAILURE CODE [DHX1MA]..........................................................................................1781 FAILURE CODE [DKULKA]..........................................................................................1782 FAILURE CODE [DKULKB]..........................................................................................1784 FAILURE CODE [DKULKY]..........................................................................................1787 FAILURE CODE [DLM5KA]..........................................................................................1789 FAILURE CODE [DLM5MB]..........................................................................................1793 FAILURE CODE [DR10KA]..........................................................................................1795 FAILURE CODE [DR12KA]..........................................................................................1800 FAILURE CODE [DR20KA]..........................................................................................1802 FAILURE CODE [DR21KX]..........................................................................................1804 FAILURE CODE [DR30KA]..........................................................................................1805 FAILURE CODE [DR31KX]..........................................................................................1807 FAILURE CODE [DR40KA]..........................................................................................1808 FAILURE CODE [DUMBKA]..........................................................................................1810 FAILURE CODE [DUMBKB]..........................................................................................1813 FAILURE CODE [DV00KA]..........................................................................................1815 FAILURE CODE [DV00KB]..........................................................................................1816 FAILURE CODE [DV20KB]..........................................................................................1817 FAILURE CODE [DW43KA]..........................................................................................1819 FAILURE CODE [DW43KB]..........................................................................................1821 FAILURE CODE [DW43KY]..........................................................................................1823 FAILURE CODE [DW45KA]..........................................................................................1825 FAILURE CODE [DW45KB]..........................................................................................1829 FAILURE CODE [DW45KY]..........................................................................................1833 FAILURE CODE [DW4CKY]..........................................................................................1835 FAILURE CODE [DW91KA]..........................................................................................1837 FAILURE CODE [DW91KB]..........................................................................................1839 FAILURE CODE [DW91KY]..........................................................................................1841 FAILURE CODE [DWA2KA]..........................................................................................1843 FAILURE CODE [DWA2KB]..........................................................................................1845 FAILURE CODE [DWA2KY]..........................................................................................1847 FAILURE CODE [DWJ0KA]..........................................................................................1849 FAILURE CODE [DWJ0KB]..........................................................................................1851 FAILURE CODE [DWJ0KY]..........................................................................................1853 FAILURE CODE [DWK2KA]..........................................................................................1855 FAILURE CODE [DWK2KB]..........................................................................................1857 FAILURE CODE [DWK2KY]..........................................................................................1859 FAILURE CODE [DWN5KA]..........................................................................................1861 FAILURE CODE [DWN5KB]..........................................................................................1864 FAILURE CODE [DWN5KY]..........................................................................................1866 FAILURE CODE [DWNSKA]..........................................................................................1868 FAILURE CODE [DWNSKB]..........................................................................................1870 FAILURE CODE [DWNSKY]..........................................................................................1872 FAILURE CODE [DXA8KA]..........................................................................................1874 FAILURE CODE [DXA8KB]..........................................................................................1878 FAILURE CODE [DXE4KA]..........................................................................................1881 FAILURE CODE [DXE4KB]..........................................................................................1883 FAILURE CODE [DXE4KY]..........................................................................................1885 FAILURE CODE [DXE7KA]..........................................................................................1887 FAILURE CODE [DXE7KB]..........................................................................................1889 FAILURE CODE [DXE7KY]..........................................................................................1891 FAILURE CODE [DXE8KA]..........................................................................................1893 FAILURE CODE [DXE8KB]..........................................................................................1895 FAILURE CODE [DXE8KY]..........................................................................................1897 FAILURE CODE [DXE9KA]..........................................................................................1899 FAILURE CODE [DXE9KB]..........................................................................................1901 FAILURE CODE [DXE9KY]..........................................................................................1903 FAILURE CODE [DXEAKA]..........................................................................................1905 FAILURE CODE [DXEAKB]..........................................................................................1907 FAILURE CODE [DXEAKY]..........................................................................................1909 FAILURE CODE [DXEKKA]..........................................................................................1911 FAILURE CODE [DXEKKB]..........................................................................................1913 FAILURE CODE [DXEKKY]..........................................................................................1915 FAILURE CODE [DXELKA]..........................................................................................1917 FAILURE CODE [DXELKB]..........................................................................................1919 FAILURE CODE [DXELKY]..........................................................................................1921 FAILURE CODE [DY20KA]..........................................................................................1923 FAILURE CODE [DY20MA]..........................................................................................1926 FAILURE CODE [DY2CKB]..........................................................................................1929 FAILURE CODE [DY2DKB]..........................................................................................1933 FAILURE CODE [DY2EKB]..........................................................................................1936 FAILURE CODE [F313KA]..........................................................................................1939 FAILURE CODE [F313KB]..........................................................................................1941 FAILURE CODE [F318KB]..........................................................................................1943 FAILURE CODE [F318KY]..........................................................................................1945 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)......................................................................1947 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)..................................................................1947 MANUAL PREHEATING SYSTEM DOES NOT WORK.........................................................................1953 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP..............................................1956 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING................................1958 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING..................................1961 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...................................1962 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING.......................................1963 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..................................................1964 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....................................................1965 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....................................1966 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...........................................1967 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.....................................1968 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.......................................................1969 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL...........................................................1971 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.................................1972 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE............................1973 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY.....................................................................1974 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM..................................1977 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE.................................1979 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED.........................................................1980 FUNCTION SWITCH DOES NOT OPERATE...............................................................................1981 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER).......................................................1982 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF........1983 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER........................................................1984 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED...........................1986 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED..............................1987 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE.....................................1988 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE....................................1989 ALARM BUZZER CANNOT BE CANCELED................................................................................1990 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION.......................................1991 SERVICE MODE CANNOT BE SELECTED................................................................................1992 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE................................................1993 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK.................................................1996 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING.................................1998 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE.................2000 WORK EQUIPMENT DOES NOT OPERATE WHILE LOCK LEVER AUTOMATIC RELEASE SWITCH IS IN RELEASE POSITION...............2002 ALARM DOES NOT SOUND DURING TRAVEL.............................................................................2004 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED..........................................................2006 HORN DOES NOT SOUND............................................................................................2007 HORN DOES NOT STOP SOUNDING....................................................................................2009 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF.......................................2010 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...............................................2011 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE..........................................2013 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................2014 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................2015 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...........................................2016 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION............................................2017 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................2018 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................2019 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.............................................2020 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION............................................2021 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...........................................2022 BLADE RAISE ON IS NOT DISPLAYED CORRECTLY WITH MONITORING......................................................2025 BLADE LOWER ON IS NOT DISPLAYED CORRECTLY WITH MONITORING......................................................2026 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY.......................................................................2027 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)......................................................2028 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)........................................................2028 FAILURE MODE AND CAUSE TABLE...................................................................................2029 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK...............................................................2038 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER......................................................2039 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR...................................................................2041 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP..............................................................2042 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS.....................................................................2043 SPEED OR POWER OF BOOM IS LOW..................................................................................2045 ARM SPEED OR POWER IS LOW......................................................................................2048 BUCKET SPEED OR POWER IS LOW...................................................................................2051 BLADE SPEED OR POWER IS LOW....................................................................................2054 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION...............................................................2056 HYDRAULIC DRIFT OF BOOM IS LARGE...............................................................................2057 HYDRAULIC DRIFT OF ARM IS LARGE................................................................................2058 HYDRAULIC DRIFT OF BUCKET IS LARGE.............................................................................2059 HYDRAULIC DRIFT OF BLADE IS LARGE..............................................................................2060 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...............................2062 TIME LAG OF WORK EQUIPMENT IS LARGE............................................................................2063 ATTACHMENT CIRCUIT CANNOT BE CHANGED...........................................................................2064 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED...............................................................2065 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER............................2066 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY..........................................2067 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW........................................2068 MACHINE DOES NOT TRAVEL STRAIGHT...............................................................................2069 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW...........................................................2072 TRAVEL SPEED IS LOW............................................................................................2074 ONE OF TRACKS DOES NOT RUN.....................................................................................2076 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST..............................................2078 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT......................................................2079 SWINGS ONLY IN ONE DIRECTION...................................................................................2080 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)...................................2081 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION............................2082 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)..............................2083 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)..........2084 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING.............................................................2085 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING...............................................2086 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED).........................................2087 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)........................................2088 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY).........................................................2089 UNUSUAL NOISE IS HEARD FROM AROUND FAN.........................................................................2090 TROUBLESHOOTING OF ENGINE (S-MODE).................................................................................2091 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)........................................................2091 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.........................................2092 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT.....................................................................2093 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START).................2094 ENGINE STARTABILITY IS POOR....................................................................................2095 ENGINE DOES NOT PICK UP SMOOTHLY...............................................................................2097 ENGINE STOPS DURING OPERATION..................................................................................2099 ENGINE RUNS ROUGH OR IS UNSTABLE...............................................................................2101 OUTPUT IS NOT SUFFICIENT (POWER IS LOW)........................................................................2102 EXHAUST IS BLACK (KDPF GETS CLOGGED IN A SHORT TIME)...........................................................2105 ENGINE OIL CONSUMPTION IS EXCESSIVE............................................................................2107 ENGINE OIL BECOMES CONTAMINATED QUICKLY........................................................................2108 FUEL CONSUMPTION IS EXCESSIVE..................................................................................2109 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)..........................................2110 OIL PRESSURE DROPS.............................................................................................2111 FUEL MIXES INTO ENGINE OIL.....................................................................................2112 WATER MIXES INTO ENGINE OIL (MILKY)............................................................................2113 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...............................................................2114 THERE IS AN UNUSUAL NOISE......................................................................................2115 VIBRATION IS EXCESSIVE.........................................................................................2117 AIR CANNOT BE BLED FROM FUEL CIRCUIT...........................................................................2118 ACTIVE REGENERATION IS EXECUTED FREQUENTLY.....................................................................2119 ACTIVE REGENERATION TAKES LONG.................................................................................2120 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION............................................................2121 AdBlue/DEF CONSUMPTION IS EXCESSIVE............................................................................2122 THERE IS UNUSUAL SMELL (IRRITATING ODOR).......................................................................2124 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)......................................................2125 50 DISASSEMBLY AND ASSEMBLY............................................................................................2127 CONTENTS...........................................................................................................2128 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY....................................................................2134 HOW TO READ THIS MANUAL........................................................................................2134 COATING MATERIALS LIST.........................................................................................2136 SPECIAL TOOLS LIST.............................................................................................2140 SKETCHES OF SPECIAL TOOLS......................................................................................2159 PREPARATION........................................................................................................2162 DRAIN AND ADD COOLANT..........................................................................................2162 DRAIN COOLANT..............................................................................................2163 ADD COOLANT................................................................................................2164 DRAIN AND ADD HYDRAULIC OIL....................................................................................2166 DRAIN HYDRAULIC OIL........................................................................................2167 ADD HYDRAULIC OIL..........................................................................................2168 DRAIN AND ADD FUEL.............................................................................................2171 DRAIN FUEL.................................................................................................2171 ADD FUEL...................................................................................................2172 COLLECT AND REFILL REFRIGERANT.................................................................................2174 COLLECT REFRIGERANT........................................................................................2175 REFILL REFRIGERANT.........................................................................................2175 ENGINE AND COOLING SYSTEM..........................................................................................2177 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS NOT REMOVED)...........................2177 REMOVE SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS NOT REMOVED)...................................2178 INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS NOT REMOVED)..................................2185 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS REMOVED)...............................2193 REMOVE SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS REMOVED).......................................2194 INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS REMOVED)......................................2197 REMOVE AND INSTALL INJECTOR ASSEMBLY...........................................................................2201 REMOVE INJECTOR ASSEMBLY...................................................................................2202 INSTALL INJECTOR ASSEMBLY..................................................................................2216 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY......................................................................2232 REMOVE CYLINDER HEAD ASSEMBLY..............................................................................2234 INSTALL CYLINDER HEAD ASSEMBLY.............................................................................2262 REMOVE AND INSTALL EGR VALVE ASSEMBLY..........................................................................2296 REMOVE EGR VALVE ASSEMBLY..................................................................................2296 INSTALL EGR VALVE ASSEMBLY.................................................................................2299 REMOVE AND INSTALL EGR COOLER ASSEMBLY.........................................................................2304 REMOVE EGR COOLER ASSEMBLY.................................................................................2305 INSTALL EGR COOLER ASSEMBLY................................................................................2309 REMOVE AND INSTALL STARTING MOTOR ASSEMBLY.....................................................................2314 REMOVE STARTING MOTOR ASSEMBLY.............................................................................2315 INSTALL STARTING MOTOR ASSEMBLY............................................................................2322 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT.............................................................2330 REMOVE AIR CONDITIONER COMPRESSOR BELT.....................................................................2331 INSTALL AIR CONDITIONER COMPRESSOR BELT....................................................................2332 REMOVE AND INSTALL ALTERNATOR BELT.............................................................................2334 METHOD FOR REMOVING ALTERNATOR BELT........................................................................2334 METHOD FOR INSTALLING ALTERNATOR BELT......................................................................2336 REMOVE AND INSTALL AUTOMATIC TENSIONER.........................................................................2338 METHOD FOR REMOVING AUTOMATIC TENSIONER....................................................................2338 METHOD FOR INSTALLING AUTOMATIC TENSIONER..................................................................2338 REMOVE AND INSTALL RADIATOR ASSEMBLY...........................................................................2339 REMOVE RADIATOR ASSEMBLY...................................................................................2340 INSTALL RADIATOR ASSEMBLY..................................................................................2343 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY...............................................................2348 REMOVE HYDRAULIC OIL COOLER ASSEMBLY.......................................................................2348 INSTALL HYDRAULIC OIL COOLER ASSEMBLY......................................................................2351 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY........................................................................2354 REMOVE AFTERCOOLER ASSEMBLY................................................................................2354 INSTALL AFTERCOOLER ASSEMBLY...............................................................................2356 REMOVE AND INSTALL FAN CLUTCH ASSEMBLY.........................................................................2358 REMOVE FAN CLUTCH ASSEMBLY.................................................................................2359 INSTALL FAN CLUTCH ASSEMBLY................................................................................2367 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY...............................................................2379 REMOVE ENGINE AND MAIN PUMP ASSEMBLY.......................................................................2381 INSTALL ENGINE AND MAIN PUMP ASSEMBLY......................................................................2414 REMOVE AND INSTALL ENGINE FRONT OIL SEAL.......................................................................2449 METHOD FOR REMOVING ENGINE FRONT OIL SEAL..................................................................2449 METHOD FOR INSTALLING ENGINE FRONT OIL SEAL................................................................2450 REMOVE AND INSTALL ENGINE REAR OIL SEAL........................................................................2452 REMOVE ENGINE REAR OIL SEAL................................................................................2453 INSTALL ENGINE REAR OIL SEAL...............................................................................2454 REMOVE AND INSTALL FUEL COOLER ASSEMBLY........................................................................2458 REMOVE FUEL COOLER ASSEMBLY................................................................................2459 INSTALL FUEL COOLER ASSEMBLY...............................................................................2460 REMOVE AND INSTALL KDPF ASSEMBLY...............................................................................2461 REMOVE KDPF ASSEMBLY.......................................................................................2462 INSTALL KDPF ASSEMBLY......................................................................................2464 DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY.........................................................................2468 DISASSEMBLE KDPF ASSEMBLY..................................................................................2470 ASSEMBLE KDPF ASSEMBLY.....................................................................................2475 REMOVE AND INSTALL KDPF AND SCR ASSEMBLY.......................................................................2482 REMOVE KDPF AND SCR ASSEMBLY...............................................................................2483 INSTALL KDPF AND SCR ASSEMBLY..............................................................................2496 REMOVE AND INSTALL FUEL TANK ASSEMBLY..........................................................................2510 REMOVE FUEL TANK ASSEMBLY..................................................................................2511 INSTALL FUEL TANK ASSEMBLY.................................................................................2528 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY....................................................................2545 REMOVE AdBlue/DEF TANK ASSEMBLY............................................................................2546 INSTALL AdBlue/DEF TANK ASSEMBLY...........................................................................2554 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY......................................................2561 REMOVE AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..............................................................2562 INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.............................................................2569 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR......................................................................2577 REMOVE AdBlue/DEF TANK SENSOR..............................................................................2577 INSTALL AdBlue/DEF TANK SENSOR.............................................................................2578 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER....................................................................2585 METHOD FOR REMOVING AdBlue/DEF TANK STRAINER...............................................................2585 METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER.............................................................2585 REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER..........................................................2586 REMOVE AdBlue/DEF TANK FILLER PORT FILTER..................................................................2587 INSTALL AdBlue/DEF TANK FILLER PORT FILTER.................................................................2588 REMOVE AND INSTALL SCR ASSEMBLY................................................................................2591 REMOVE SCR ASSEMBLY........................................................................................2592 INSTALL SCR ASSEMBLY.......................................................................................2597 REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY.......................................................................2603 REMOVE BELLOWS PIPE ASSEMBLY...............................................................................2604 INSTALL BELLOWS PIPE ASSEMBLY..............................................................................2608 REMOVE AND INSTALL KCCV ASSEMBLY...............................................................................2613 REMOVE KCCV ASSEMBLY.......................................................................................2614 INSTALL KCCV ASSEMBLY......................................................................................2616 REMOVE AND INSTALL EXHAUST THROTTLE VALVE......................................................................2620 REMOVE EXHAUST THROTTLE VALVE..............................................................................2621 INSTALL EXHAUST THROTTLE VALVE.............................................................................2630 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE......................................................................2640 REMOVE AdBlue/DEF MIXING TUBE..............................................................................2641 INSTALL AdBlue/DEF MIXING TUBE.............................................................................2650 REMOVE AND INSTALL AdBlue/DEF INJECTOR.........................................................................2660 REMOVE AdBlue/DEF INJECTOR.................................................................................2661 INSTALL AdBlue/DEF INJECTOR................................................................................2665 REMOVE AND INSTALL AdBlue/DEF PUMP.............................................................................2670 REMOVE AdBlue/DEF PUMP.....................................................................................2671 INSTALL AdBlue/DEF PUMP....................................................................................2676 REMOVE AND INSTALL AdBlue/DEF HOSE.............................................................................2681 REMOVE AdBlue/DEF HOSE.....................................................................................2682 INSTALL AdBlue/DEF HOSE....................................................................................2693 REMOVE AND INSTALL AIR CLEANER ASSEMBLY........................................................................2703 REMOVE AIR CLEANER ASSEMBLY................................................................................2704 INSTALL AIR CLEANER ASSEMBLY...............................................................................2707 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY.........................................................2712 REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY.................................................................2712 INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY................................................................2714 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY..........................................................2716 REMOVE AIR CONDITIONER CONDENSER ASSEMBLY..................................................................2716 INSTALL AIR CONDITIONER CONDENSER ASSEMBLY.................................................................2718 POWER TRAIN........................................................................................................2721 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.......................................................2721 REMOVE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...............................................................2722 INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY..............................................................2725 DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.................................................2728 DISASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY..........................................................2739 ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.............................................................2757 REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY....................................................2777 REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY............................................................2778 INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY...........................................................2781 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY..............................................................2784 METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY..........................................................2784 METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY.............................................................2787 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY.......................................................................2794 METHOD FOR REMOVING SWING CIRCLE ASSEMBLY..................................................................2794 METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY................................................................2795 UNDERCARRIAGE AND FRAME............................................................................................2796 SEPARATION AND CONNECTION OF TRACK ASSEMBLY....................................................................2796 METHOD FOR SEPARATING TRACK ASSEMBLY.......................................................................2796 METHOD FOR INSTALLING TRACK ASSEMBLY.......................................................................2798 REMOVE AND INSTALL SPROCKET....................................................................................2801 METHOD FOR REMOVING SPROCKET...............................................................................2801 METHOD FOR INSTALLING SPROCKET.............................................................................2801 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY............................................................2803 METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY.......................................................2803 METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY.....................................................2803 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY........................................................................2805 METHOD FOR DISASSEMBLING IDLER ASSEMBLY....................................................................2805 METHOD FOR ASSEMBLING IDLER ASSEMBLY.......................................................................2806 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY.............................................................2810 METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY............................................................2810 METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY...............................................................2812 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY.................................................................2815 METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY.............................................................2815 METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY................................................................2817 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY....................................................................2820 REMOVE REVOLVING FRAME ASSEMBLY............................................................................2821 INSTALL REVOLVING FRAME ASSEMBLY...........................................................................2824 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY......................................................................2827 REMOVE COUNTERWEIGHT ASSEMBLY..............................................................................2828 INSTALL COUNTERWEIGHT ASSEMBLY.............................................................................2839 HYDRAULIC SYSTEM...................................................................................................2853 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY................................................................2853 REMOVE CENTER SWIVEL JOINT ASSEMBLY........................................................................2854 INSTALL CENTER SWIVEL JOINT ASSEMBLY.......................................................................2859 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY..........................................................2865 METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY......................................................2865 METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY.........................................................2866 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY.....................................................................2867 REMOVE HYDRAULIC TANK ASSEMBLY.............................................................................2869 INSTALL HYDRAULIC TANK ASSEMBLY............................................................................2877 REMOVE AND INSTALL MAIN PUMP ASSEMBLY..........................................................................2887 REMOVE MAIN PUMP ASSEMBLY..................................................................................2888 INSTALL MAIN PUMP ASSEMBLY.................................................................................2896 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY......................................................................2904 REMOVE CONTROL VALVE ASSEMBLY..............................................................................2906 INSTALL CONTROL VALVE ASSEMBLY.............................................................................2926 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY................................................................2945 METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY...............................................................2945 METHOD FOR REPLACING PRESSURE REDUCING VALVE CARTRIDGE ASSEMBLY............................................2948 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................2951 METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY.................................................2951 METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY....................................................2952 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY.............................................................2954 METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY.........................................................2954 METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY............................................................2954 WORK EQUIPMENT.....................................................................................................2956 REMOVE AND INSTALL BLADE ASSEMBLY..............................................................................2956 METHOD FOR REMOVING BLADE ASSEMBLY.........................................................................2956 METHOD FOR INSTALLING BLADE ASSEMBLY.......................................................................2957 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY.....................................................................2959 REMOVE WORK EQUIPMENT ASSEMBLY.............................................................................2961 INSTALL WORK EQUIPMENT ASSEMBLY............................................................................2969 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY......................................................2979 METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY..................................................2980 METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY.....................................................2982 CAB AND ITS ATTACHMENTS............................................................................................2989 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY.....................................................................2989 REMOVE OPERATOR CAB ASSEMBLY...............................................................................2989 INSTALL OPERATOR CAB ASSEMBLY..............................................................................2994 REMOVE AND INSTALL OPERATOR'S CAB DOOR.........................................................................2999 METHOD FOR INSTALLING OPERATOR'S CAB DOOR..................................................................2999 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)..........................................................3003 METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS).....................................................3004 METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)...................................................3005 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY.......................................................................3014 REMOVE FRONT WINDOW ASSEMBLY...............................................................................3014 METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY................................................................3017 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY........................................................................3018 METHOD FOR REMOVING FLOOR FRAME ASSEMBLY...................................................................3018 METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY.................................................................3028 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY...............................................................3039 REMOVE AIR CONDITIONER UNIT ASSEMBLY.......................................................................3040 INSTALL AIR CONDITIONER UNIT ASSEMBLY......................................................................3049 REMOVE AND INSTALL OPERATOR'S SEAT.............................................................................3059 REMOVE OPERATOR'S SEAT.....................................................................................3059 INSTALL OPERATOR'S SEAT....................................................................................3062 REMOVE AND INSTALL SEATBELT....................................................................................3065 REMOVE SEATBELT............................................................................................3066 INSTALL SEATBELT...........................................................................................3067 REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY.......................................................3068 REMOVE WORK EQUIPMENT CONTROL LEVER ASSEMBLY...............................................................3068 INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY..............................................................3074 REMOVE AND INSTALL FRONT WIPER ASSEMBLY........................................................................3082 REMOVE FRONT WIPER ASSEMBLY................................................................................3082 METHOD FOR INSTALLING FRONT WIPER ASSEMBLY.................................................................3087 ELECTRICAL SYSTEM..................................................................................................3095 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY..................................................................3095 REMOVE ENGINE CONTROLLER ASSEMBLY..........................................................................3096 INSTALL ENGINE CONTROLLER ASSEMBLY.........................................................................3098 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY....................................................................3100 REMOVE PUMP CONTROLLER ASSEMBLY............................................................................3100 INSTALL PUMP CONTROLLER ASSEMBLY...........................................................................3103 REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY...............................................................3107 METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY..........................................................3107 METHOD FOR INSTALLING KomVision CONTROLLER ASSEMBLY........................................................3109 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY....................................................................3111 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY...............................................................3111 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY.............................................................3114 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR........................................................3118 REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR................................................................3119 INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR...............................................................3120 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR..............................................................3121 REMOVE KCCV CRANKCASE PRESSURE SENSOR......................................................................3122 INSTALL KCCV CRANKCASE PRESSURE SENSOR.....................................................................3124 REMOVE AND INSTALL KDPF TEMPERATURE SENSOR.....................................................................3127 REMOVE KDPF TEMPERATURE SENSOR.............................................................................3129 INSTALL KDPF TEMPERATURE SENSOR............................................................................3132 REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR...........................................................3136 REMOVE KDPF DIFFERENTIAL PRESSURE SENSOR...................................................................3138 INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR..................................................................3140 REMOVE AND INSTALL SCR TEMPERATURE SENSOR......................................................................3144 REMOVE SCR TEMPERATURE SENSOR..............................................................................3145 INSTALL SCR TEMPERATURE SENSOR.............................................................................3149 REMOVE AND INSTALL TURBOCHARGER OUTLET NOx SENSOR..............................................................3153 REMOVE TURBOCHARGER OUTLET NOx SENSOR......................................................................3154 INSTALL TURBOCHARGER OUTLET NOx SENSOR.....................................................................3157 REMOVE AND INSTALL SCR OUTLET NOx SENSOR.......................................................................3160 REMOVE SCR OUTLET NOx SENSOR...............................................................................3161 INSTALL SCR OUTLET NOx SENSOR..............................................................................3164 REMOVE AND INSTALL AMMONIA SENSOR..............................................................................3167 REMOVE AMMONIA SENSOR......................................................................................3168 INSTALL AMMONIA SENSOR.....................................................................................3170 REMOVE AND INSTALL KomVision CAMERA............................................................................3172 REMOVE KomVision CAMERA....................................................................................3173 INSTALL KomVision CAMERA...................................................................................3178 REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY........................................................3185 REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY................................................................3185 INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY...............................................................3188 REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS.......................................................3191 REMOVE COMMUNICATION TERMINAL WIRING HARNESS...............................................................3191 INSTALL COMMUNICATION TERMINAL WIRING HARNESS..............................................................3195 REMOVE AND INSTALL COMMUNICATION TERMINAL......................................................................3201 REMOVE COMMUNICATION TERMINAL..............................................................................3201 INSTALL COMMUNICATION TERMINAL.............................................................................3202 60 MAINTENANCE STANDARD................................................................................................3205 CONTENTS...........................................................................................................3206 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD......................................................................3207 ENGINE AND COOLING SYSTEM..........................................................................................3209 MAINTENANCE STANDARD OF ENGINE MOUNT...........................................................................3209 MAINTENANCE STANDARD FOR PTO...................................................................................3210 MAINTENANCE STANDARD OF COOLING SYSTEM.........................................................................3211 POWER TRAIN........................................................................................................3212 MAINTENANCE STANDARD OF SWING CIRCLE...........................................................................3212 MAINTENANCE STANDARD OF SWING MACHINERY........................................................................3213 MAINTENANCE STANDARD OF SPROCKET...............................................................................3215 UNDERCARRIAGE AND FRAME............................................................................................3216 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION..........................................................3216 MAINTENANCE STANDARD OF IDLER..................................................................................3218 MAINTENANCE STANDARD OF TRACK ROLLER...........................................................................3219 MAINTENANCE STANDARD OF CARRIER ROLLER.........................................................................3220 MAINTENANCE STANDARD OF TRACK SHOE.............................................................................3221 MAINTENANCE STANDARD OF TRIPLE SHOE............................................................................3224 MAINTENANCE STANDARD OF ROAD LINER.............................................................................3225 HYDRAULIC SYSTEM...................................................................................................3226 MAINTENANCE STANDARD OF HYDRAULIC TANK.........................................................................3226 MAINTENANCE STANDARD OF MAIN PUMP..............................................................................3227 MAINTENANCE STANDARD OF PC-EPC VALVE...........................................................................3231 MAINTENANCE STANDARD OF SWING MOTOR............................................................................3232 MAINTENANCE STANDARD OF TRAVEL MOTOR...........................................................................3235 MAINTENANCE STANDARD OF CONTROL VALVE..........................................................................3236 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE.....................................................3247 MAINTENANCE STANDARD OF BLADE PPC VALVE........................................................................3250 MAINTENANCE STANDARD OF TRAVEL PPC VALVE.......................................................................3252 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE).........................................3255 MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE.........................................3257 MAINTENANCE STANDARD OF SOLENOID VALVE.........................................................................3258 MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE SOLENOID VALVE..................................................3260 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)...................................3261 MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT).............................3262 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT....................................................................3263 WORK EQUIPMENT.....................................................................................................3264 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE.................................................................3264 DIMENSION OF ARM...........................................................................................3269 DIMENSIONS OF BUCKET.......................................................................................3271 MAINTENANCE STANDARD OF BOOM CYLINDER..........................................................................3273 MAINTENANCE STANDARD OF ARM CYLINDER...........................................................................3274 MAINTENANCE STANDARD OF BUCKET CYLINDER........................................................................3275 MAINTENANCE STANDARD OF BLADE CYLINDER.........................................................................3276 CAB AND ITS ATTACHMENTS............................................................................................3277 MAINTENANCE STANDARD OF CAB MOUNT..............................................................................3277 80 APPENDIX............................................................................................................3279 CONTENTS...........................................................................................................3280 AIR CONDITIONER SYSTEM.............................................................................................3282 PRECAUTIONS FOR REFRIGERANT....................................................................................3282 AIR CONDITIONER COMPONENT......................................................................................3283 SPECIFICATIONS OF AIR CONDITIONER..............................................................................3285 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE..............................................................3286 OUTLINE OF REFRIGERATION CYCLE.................................................................................3287 COMPONENT PARTS OF AIR CONDITIONER SYSTEM..........................................................................3289 AIR CONDITIONER UNIT...........................................................................................3289 CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT..............................................................3289 FUNCTION OF AIR CONDITIONER UNIT...........................................................................3291 COMPONENT PARTS OF AIR CONDITIONER UNIT........................................................................3292 FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT...................................................3292 FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT..................................................3292 FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT................................3292 FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT..................................................3293 STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT.............................................3294 FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT..............................................3294 OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT..................................................3294 FUNCTION OF DUAL PRESSURE SWITCH...........................................................................3295 AIR CONDITIONER CONTROLLER.....................................................................................3296 STRUCTURE OF AIR CONDITIONER CONTROLLER....................................................................3296 COMPRESSOR.....................................................................................................3297 STRUCTURE OF COMPRESSOR....................................................................................3297 SPECIFICATIONS OF COMPRESSOR...............................................................................3297 FUNCTION OF COMPRESSOR.....................................................................................3297 CONDENSER......................................................................................................3298 STRUCTURE OF CONDENSER.....................................................................................3298 SPECIFICATIONS OF CONDENSER................................................................................3298 FUNCTION OF CONDENSER......................................................................................3298 SENSORS FOR AIR CONDITIONER SYSTEM.............................................................................3300 STRUCTURE OF SUNLIGHT SENSOR...............................................................................3300 FUNCTION OF SUNLIGHT SENSOR................................................................................3300 STRUCTURE OF AMBIENT TEMPERATURE SENSOR....................................................................3300 FUNCTION OF AMBIENT TEMPERATURE SENSOR.....................................................................3300 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER........................................3302 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER..............................................3304 AIR CONDITIONER SYSTEM DIAGRAM.....................................................................................3306 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER.........................................................3307 FUNCTION OF AIR CONDITIONER CONTROLLER.....................................................................3308 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS......................................3309 TESTING AIR LEAKAGE (DUCT).........................................................................................3318 METHOD FOR TESTING AIR LEAKAGE (DUCT)..........................................................................3318 TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION..............................................................3320 HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR.................3321 TEST VENT (MODE) CHANGEOVER........................................................................................3322 METHOD FOR TESTING VENT (MODE) CHANGEOVER......................................................................3322 TESTING FRESH/RECIRC AIR CHANGEOVER................................................................................3323 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................3323 TEST SUNLIGHT SENSOR...............................................................................................3324 METHOD FOR TESTING SUNLIGHT SENSOR.............................................................................3324 TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT........................................................................3325 METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT......................................................3325 TEST RELAYS........................................................................................................3327 METHOD FOR TESTING RELAYS......................................................................................3327 AIR CONDITIONER TROUBLESHOOTING CHART 1............................................................................3328 AIR CONDITIONER TROUBLESHOOTING CHART 2............................................................................3329 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.....................................................................3332 FAILURE CODE [879AKA]..............................................................................................3334 FAILURE CODE [879AKB]..............................................................................................3336 FAILURE CODE [879BKA]..............................................................................................3338 FAILURE CODE [879BKB]..............................................................................................3340 FAILURE CODE [879CKA]..............................................................................................3342 FAILURE CODE [879CKB]..............................................................................................3343 FAILURE CODE [879DKZ]..............................................................................................3344 FAILURE CODE [879EMC]..............................................................................................3347 FAILURE CODE [879FMC]..............................................................................................3348 FAILURE CODE [879GKX]..............................................................................................3349 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE).........................................3351 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)..........................................3353 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL).................................3356 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER....................................................................3358 TROUBLESHOOTING USING GAUGE PRESSURE...............................................................................3360 CONNECTION OF SERVICE TOOL.........................................................................................3362 METHOD FOR CONNECTING SERVICE TOOL.............................................................................3362 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS............................3364 HANDLE COMPRESSOR OIL..............................................................................................3366 METHOD FOR REPLACING DESICCANT.....................................................................................3368 90 CIRCUIT DIAGRAMS....................................................................................................3371 CONTENTS...........................................................................................................3372 HOW TO READ THE CODES FOR ELECTRIC CABLE...........................................................................3373 HYDRAULIC CIRCUIT DIAGRAM..........................................................................................3377 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM......................................................................3377 HYDRAULIC CIRCUIT DIAGRAM (BLADE LESS SPECIFICATION, MACHINE WITH 2ND-LINE ATTACHMENT IS INSTALLABLE)..........3381 HYDRAULIC CIRCUIT DIAGRAM (BLADE SPECIFICATION, MACHINE WITH 2ND-LINE ATTACHMENT IS INSTALLABLE)...............3383 HYDRAULIC CIRCUIT DIAGRAM (2-PIECE BOOM SPECIFICATION, MACHINE WITH 2ND-LINE ATTACHMENT IS INSTALLABLE)........3385 HYDRAULIC CIRCUIT DIAGRAM (MACHINE WITH TOOL CONTROL SYSTEM)...................................................3387 ELECTRICAL CIRCUIT DIAGRAM.........................................................................................3389 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM.....................................................................3389 ELECTRICAL CIRCUIT DIAGRAM (1/11)..............................................................................3393 ELECTRICAL CIRCUIT DIAGRAM (2/11)..............................................................................3395 ELECTRICAL CIRCUIT DIAGRAM (3/11)..............................................................................3397 ELECTRICAL CIRCUIT DIAGRAM (4/11)..............................................................................3399 ELECTRICAL CIRCUIT DIAGRAM (5/11)..............................................................................3401 ELECTRICAL CIRCUIT DIAGRAM (6/11)..............................................................................3403 ELECTRICAL CIRCUIT DIAGRAM (7/11)..............................................................................3405 ELECTRICAL CIRCUIT DIAGRAM (8/11)..............................................................................3407 ELECTRICAL CIRCUIT DIAGRAM (9/11)..............................................................................3409 ELECTRICAL CIRCUIT DIAGRAM (10/11).............................................................................3411 ELECTRICAL CIRCUIT DIAGRAM (11/11).............................................................................3413 INDEX...................................................................................................................3415
DESCRIPTION:
KOMATSU PC138US-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL WENBM00310 – 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
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