Komatsu PC200-10M0 Hydraulic Excavator Shop Manual SEN06867-03 – PDF DOWNLOAD

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Komatsu PC200-10M0 Hydraulic Excavator Shop Manual SEN06867-03 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu PC200-10M0 Hydraulic Excavator Shop Manual SEN06867-03 – PDF DOWNLOAD

SERIAL NUMBERS 700001 and up

FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE SHOP MANUAL:
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual:
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.

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TABLE OF CONTENTS:

Komatsu PC200-10M0 Hydraulic Excavator Shop Manual SEN06867-03 – PDF DOWNLOAD

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 16
FOREWORD, SAFETY, BASIC INFORMATION 21
HOW TO READ THE SHOP MANUAL 21
SAFETY NOTICE FOR OPERATION 23
PRECAUTIONS TO PREVENT FIRE 31
ACTIONS IF FIRE OCCURS 32
PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS 33
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 34
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS 37
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT 44
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 46
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 47
PRACTICAL USE OF KOMTRAX 48
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 49
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 49
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 50
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 51
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 53
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 57
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 58
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 60
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 61
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 63
HOW TO READ ELECTRICAL WIRE CODE 64
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 68
STANDARD TIGHTENING TORQUE TABLE 71
CONVERSION TABLE 78
01 SPECIFICATION 83
CONTENTS 84
ABBREVIATION LIST 85
SPECIFICATIONS 90
SPECIFICATION DRAWING 90
SPECIFICATION DRAWING: PC200-10M0 90
WORKING RANGE DRAWINGS 92
WORKING RANGE DRAWINGS: PC200-10M0 92
SPECIFICATIONS 94
SPECIFICATION: PC200-10M0 94
WEIGHT TABLE 97
WEIGHT TABLE: PC200-10M0 97
FUEL, COOLANT AND LUBRICANT TO MEET AMBIENT TEMPERATURE 99
10 STRUCTURE AND FUNCTION 101
CONTENTS 102
ABBREVIATION LIST 105
BOOT-UP SYSTEM 110
LAYOUT DRAWING OF BOOT-UP SYSTEM 110
SYSTEM OPERATING LAMP SYSTEM 111
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 111
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 111
OPERATION OF SYSTEM OPERATING LAMP 111
BATTERY DISCONNECT SWITCH 112
FUNCTION OF BATTERY DISCONNECT SWITCH 112
OPERATION OF BATTERY DISCONNECT SWITCH 112
ENGINE SYSTEM 113
LAYOUT DRAWING OF ENGINE SYSTEM 113
ENGINE CONTROL SYSTEM 114
ENGINE CONTROL SYSTEM DRAWING 114
OPERATION OF ENGINE CONTROL SYSTEM 114
AUTO-DECELERATION SYSTEM 116
AUTO-DECELERATION SYSTEM DRAWING 116
FUNCTION OF AUTO-DECELERATION SYSTEM 116
OPERATION OF AUTO-DECELERATION SYSTEM 117
ENGINE AUTOMATIC WARM-UP SYSTEM 118
ENGINE AUTOMATIC WARM-UP SYSTEM DRAWING 118
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 119
OPERATION OF ENGINE AUTOMATIC WARM-UP SYSTEM 119
OVERHEAT PREVENTION SYSTEM 120
OVERHEAT PREVENTION SYSTEM DRAWING 120
FUNCTION OF OVERHEAT PREVENTION SYSTEM 121
OPERATION OF OVERHEAT PREVENTION SYSTEM 121
TURBOCHARGER PROTECTION SYSTEM 123
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 123
COOLING SYSTEM 124
LAYOUT DRAWING OF COOLING SYSTEM 124
SPECIFICATIONS OF COOLING SYSTEM 125
CONTROL SYSTEM 126
LAYOUT DRAWING OF CONTROL SYSTEM PARTS 126
MACHINE MONITOR SYSTEM 128
MACHINE MONITOR SYSTEM DIAGRAM 128
FUNCTION OF MACHINE MONITOR SYSTEM 128
KOMTRAX SYSTEM 130
KOMTRAX SYSTEM DIAGRAM 130
FUNCTION OF KOMTRAX SYSTEM 130
CONTROL SYSTEM 131
MACHINE MONITOR 131
GATEWAY FUNCTION CONTROLLER 142
PUMP CONTROLLER 145
RESISTOR FOR PC-EPC VALVE 149
CAN TERMINATING RESISTOR 149
ENGINE CONTROLLER 150
FUEL CONTROL DIAL 154
HYDRAULIC SYSTEM 155
LAYOUT DRAWING OF HYDRAULIC SYSTEM 155
CLSS 158
CLSS SYSTEM DIAGRAM 158
FUNCTION OF CLSS 159
PRESSURE COMPENSATION CONTROL 176
ENGINE AND PUMP COMBINED CONTROL SYSTEM 177
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 177
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 178
PUMP AND VALVE CONTROL SYSTEM 182
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 182
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 183
HYDRAULIC SYSTEM 185
HYDRAULIC TANK 185
MAIN PUMP 187
CONTROL VALVE 207
WORK EQUIPMENT SYSTEM 251
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 251
ONE-TOUCH POWER MAXIMIZING SYSTEM 255
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 255
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 256
PPC LOCK SYSTEM 257
PPC LOCK SYSTEM DIAGRAM 257
FUNCTION OF PPC LOCK SYSTEM 258
ATTACHMENT OIL FLOW ADJUSTER SYSTEM 259
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 259
FUNCTION OF ATTACHMENT OIL FLOW ADJUSTER SYSTEM 260
WORK EQUIPMENT SYSTEM 261
WORK EQUIPMENT AND SWING PPC VALVE 261
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 265
2ND-LINE ATTACHMENT PPC VALVE 269
SOLENOID VALVE 273
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 275
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 277
PILOT CIRCUIT ACCUMULATOR 280
ATTACHMENT CIRCUIT ACCUMULATOR 280
SWING SYSTEM 283
LAYOUT DRAWING OF SWING SYSTEM 283
SWING CONTROL SYSTEM DIAGRAM 285
FUNCTION OF SWING CONTROL SYSTEM 285
SWING SYSTEM 289
SWING MOTOR 289
SWING MACHINERY 295
SWING CIRCLE 298
TRAVEL SYSTEM 299
LAYOUT DRAWING OF TRAVEL SYSTEM 299
TRAVEL CONTROL SYSTEM DIAGRAM 301
FUNCTION OF TRAVEL CONTROL SYSTEM 302
TRAVEL SYSTEM 303
TRAVEL MOTOR 303
FINAL DRIVE 314
TRAVEL PPC VALVE 315
CENTER SWIVEL JOINT 320
FUNCTION OF SWING CIRCLE 322
UNDERCARRIAGE AND FRAME 323
LAYOUT DRAWING OF UNDERCARRIAG 323
SPECIFICATIONS OF UNDERCARRIAGE 323
WORK EQUIPMENT 325
STRUCTURE OF WORK EQUIPMENT 325
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 326
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 326
BUCKET CLEARANCE ADJUSTMENT SHIM 327
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 327
CAB RELATED PARTS 328
ROPS CAB 328
STRUCTURE OF ROPS CAB 328
FUNCTION OF ROPS CAB 328
CAB MOUNT 329
STRUCTURE OF CAB MOUNT 329
FUNCTION OF CAB MOUNT 330
CAB TIPPING STOPPER 331
STRUCTURE OF CAB TIPPING STOPPER 331
FUNCTION OF CAB TIPPING STOPPER 331
20 STANDARD VALUE TABLE 333
CONTENTS 334
STANDARD VALUE TABLE FOR ENGINE 335
STANDARD VALUE TABLE FOR ENGINE: PC200-10M0 335
STANDARD VALUE TABLE FOR MACHINE: PC200-10M0 339
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE 352
30 TESTING AND ADJUSTING 355
CONTENTS 356
RELATED INFORMATION ON TESTING AND ADJUSTING 359
TOOLS FOR TESTING AND ADJUSTING 359
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 364
ENGINE AND COOLING SYSTEM 366
TEST ENGINE SPEED 366
TEST ENGINE HIGH IDLE SPEED 366
Test engine low idle speed 366
TEST ENGINE SPEED AT 2 PUMPS RELIEF 366
Test engine speed at 2 pumps relief and one-touch power maximizing 367
TEST ENGINE SPEED WITH AUTO-DECELERATION 367
Test boost pressure 369
TEST BOOST PRESSURE ON MACHINE MONITOR 369
TEST BOOST PRESSURE BY TESTING TOOL 370
TEST EXHAUST GAS COLOR 372
Test exhaust gas color by handy smoke checker 372
TEST EXHAUST GAS COLOR BY SMOKE METER 373
Test and adjust valve clearance 375
TEST VALVE CLEARANCE 375
Adjust valve clearance 376
TEST COMPRESSION PRESSURE 378
TEST COMPRESSION PRESSURE 378
TEST BLOWBY PRESSURE 381
TEST BLOWBY PRESSURE ON MACHINE MONITOR (MACHINE WITH BLOWBY PRESSURE SENSOR (OPT)) 381
Test blowby pressure (machine without blowby pressure sensor) 382
TEST ENGINE OIL PRESSURE 384
TEST ENGINE OIL PRESSURE 384
Test fuel pressure 386
TEST FUEL PRESSURE 387
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 392
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 393
BLEED AIR FROM FUEL SYSTEM 397
Bleed air from fuel system 397
Test fuel system for leakage 399
Test fuel circuit for leakage 399
CYLINDER CUT-OUT MODE OPERATION 401
NO-INJECTION CRANKING OPERATION 402
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 403
CHECK AIR CONDITIONER COMPRESSOR BELT 403
ADJUST AIR CONDITIONER COMPRESSOR BELT 403
POWER TRAIN 405
Test swing circle bearing clearance 405
Test swing circle bearing clearance 405
UNDERCARRIAGE AND FRAME 406
Test and adjust track shoe tension 406
Test track shoe tension 406
Adjust track shoe tension 406
HYDRAULIC SYSTEM 408
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 408
RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK 408
Release remaining pressure in hydraulic cylinder circuit 408
Release remaining pressure for machines without anti-drop valve 408
Release remaining pressure for machines with boom anti-drop valve 408
Release remaining pressure from swing motor circuit 410
RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 410
Test and adjust oil pressure in work equipment, swing, and travel circuits 411
Test oil pressure in work equipment, swing, and travel circuits 411
Adjust oil pressure in work equipment, swing, and travel circuits 418
TEST OIL PRESSURE OF CONTROL CIRCUIT 420
Test oil pressure of control circuit 420
Test and adjust oil pressure in pump PC control circuit 422
Test PC valve outlet pressure (servo piston inlet pressure) 422
TEST PC-EPC VALVE OUTLET PRESSURE 423
Adjust oil pressure in pump PC control circuit 424
Test and adjust oil pressure in pump LS control circuit 426
Test LS differential pressure with machine monitor 426
Test LS differential pressure by testing tool 428
Test LS valve outlet pressure (servo piston inlet pressure) 429
Test LS-EPC valve outlet pressure 431
Adjust LS valve 432
Test outlet pressure of solenoid valve 433
Test outlet pressure of solenoid valve 433
OPERATING CONDITION OF SOLENOID VALVE 435
Test PPC valve outlet pressure 437
Test outlet pressure of PPC valve with machine monitor 437
TEST OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL 438
Adjust play of work equipment and swing PPC valve 441
Adjust play of work equipment and swing PPC valve 441
Test parts causing hydraulic drift in work equipment 442
Test parts causing hydraulic drift of boom cylinder and bucket cylinder 442
Test parts causing hydraulic drift of arm cylinder 442
Test parts causing hydraulic drift of boom hydraulic drift prevention valve 443
Test parts causing hydraulic drift of PPC valve 443
Test oil leakage 444
TEST OIL LEAKAGE FROM BOOM CYLINDER 444
TEST OIL LEAKAGE FROM ARM CYLINDER 445
TEST OIL LEAKAGE FROM BUCKET CYLINDER 446
Test oil leakage from swing motor 446
Test oil leakage from travel motor 447
Bleed air from hydraulic system 449
Bleed air from main pump 450
BLEED AIR FROM CYLINDER 451
BLEED AIR FROM SWING MOTOR 452
BLEED AIR FROM TRAVEL MOTOR 452
CAB RELATED PARTS 454
Test cab tipping stopper 454
Test cab tipping stopper 454
ADJUST MIRRORS 455
ADJUST MACHINE LEFT FRONT MIRROR (A) 455
Adjust regular position of machine left front mirror (A) 456
ADJUST MACHINE RIGHT FRONT MIRROR (B) 457
ADJUST REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 457
ADJUST MACHINE RIGHT SIDE MIRROR (C) 458
ELECTRICAL SYSTEM 460
SET AND OPERATE MACHINE MONITOR 460
OPERATOR MODE 464
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 464
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 464
CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 465
CHECK FUNCTION OF SERVICE METER 465
SET USAGE LIMITATION AND CHANGE MAINTENANCE PASSWORD 465
SERVICE MODE 468
OPERATE SERVICE MODE 468
Check pre-defined monitoring information 469
CHECK MONITORING INFORMATION 474
ABNORMALITY RECORD MENU 481
CHECK MAINTENANCE RECORD 484
MAINTENANCE MODE SETTING 486
Phone number entry setting 490
DEFAULT SETTING MENU 491
TESTING MENU 500
ADJUSTMENT MENU 503
NO-INJECTION CRANKING OPERATION 514
KOMTRAX SETTINGS MENU 517
Display service message 519
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 521
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 527
Adjust rearview camera angle 529
ADJUST REARVIEW CAMERA ANGLE 529
ENGINE CONTROLLER VOLTAGE CIRCUIT 531
TEST DIODES 532
TEST DIODES BY DIGITAL TESTER 532
TEST DIODES BY ANALOG TESTER 532
Pm-CLINIC 533
PM CLINIC SERVICE 533
PM CLINIC CHECK SHEET: PC200-10M0 536
40 TROUBLESHOOTING 545
CONTENTS 546
RELATED INFORMATION TO TROUBLESHOOT 553
PRECAUTIONS FOR TROUBLESHOOTING 553
SEQUENCE OF EVENTS IN TROUBLESHOOTING 554
CHECKS BEFORE TROUBLESHOOTING 556
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 558
WALK-AROUND CHECK 558
TEST ENGINE RELATED PARTS 559
TEST WORK EQUIPMENT AND UNDERCARRIAGE 561
CHECK ELECTRIC EQUIPMENT 562
CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER 567
CONNECT ADAPTER TO TROUBLESHOOT MONITOR 567
CONNECT ADAPTER TO TROUBLESHOOT PUMP CONTROLLER 569
CONNECT ADAPTER TO TROUBLESHOOT KOMTRAX TERMINAL 573
CONNECT ADAPTER TO TROUBLESHOOT ENGINE CONTROLLER 575
CONNECT ADAPTER TO TROUBLESHOOT ENGINE INTERMEDIATE CONNECTOR 576
DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PUSH 578
DISCONNECT AND CONNECT DEUTSCH CONNECTOR 578
DISCONNECT AND CONNECT BOSCH CONNECTOR 578
DISCONNECT AND CONNECT AMP CONNECTOR 579
DISCONNECT AND CONNECT SUMITOMO CONNECTOR 580
DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PULL 581
DISCONNECT AND CONNECT DELPHI CONNECTOR AND PACKARD CONNECTOR 581
DISCONNECT AND CONNECT SLIDE TYPE CONNECTOR 582
DISCONNECT AND CONNECT FRAMATOME CONNECTOR 582
DISCONNECT AND CONNECT TYCO CONNECTOR 583
DISCONNECT AND CONNECT CONNECTOR WITH HOUSING TO ROTATE 584
PROCEDURE FOR TROUBLESHOOTING 585
INFORMATION DESCRIBED IN TROUBLESHOOTING 586
DIAGNOSE OPEN CIRCUIT OF HYDRAULIC PRESSURE SENSOR SYSTEM WIRING HARNESS 589
CONNECTOR LIST AND LAYOUT 592
CONNECTOR CONTACT IDENTIFICATION 604
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 646
FUSE LOCATION AND CONNECTION TABLE 652
DRAWING OF SHORT CIRCUIT ELECTRICAL CONNECTOR FOR TROUBLESHOOTING 654
FAILURE CODES TABLE 656
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 664
FAILURE CODE [602KNX] 664
FAILURE CODE [6AZ0ZG] 667
FAILURE CODE [879AKA] 671
FAILURE CODE [879AKB] 673
FAILURE CODE [879BKA] 675
FAILURE CODE [879BKB] 678
FAILURE CODE [879CKA] 681
FAILURE CODE [879CKB] 683
FAILURE CODE [879DKZ] 685
FAILURE CODE [879EMC] 688
FAILURE CODE [879FMC] 690
FAILURE CODE [879GKX] 692
FAILURE CODE [989L00] 695
FAILURE CODE [989M00] 697
FAILURE CODE [989N00] 699
FAILURE CODE [A900FR] 700
FAILURE CODE [A900N6] 701
FAILURE CODE [A900NY] 702
FAILURE CODE [AA10NX] 703
FAILURE CODE [AB00KE] 706
FAILURE CODE [B@BAZG] 710
FAILURE CODE [B@BAZK] 711
FAILURE CODE [B@BCZK] 714
FAILURE CODE [B@BCNS] 716
FAILURE CODE [B@BCQA] 717
FAILURE CODE [B@HANS] 719
FAILURE CODE [CA111] 722
FAILURE CODE [CA115] 723
FAILURE CODE [CA122] 724
FAILURE CODE [CA123] 726
FAILURE CODE [CA131] 728
FAILURE CODE [CA132] 730
FAILURE CODE [CA135] 732
FAILURE CODE [CA141] 735
FAILURE CODE [CA144] 738
FAILURE CODE [CA145] 740
FAILURE CODE [CA153] 742
FAILURE CODE [CA154] 744
FAILURE CODE [CA155] 746
FAILURE CODE [CA187] 747
FAILURE CODE [CA221] 749
FAILURE CODE [CA222] 751
FAILURE CODE [CA227] 753
FAILURE CODE [CA234] 754
FAILURE CODE [CA238] 755
FAILURE CODE [CA271] 757
FAILURE CODE [CA272] 759
FAILURE CODE [CA322] 761
FAILURE CODE [CA324] 763
FAILURE CODE [CA331] 765
FAILURE CODE [CA332] 767
FAILURE CODE [CA342] 769
FAILURE CODE [CA351] 770
FAILURE CODE [CA352] 771
FAILURE CODE [CA386] 773
FAILURE CODE [CA428] 774
FAILURE CODE [CA429] 776
FAILURE CODE [CA435] 778
FAILURE CODE [CA441] 780
FAILURE CODE [CA442] 782
FAILURE CODE [CA449] 783
FAILURE CODE [CA451] 784
FAILURE CODE [CA452] 786
FAILURE CODE [CA488] 788
FAILURE CODE [CA553] 789
FAILURE CODE [CA559] 790
FAILURE CODE [CA689] 792
FAILURE CODE [CA731] 794
FAILURE CODE [CA757] 796
FAILURE CODE [CA778] 797
FAILURE CODE [CA2185] 802
FAILURE CODE [CA2186] 804
FAILURE CODE [CA2249] 806
FAILURE CODE [CA2311] 807
FAILURE CODE [CA2555] 808
FAILURE CODE [CA2556] 811
FAILURE CODE [D110KB] 813
FAILURE CODE [D19JKZ] 817
FAILURE CODE [D811MC] 821
FAILURE CODE [D862KA] 822
FAILURE CODE [D8ALKA] 825
FAILURE CODE [D8ALKB] 829
FAILURE CODE [D8AQKR] 832
FAILURE CODE [D8ARKR] 842
FAILURE CODE [D8G1KT] 848
FAILURE CODE [D8G6KT] 849
FAILURE CODE [DA20MC] 850
FAILURE CODE [DA22KK] 851
FAILURE CODE [DA25KP] 856
FAILURE CODE [DA26KP] 860
FAILURE CODE [DA29KQ] 866
FAILURE CODE [DA2LKA] 871
FAILURE CODE [DA2LKB] 875
FAILURE CODE [DA2QKR] 878
FAILURE CODE [DA2RKR] 889
FAILURE CODE [DAF0MB] 898
FAILURE CODE [DAF0MC] 899
FAILURE CODE [DAF8KB] 900
FAILURE CODE [DAF9KQ] 902
FAILURE CODE [DAFGMC] 904
FAILURE CODE [DAFLKA] 906
FAILURE CODE [DAFLKB] 910
FAILURE CODE [DAFQKR] 913
FAILURE CODE [DAZ9KQ] 923
FAILURE CODE [DAZQKR] 925
FAILURE CODE [DB2QKR] 934
FAILURE CODE [DDPAKA] 944
FAILURE CODE [DGH2KA] 947
FAILURE CODE [DGH2KB] 950
FAILURE CODE [DHA4KA] 953
FAILURE CODE [DHE5MA] 956
FAILURE CODE [DHPAMA] 960
FAILURE CODE [DHPBMA] 964
FAILURE CODE [DHS3MA] 968
FAILURE CODE [DHS4MA] 972
FAILURE CODE [DHS8MA] 976
FAILURE CODE [DHS9MA] 980
FAILURE CODE [DHSAMA] 984
FAILURE CODE [DHSBMA] 988
FAILURE CODE [DHSCMA] 992
FAILURE CODE [DHSDMA] 996
FAILURE CODE [DHSFMA] 1000
FAILURE CODE [DHSGMA] 1004
FAILURE CODE [DHSHMA] 1008
FAILURE CODE [DHSJMA] 1012
FAILURE CODE [DJG1KX] 1016
FAILURE CODE [DKR2MA] 1019
FAILURE CODE [DKR2NX] 1023
FAILURE CODE [DR31KX] 1025
FAILURE CODE [DV20KB] 1026
FAILURE CODE [DW43KA] 1029
FAILURE CODE [DW43KB] 1032
FAILURE CODE [DW43KY] 1035
FAILURE CODE [DW45KA] 1037
FAILURE CODE [DW45KB] 1041
FAILURE CODE [DW45KY] 1045
FAILURE CODE [DW91KA] 1048
FAILURE CODE [DW91KB] 1050
FAILURE CODE [DW91KY] 1053
FAILURE CODE [DWA2KA] 1055
FAILURE CODE [DWA2KB] 1057
FAILURE CODE [DWA2KY] 1060
FAILURE CODE [DWK0KA] 1062
FAILURE CODE [DWK0KB] 1064
FAILURE CODE [DWK0KY] 1067
FAILURE CODE [DWK2KA] 1069
FAILURE CODE [DWK2KB] 1071
FAILURE CODE [DWK2KY] 1074
FAILURE CODE [DWK8KA] 1076
FAILURE CODE [DWK8KB] 1078
FAILURE CODE [DWK8KY] 1081
FAILURE CODE [DXA8KA] 1083
FAILURE CODE [DXA8KB] 1086
FAILURE CODE [DXA9KA] 1090
FAILURE CODE [DXA9KB] 1093
FAILURE CODE [DXE0KA] 1097
FAILURE CODE [DXE0KB] 1100
FAILURE CODE [DXE4KA] 1103
FAILURE CODE [DXE4KB] 1106
FAILURE CODE [DXE4KY] 1109
FAILURE CODE [DXE5KA] 1111
FAILURE CODE [DXE5KB] 1114
FAILURE CODE [DXE6KA] 1117
FAILURE CODE [DXE6KB] 1120
FAILURE CODE [DY20KA] 1123
FAILURE CODE [DY20MA] 1127
FAILURE CODE [DY2CKB] 1131
FAILURE CODE [DY2DKB] 1136
FAILURE CODE [DY2EKB] 1139
FAILURE CODE [F313KA] 1142
FAILURE CODE [F313KB] 1144
FAILURE CODE [F318KB] 1147
FAILURE CODE [F318KY] 1150
FAILURE CODE [F@BBZL] 1152
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1155
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1155
MANUAL PREHEATING SYSTEM DOES NOT WORK 1165
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1169
WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP 1173
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1178
WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL CAUTION LAMP LIGHTS UP IN YELLOW 1183
WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL CAUTION LAMP LIGHTS UP IN YELLOW 1185
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION 1187
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION 1189
AIR CLEANER CLOGGING MONITOR LIGHT UP IN YELLOW WHILE ENGINE IS IN OPERATION 1191
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1193
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1197
WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1198
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1199
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1201
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1202
FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1204
FUEL GAUGE INDICATES INCORRECT LEVEL 1207
COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1209
COOLANT TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE 1210
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1212
HYDRAULIC OIL TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE 1215
MACHINE MONITOR SHOWS INCORRECT MODEL 1217
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 1218
FUNCTION SWITCH DOES NOT OPERATE 1219
AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER) 1220
AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED 1222
AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION 1223
WORK MODE SELECTOR SCREEN DOES NOT APPEAR WHILE WORK MODE SWITCH IS OPERATED 1226
ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED 1227
TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED 1228
TRAVEL SPEED DOES NOT CHANGE WHILE TRAVEL SPEED IS CHANGED 1229
ALARM BUZZER DOES NOT STOP 1231
SERVICE METER IS NOT DISPLAYED WHILE STARTING SWITCH IS IN OFF POSITION 1232
MACHINE DOES NOT CHANGE TO SERVICE MODE 1233
ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE 1234
ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK 1238
MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED 1240
MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON 1244
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY 1247
ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED 1251
TRAVEL ALARM DOES NOT SOUND 1253
TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS 1256
HORN DOES NOT SOUND 1258
HORN DOES NOT STOP 1262
WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED 1264
WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED 1265
WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED 1268
BOOM RAISE IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION 1271
BOOM LOWER IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION 1272
ARM OUT IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION 1273
ARM IN IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION 1274
BUCKET DUMP IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION 1275
BUCKET CURL IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION 1276
SWING IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION 1277
TRAVEL IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION 1278
SERVICE IN IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION 1279
ATTACHMENT CIRCUIT CANNOT BE CHANGED 1282
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1284
QUICK COUPLER DOES NOT WORK 1286
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1291
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (H MODE) 1291
ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK 1292
All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER 1294
FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1307
UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 1312
ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1314
BOOM SPEED OR POWER IS LOW 1323
Arm speed or power is low 1335
BUCKET SPEED OR POWER IS LOW 1346
WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1356
HYDRAULIC DRIFT OF BOOM IS LARGE 1360
HYDRAULIC DRIFT OF ARM IS LARGE 1362
HYDRAULIC DRIFT OF BUCKET IS LARGE 1366
WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 1369
TIME LAG OF WORK EQUIPMENT IS LARGE 1371
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 1378
ATTACHMENT CIRCUIT CANNOT BE CHANGED 1381
OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 1383
IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER 1385
IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1387
IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISE SPEED IS LOW 1388
MACHINE DOES NOT TRAVEL STRAIGHT 1389
MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 1400
TRAVEL SPEED IS SLOW 1415
ONE OF TRACKS DOES NOT RUN 1426
TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1435
MACHINE DOES NOT SWING TO RIGHT OR LEFT 1438
SWINGS ONLY IN ONE DIRECTION 1443
SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 1446
SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION 1453
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1457
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1459
SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS 1463
LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS 1465
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 1468
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1470
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT MOVE) 1474
UNUSUAL NOISE IS HEARD FROM AROUND FAN 1476
TROUBLESHOOTING OF ENGINE (S-MODE) 1477
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1477
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO 1478
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1479
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1480
ENGINE STARTABILITY IS POOR 1482
ENGINE DOES NOT PICK UP SMOOTHLY 1484
ENGINE STOPS DURING OPERATION 1486
ENGINE RUNS ROUGH OR IS UNSTABLE 1488
ENGINE LACKS POWER 1489
EXHAUST SMOKE IS BLACK 1491
ENGINE OIL CONSUMPTION IS EXCESSIVE 1493
OIL BECOMES CONTAMINATED QUICKLY 1494
FUEL CONSUMPTION IS EXCESSIVE 1495
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1496
OIL PRESSURE DROPS 1497
FUEL MIXES INTO ENGINE OIL 1498
WATER MIXES INTO ENGINE OIL (MILKY) 1499
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 1500
UNUSUAL NOISE IS HEARD 1501
VIBRATION IS EXCESSIVE 1502
AIR CANNOT BE BLED FROM FUEL CIRCUIT 1503
50 DISASSEMBLY AND ASSEMBLY 1505
CONTENTS 1506
ABBREVIATION LIST 1509
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1514
HOW TO READ THIS MANUAL 1514
COATING MATERIALS LIST 1516
SPECIAL TOOLS LIST 1520
SKETCHES OF SPECIAL TOOLS 1530
PREPARATION 1535
DRAIN AND ADD COOLANT 1535
DRAIN COOLANT 1535
ADD COOLANT 1536
DRAIN AND ADD HYDRAULIC OIL 1538
DRAIN HYDRAULIC OIL 1538
ADD HYDRAULIC OIL 1539
DRAIN AND ADD FUEL 1542
DRAIN FUEL 1542
ADD FUEL 1543
COLLECT AND REFILL REFRIGERANT 1546
COLLECT REFRIGERANT 1546
REFILL REFRIGERANT 1546
ENGINE AND COOLING SYSTEM 1547
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1547
REMOVE SUPPLY PUMP ASSEMBLY 1548
INSTALL SUPPLY PUMP ASSEMBLY 1552
REMOVE AND INSTALL INJECTOR ASSEMBLY 1556
REMOVE INJECTOR ASSEMBLY 1557
INSTALL INJECTOR ASSEMBLY 1561
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 1568
REMOVE CYLINDER HEAD ASSEMBLY 1571
INSTALL CYLINDER HEAD ASSEMBLY 1581
REMOVE AND INSTALL RADIATOR ASSEMBLY 1600
REMOVE RADIATOR ASSEMBLY 1600
INSTALL RADIATOR ASSEMBLY 1603
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1606
REMOVE HYDRAULIC OIL COOLER ASSEMBLY 1607
INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1610
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 1613
REMOVE AFTERCOOLER ASSEMBLY 1613
INSTALL AFTERCOOLER ASSEMBLY 1615
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 1618
REMOVE ENGINE AND MAIN PUMP ASSEMBLY 1619
INSTALL ENGINE AND MAIN PUMP ASSEMBLY 1634
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 1650
REMOVE ENGINE FRONT OIL SEAL 1650
INSTALL ENGINE FRONT OIL SEAL 1652
REMOVE AND INSTALL ENGINE REAR OIL SEAL 1655
REMOVE ENGINE REAR OIL SEAL 1655
INSTALL ENGINE REAR OIL SEAL 1657
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 1661
REMOVE ENGINE HOOD ASSEMBLY 1661
INSTALL ENGINE HOOD ASSEMBLY 1663
REMOVE AND INSTALL FUEL TANK ASSEMBLY 1665
REMOVE FUEL TANK ASSEMBLY 1666
INSTALL FUEL TANK ASSEMBLY 1670
POWER TRAIN 1676
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1676
REMOVE TRAVEL MOTOR AND FIANL DRIVE ASSEMBLY 1676
INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1678
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 1680
DISASSEMBLE FINAL DRIVE ASSEMBLY 1681
ASSEMBLE FINAL DRIVE ASSEMBLY 1686
REMOVE AND INSTALL SWIVEL MOTOR AND SWING MACHINERY ASSEMBLY 1698
REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY 1699
INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 1701
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 1705
DISASSEMBLE SWING MACHINERY ASSEMBLY 1706
ASSEMBLE SWING MACHINERY ASSEMBLY 1712
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 1721
REMOVE SWING CIRCLE ASSEMBLY 1721
INSTALL SWING CIRCLE ASSEMBLY 1721
UNDERCARRIAGE AND FRAME 1723
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 1723
SEPARATE TRACK ASSEMBLY 1723
INSTALL TRACK ASSEMBLY 1725
REMOVE AND INSTALL SPROCKET 1729
REMOVE SPROCKET 1729
INSTALL SPROCKET 1729
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 1731
REMOVE IDLER AND IDLER CUSHION ASSEMBLY 1731
INSTALL IDLER AND IDLER CUSHION ASSEMBLY 1732
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 1733
DISASSEMBLE IDLER ASSEMBLY 1733
ASSEMBLE IDLER ASSEMBLY 1735
DISASSEMBLE AND ASSEMBLE IDLER CUSHION ASSEMBLY 1742
DISASSEMBLE IDLER CUSHION ASSEMBLY 1743
ASSEMBLE IDLER CUSHION ASSEMBLY 1744
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 1746
DISASSEMBLE TRACK ROLLER ASSEMBLY 1746
ASSEMBLE TRUCK ROLLER ASSEMBLY 1747
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 1749
DISASSEMBLE CARRIER ROLLER ASSEMBLY 1749
ASSEMBLE CARRIER ROLLER ASSEMBLY 1751
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 1754
REMOVE REVOLVING FRAME ASSEMBLY 1755
INSTALL REVOLVING FRAME ASSEMBLY 1758
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 1761
REMOVE COUNTERWEIGHT ASSEMBLY 1761
INSTALL COUNTERWEIGHT ASSEMBLY 1762
HYDRAULIC SYSTEM 1764
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 1764
REMOVE CENTER SWIVEL JOINT ASSEMBLY 1765
INSTALL CENTER SWIVEL JOINT ASSEMBLY 1768
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 1772
DISASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 1772
ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 1773
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 1776
REMOVE HYDRAULIC TANK ASSEMBLY 1777
INSTALL HYDRAULIC TANK ASSEMBLY 1781
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 1788
REMOVE MAIN PUMP ASSEMBLY 1789
INSTALL MAIN PUMP ASSEMBLY 1796
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 1806
REMOVE CONTROL VALVE ASSEMBLY 1807
INSTALL CONTROL VALVE ASSEMBLY 1819
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 1832
REPLACE PRESSURE COMPENSATION VALVE SEAL RING 1832
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 1835
DISASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 1835
ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 1835
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 1838
DISASSEMBLE TRAVEL PPC VALVE ASSEMBLY 1838
ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 1839
WORK EQUIPMENT 1841
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 1841
REMOVE WORK EQUIPMENT ASSEMBLY 1842
INSTALL WORK EQUIPMENT ASSEMBLY 1845
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 1848
DISASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 1849
ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 1854
CAB RELATED PARTS 1863
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY 1863
REMOVE OPERATOR CAB ASSEMBLY 1864
INSTALL OPERATOR CAB ASSEMBLY 1874
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 1884
REMOVE OPERATOR CAB GLASS (ADHERED GLASS) 1886
INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 1886
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 1897
REMOVE FRONT WINDOW ASSEMBLY 1897
INSTALL FRONT WINDOW ASSEMBLY 1900
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 1906
REMOVE FLOOR FRAME ASSEMBLY 1907
INSTALL FLOOR FRAME ASSEMBLY 1913
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 1921
REMOVE AIR CONDITIONER UNIT ASSEMBLY 1922
INSTALL AIR CONDITIONER UNIT ASSEMBLY 1930
REMOVE AND INSTALL OPERATOR SEAT 1938
REMOVE OPERATOR SEAT 1938
INSTALL OPERATOR SEAT 1939
REMOVE AND INSTALL SEATBELT 1941
REMOVE SEATBELT 1941
INSTALL SEATBELT 1942
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 1943
REMOVE FRONT WIPER ASSEMBLY 1943
INSTALL FRONT WIPER ASSEMBLY 1948
ELECTRICAL SYSTEM 1956
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 1956
REMOVE ENGINE CONTROLLER ASSEMBLY 1957
INSTALL ENGINE CONTROLLER ASSEMBLY 1958
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 1960
REMOVE PUMP CONTROLLER ASSEMBLY 1960
INSTALL PUMP CONTROLLER ASSEMBLY 1962
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 1966
REMOVE MACHINE MONITOR ASSEMBLY 1966
INSTALL MACHINE MONITOR ASSEMBLY 1969
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 1973
REMOVE KOMTRAX TERMINAL ASSEMBLY 1973
INSTALL KOMTRAX TERMINAL ASSEMBLY 1976
60 MAINTENANCE STANDARD 1979
CONTENTS 1980
ABBREVIATION LIST 1981
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 1986
ENGINE AND COOLING SYSTEM 1988
MAINTENANCE STANDARD OF ENGINE MOUNT 1988
MAINTENANCE STANDARD OF COOLING SYSTEM 1989
POWER TRAIN 1990
MAINTENANCE STANDARD OF SWING CIRCLE 1990
MAINTENANCE STANDARD OF SWING MACHINERY 1991
MAINTENANCE STANDARD OF FINAL DRIVE 1994
MAINTENANCE STANDARD OF SPROCKET 1996
SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 1997
UNDERCARRIAGE AND FRAME 1998
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 1998
MAINTENANCE STANDARD OF IDLER 1999
MAINTENANCE STANDARD OF TRACK ROLLER 2001
MAINTENANCE STANDARD OF CARRIER ROLLER 2003
MAINTENANCE STANDARD OF TRACK SHOE 2004
MAINTENANCE STANDARD OF TRIPLE SHOE 2007
MAINTENANCE STANDARD OF SWAMP SHOE 2008
MAINTENANCE STANDARD OF ROAD LINER 2009
HYDRAULIC SYSTEM 2010
MAINTENANCE STANDARD OF HYDRAULIC TANK 2010
MAINTENANCE STANDARD OF MAIN PUMP 2011
MAINTENANCE STANDARD OF LS-EPC VALVE 2013
MAINTENANCE STANDARD OF PC-EPC VALVE 2014
MAINTENANCE STANDARD OF SWING MOTOR 2015
MAINTENANCE STANDARD OF TRAVEL MOTOR 2017
MAINTENANCE STANDARD OF CONTROL VALVE 2020
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2030
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2033
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2036
MAINTENANCE STANDARD OF ATTACHMENT OIL FLOW ADJUSTER EPC VALVE 2037
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE 2038
MAINTENANCE STANDARD OF SOLENOID VALVE 2039
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 2041
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2042
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 2043
WORK EQUIPMENT 2044
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2044
DIMENSIONS OF ARM 2050
DIMENSIONS OF BUCKET 2052
MAINTENANCE STANDARD OF BOOM CYLINDER 2054
MAINTENANCE STANDARD OF ARM CYLINDER 2055
MAINTENANCE STANDARD OF BUCKET CYLINDER 2056
80 OTHERS 2057
CONTENTS 2058
ABBREVIATION 2060
AIR CONDITIONER SYSTEM 2065
PRECAUTIONS FOR REFRIGERANT 2065
LAYOUT DRAWING OF AIR CONDITIONER SYSTEM 2066
SPECIFICATION OF AIR CONDITIONER 2068
CONFIGURATION OF REFRIGERATION CYCLE 2069
FUNCTION OF REFRIGERATION CYCLE 2070
SYSTEM DIAGRAM OF AIR CONDITIONER 2071
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2072
AIR CONDITIONER UNIT 2072
STRUCTURE OF AIR CONDITIONER UNIT 2073
FUNCTION OF AIR CONDITIONER UNIT 2074
COMPONENT PARTS OF AIR CONDITIONER UNIT 2075
AIR CONDITIONER CONTROLLER 2079
STRUCTURE OF AIR CONDITIONER CONTROLLER 2079
FUNCTION OF AIR CONDITIONER CONTROLLER 2079
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2079
COMPRESSOR 2081
STRUCTURE OF COMPRESSOR 2081
SPECIFICATIONS OF COMPRESSOR 2081
FUNCTION OF COMPRESSOR 2081
OPERATION OF COMPRESSOR 2081
CONDENSER 2082
STRUCTURE OF CONDENSER 2082
SPECIFICATIONS OF CONDENSOR 2082
FUNCTION OF COMPRESSOR 2082
AIR CONDITIONER RELATED SENSORS 2084
STRUCTURE OF SUNLIGHT SENSOR 2084
FUNCTION OF SUNLIGHT SENSOR 2084
STRUCTURE OF OUTSIDE TEMPERATURE SENSOR 2084
FUNCTION OF OUTSIDE AIR TEMPERATURE SENSOR 2084
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS OF AIR CONDITIONER 2085
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2087
TEST AIR LEAKAGE (DUCT CONNECTION) 2091
TEST AIR LEAKAGE (DUCT CONNECTION) 2091
TEST AIR CONDITIONER BY SELF-DIAGNOSIS FUNCTION 2094
TEST VENT (MODE) CHANGEOVER 2095
TEST VENT (MODE) CHANGEOVER 2095
TEST FRESH/RECIRC AIR CHANGEOVER 2097
TEST FRESH/RECIRC AIR CHANGEOVER 2097
TEST SUNLIGHT SENSOR 2098
TEST SUNLIGHT SENSOR 2098
TEST DUAL PRESSURE SWITCH 2099
TEST DUAL PRESSURE SWITCH 2099
TEST RELAY 2100
TEST RELAY 2100
SIMPLE CHECK OF REFRIGERANT VOLUME THROUGH SIGHT GLASS 2102
PROCEDURE FOR TROUBLE SHOOTING OF AIR CONDITIONER 2103
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2104
FAILURE CODE [879AKA] 2107
FAILURE CODE [879AKB] 2109
FAILURE CODE [879BKA] 2111
FAILURE CODE [879BKB] 2114
FAILURE CODE [879CKA] 2117
FAILURE CODE [879CKB] 2119
FAILURE CODE [879DKZ] 2121
FAILURE CODE [879EMC] 2124
FAILURE CODE [879FMC] 2126
FAILURE CODE [879GKX] 2128
AIR CONDITIONER DOES NOT OPERATE 2131
DEFECTIVE COOLING 2134
HEATER DOES NOT OPERATE 2143
COOL AIR DOES NOT COME OUT 2147
NO AIR COMES OUT OR AIR FLOW IS ABNORMAL 2153
FRESH/RECIRC AIR CHANGEOVER NOT POSSIBLE 2157
CONNECT SERVICE TOOL 2161
CONNECT SERVICE TOOL 2162
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPING 2163
HANDLE COMPRESSOR OIL 2165
REPLACE DESICCANT 2167
90 CIRCUIT DIAGRAMS 2169
CONTENTS 2170
ABBREVIATION LIST 2171
HOW TO READ THE CODES FOR ELECTRIC CABLE 2176
HYDRAULIC CIRCUIT DIAGRAM 2180
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2180
HYDRAULIC CIRCUIT DIAGRAM 2185
ELECTRICAL CIRCUIT DIAGRAM 2187
SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM 2187
ELECTRICAL CIRCUIT DIAGRAM(1/7) 2191
ELECTRICAL CIRCUIT DIAGRAM(2/7) 2193
ELECTRICAL CIRCUIT DIAGRAM(3/7) 2195
ELECTRICAL CIRCUIT DIAGRAM(4/7) 2197
ELECTRICAL CIRCUIT DIAGRAM(5/7) 2199
ELECTRICAL CIRCUIT DIAGRAM(6/7) 2201
ELECTRICAL CIRCUIT DIAGRAM(7/7) 2203
INDEX 2205

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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