Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06695-01 PDF

Description

Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06695-01 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06695-01 – PDF DOWNLOAD 

Language : English
Pages : 2692
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06695-01 – PDF DOWNLOAD 

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

TABLE OF CONTENTS:

Komatsu PC210LC-11 Hydraulic Excavator Shop Manual SEN06695-01 – PDF DOWNLOAD 

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 21
FOREWORD, SAFETY, BASIC INFORMATION 27
HOW TO READ THE SHOP MANUAL 27
SAFETY NOTICE FOR OPERATION 29
PRECAUTIONS TO PREVENT FIRE 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 41
PRECAUTIONS FOR DEF 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 42
PRECAUTIONS FOR ADDING 42
PRECAUTIONS FOR STORING 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 42
THE OTHER PRECAUTIONS 42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 53
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 55
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 56
PRACTICAL USE OF KOMTRAX 57
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 60
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 62
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 66
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 72
HOW TO READ ELECTRICAL WIRE CODE 73
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 77
STANDARD TIGHTENING TORQUE TABLE 80
CONVERSION TABLE 87
01 SPECIFICATIONS 93
CONTENTS 94
ABBREVIATION LIST 95
SPECIFICATIONS 101
SPECIFICATION DRAWING 101
SPECIFICATION DRAWING: PC210LC-11 101
WORKING RANGE DRAWINGS 102
WORKING RANGE: PC210LC-11 102
SPECIFICATIONS 103
SPECIFICATIONS: PC210LC-11 103
WEIGHT TABLE 106
WEIGHT TABLE: PC210LC-11 106
TABLE OF FUEL, COOLANT, AND LUBRICANTS 108
10 STRUCTURE AND FUNCTION 109
CONTENTS 110
ABBREVIATION LIST 113
UREA SCR SYSTEM 119
LAYOUT DRAWING OF UREA SCR SYSTEM 120
UREA SCR SYSTEM DIAGRAM 125
FUNCTION OF UREA SCR SYSTEM 126
FUNCTION OF AdBlue/DEF SYSTEM 126
INDUCEMENT STRATEGY 128
COMPONENT PARTS OF UREA SCR SYSTEM 142
AdBlue/DEF MIXING TUBE 142
SCR ASSEMBLY 143
AdBlue/DEF TANK 145
AdBlue/DEF PUMP 148
AdBlue/DEF INJECTOR 149
AdBlue/DEF HOSE 150
AdBlue/DEF TANK HEATING VALVE 151
BOOT-UP SYSTEM 152
LAYOUT DRAWING OF BOOT-UP SYSTEM 152
SYSTEM OPERATING LAMP SYSTEM 154
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 154
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 154
BATTERY DISCONNECT SWITCH 155
FUNCTION OF BATTERY DISCONNECT SWITCH 155
ENGINE SYSTEM 156
LAYOUT DRAWING OF ENGINE SYSTEM 156
SPECIFICATIONS OF ENGINE SYSTEM 157
FUNCTION OF ENGINE SYSTEM 157
ENGINE CONTROL SYSTEM 158
ENGINE CONTROL SYSTEM DIAGRAM 158
FUNCTION OF ENGINE CONTROL SYSTEM 159
AUTO-DECELERATION SYSTEM 161
AUTO-DECELERATION SYSTEM DIAGRAM 161
FUNCTION OF AUTO-DECELERATION SYSTEM 161
OPERATION OF AUTO-DECELERATION SYSTEM 162
ENGINE AUTOMATIC WARM-UP SYSTEM 163
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 163
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 164
OVERHEAT PREVENTION SYSTEM 165
OVERHEAT PREVENTION SYSTEM DIAGRAM 165
FUNCTION OF OVERHEAT PREVENTION SYSTEM 166
TURBOCHARGER PROTECTION SYSTEM 168
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 168
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 169
AUTOMATIC IDLE STOP SYSTEM 170
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 170
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 170
COMPONENT PARTS OF ENGINE SYSTEM 173
VGT 173
EGR SYSTEM 178
EGR VALVE 180
EGR COOLER 182
KCCV SYSTEM 184
KCCV VENTILATOR 186
KDPF 188
COOLING SYSTEM 192
LAYOUT DRAWING OF COOLING SYSTEM 192
SPECIFICATIONS OF COOLING SYSTEM 193
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 194
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 194
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 195
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 195
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 195
COMPONENT PARTS OF COOLING SYSTEM 197
FAN CLUTCH 197
CONTROL SYSTEM 198
LAYOUT DRAWING OF CONTROL SYSTEM 198
MACHINE MONITOR SYSTEM 201
MACHINE MONITOR SYSTEM DIAGRAM 201
KOMTRAX SYSTEM 202
KOMTRAX SYSTEM DIAGRAM 202
FUNCTION OF KOMTRAX SYSTEM 202
COMPONENT PARTS OF CONTROL SYSTEM 203
MACHINE MONITOR 203
KOMTRAX TERMINAL 218
PUMP CONTROLLER 220
RESISTOR FOR PC-EPC VALVE 224
CAN TERMINATING RESISTOR 225
ENGINE CONTROLLER 226
FUEL CONTROL DIAL 233
HYDRAULIC SYSTEM 235
LAYOUT DRAWING OF HYDRAULIC SYSTEM 235
CLSS 241
STRUCTURE OF CLSS 241
OPERATION OF UNLOAD VALVE AND LS PRESSURE 243
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 245
PRESSURE COMPENSATION CONTROL 259
ENGINE AND PUMP COMBINED CONTROL SYSTEM 262
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 262
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 264
PUMP AND VALVE CONTROL SYSTEM 269
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 269
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 271
COMPONENT PARTS OF HYDRAULIC SYSTEM 273
HYDRAULIC TANK 273
MAIN PUMP 275
CONTROL VALVE 301
WORK EQUIPMENT SYSTEM 360
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 360
STRUCTURE OF VALVE CONTROL 365
ONE-TOUCH POWER MAXIMIZING SYSTEM 367
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 367
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 368
PPC LOCK SYSTEM 369
PPC LOCK SYSTEM DIAGRAM 369
FUNCTION OF PPC LOCK SYSTEM 369
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 370
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 370
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 370
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 371
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 372
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 372
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 373
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 374
WORK EQUIPMENT AND SWING PPC VALVE 374
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 380
2ND-LINE ATTACHMENT PPC VALVE 388
SOLENOID VALVE 390
ANTI-DROP VALVE FOR BOOM 394
ANTI-DROP VALVE FOR ARM 399
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 404
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 406
PILOT CIRCUIT ACCUMULATOR 408
ATTACHMENT CIRCUIT ACCUMULATOR 409
SWING SYSTEM 410
LAYOUT DRAWING OF SWING SYSTEM 410
SWING CONTROL SYSTEM DIAGRAM 414
FUNCTION OF SWING CONTROL SYSTEM 414
COMPONENT PARTS OF SWING SYSTEM 418
SWING MOTOR 418
SWING MACHINERY 429
SWING CIRCLE 431
TRAVEL SYSTEM 432
LAYOUT DRAWING OF TRAVEL SYSTEM 432
TRAVEL CONTROL SYSTEM DIAGRAM 436
FUNCTION OF TRAVEL CONTROL SYSTEM 437
COMPONENT PARTS OF TRAVEL SYSTEM 438
TRAVEL MOTOR 438
FINAL DRIVE 451
TRAVEL PPC VALVE 453
CENTER SWIVEL JOINT 457
UNDERCARRIAGE AND FRAME 459
LAYOUT DRAWING OF UNDERCARRIAGE 459
SPECIFICATIONS OF UNDERCARRIAGE 460
WORK EQUIPMENT 461
STRUCTURE OF WORK EQUIPMENT 461
FUNCTION OF WORK EQUIPMENT 462
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 463
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 463
BUCKET CLEARANCE ADJUSTMENT SHIM 464
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 464
CAB AND ITS ATTACHMENTS 465
ROPS CAB 465
STRUCTURE OF ROPS CAB 465
FUNCTION OF ROPS CAB 465
CAB MOUNT 466
STRUCTURE OF CAB MOUNT 466
FUNCTION OF CAB MOUNT 466
CAB TIPPING STOPPER 467
STRUCTURE OF CAB TIPPING STOPPER 467
FUNCTION OF CAB TIPPING STOPPER 467
20 STANDARD VALUE TABLE 469
CONTENTS 470
ABBREVIATION LIST 471
STANDARD VALUE TABLE FOR ENGINE 477
STANDARD VALUE TABLE FOR ENGINE: PC210LC-11 477
STANDARD VALUE TABLE FOR MACHINE 481
STANDARD VALUE TABLE FOR MACHINE: PC210LC-11 481
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 494
STANDARD VALUE TABLE FOR ELECTRICAL 498
STANDARD VALUE TABLE FOR ELECTRICAL 498
30 TESTING AND ADJUSTING 509
CONTENTS 510
ABBREVIATION LIST 513
RELATED INFORMATION ON TESTING AND ADJUSTING 519
TOOLS FOR TESTING AND ADJUSTING 519
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 525
ENGINE AND COOLING SYSTEM 526
TEST ENGINE SPEED 526
METHOD FOR TESTING ENGINE SPEED 526
TEST BOOST PRESSURE 529
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 529
METHOD FOR TESTING BOOST PRESSURE 530
TEST EXHAUST GAS COLOR 531
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 531
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 532
TEST AND ADJUST VALVE CLEARANCE 534
METHOD FOR TESTING VALVE CLEARANCE 534
METHOD FOR ADJUSTING VALVE CLEARANCE 535
TEST COMPRESSION PRESSURE 536
METHOD FOR TESTING COMPRESSION PRESSURE 536
TEST BLOWBY PRESSURE 541
METHOD FOR TESTING BLOWBY PRESSURE 541
TEST ENGINE OIL PRESSURE 543
METHOD FOR TESTING ENGINE OIL PRESSURE 543
TEST EGR VALVE AND VGT OIL PRESSURE 544
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 544
TEST FUEL PRESSURE 546
METHOD FOR TESTING FUEL PRESSURE 547
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 552
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 553
BLEEDING AIR FROM FUEL SYSTEM 559
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 559
TEST FUEL CIRCUIT FOR LEAKAGE 560
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 560
HANDLE CYLINDER CUT-OUT MODE OPERATION 562
HANDLE NO-INJECTION CRANKING OPERATION 563
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 564
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 564
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 564
TEST COOLING FAN SPEED 566
METHOD FOR TESTING COOLING FAN SPEED 566
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 567
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 567
TEST SCR RELATED FUNCTIONS 568
TEST AdBlue/DEF PUMP RAISED PRESSURE 571
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 574
TEST AdBlue/DEF LINE HEATER RELAY 1 578
TEST AdBlue/DEF LINE HEATER RELAY 2 581
TEST AdBlue/DEF PUMP HEATER RELAY 583
TEST AdBlue/DEF TANK HEATER VALVE 586
TEST DENITRATION EFFICIENCY OF SCR 589
CLEAN AdBlue/DEF TANK 593
METHOD FOR CLEANING AdBlue/DEF TANK 593
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 597
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 597
POWER TRAIN 599
TEST SWING CIRCLE BEARING CLEARANCE 599
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 599
UNDERCARRIAGE AND FRAME 600
TEST AND ADJUST TRACK TENSION 600
METHOD FOR TESTING TRACK TENSION 600
METHOD FOR ADJUSTING TRACK TENSION 600
HYDRAULIC SYSTEM 602
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 602
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 602
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 603
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 604
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 610
TEST OIL PRESSURE OF CONTROL CIRCUIT 613
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 613
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 615
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 615
TEST PC-EPC VALVE OUTLET PRESSURE 616
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 617
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 618
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 618
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL 619
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 622
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 623
METHOD FOR ADJUSTING LS VALVE 624
TEST OUTLET PRESSURE OF SOLENOID VALVE 625
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 625
OPERATING CONDITION OF SOLENOID VALVE 626
TEST PPC VALVE OUTLET PRESSURE 629
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 629
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 631
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 631
TEST PUMP SWASH PLATE SENSOR 632
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 632
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 633
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 633
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 633
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 634
TEST OIL LEAKAGE 635
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 635
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 635
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 636
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 637
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 637
BLEED AIR FROM HYDRAULIC CIRCUIT 638
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 640
CAB AND ITS ATTACHMENTS 642
TEST CAB TIPPING STOPPER 642
METHOD FOR TESTING CAB TIPPING STOPPER 642
METHOD FOR ADJUSTING MIRRORS 643
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 643
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 644
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 645
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 646
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 647
ELECTRICAL SYSTEM 649
SET AND OPERATE MACHINE MONITOR 649
OPERATOR MODE 652
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 653
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 653
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 654
CHECKING FUNCTION OF SERVICE METER 654
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 654
SERVICE MODE 657
METHOD FOR OPERATING SERVICE MODE 657
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 659
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 665
ABNORMALITY RECORD MENU 676
METHOD FOR CONFIRMING MAINTENANCE RECORD 680
METHOD FOR OPERATING MAINTENANCE MODE SETTING 681
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 685
DEFAULT MENU 686
DIAGNOSTIC TESTS MENU 693
ADJUSTMENT MENU 702
METHOD FOR PERFORMING NO-INJECTION CRANKING 720
KOMTRAX SETTINGS MENU 721
METHOD FOR DISPLAYING SERVICE MESSAGE 724
METHOD FOR STARTING UP KOMTRAX TERMINAL 726
ADJUST REARVIEW CAMERA ANGLE 731
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 731
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 734
HANDLE BATTERY DISCONNECT SWITCH 735
TEST DIODES 736
METHOD FOR TESTING DIODE USING DIGITAL TESTER 736
METHOD FOR TESTING DIODE USING ANALOG TESTER 736
Pm CLINIC 737
Pm CLINIC SERVICE 737
Pm CLINIC CHECK SHEET 739
40 TROUBLESHOOTING 751
CONTENTS 752
ABBREVIATION LIST 763
RELATED INFORMATION ON TROUBLESHOOTING 769
GENERAL TROUBLESHOOTING POINTS 769
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 770
SEQUENCE OF EVENTS IN TROUBLESHOOTING 782
CHECKS BEFORE TROUBLESHOOTING 784
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 786
WALK-AROUND CHECK 786
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 788
CHECK FUEL LEVEL AND TYPE 788
CHECK IMPURE INGREDIENT IN FUEL 788
CHECK FUEL PREFILTER 789
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 789
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 790
CHECK MAIN FILTER 791
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 793
CHECK COOLANT LEVEL (RESERVOIR TANK) 794
CHECK CLOGGING OF AIR CLEANER 794
OUTER ELEMENT – CLEAN 795
ELEMENTS – REPLACE 797
CHECK HYDRAULIC OIL LEVEL 798
CHECK HYDRAULIC OIL STRAINER 799
CHECK HYDRAULIC FILTER 800
CHECK OIL LEVEL IN SWING MACHINERY CASE 801
CHECK OIL LEVEL IN DAMPER CASE 802
CHECK OIL LEVEL IN FINAL DRIVE CASE 802
BLEED AIR FROM FUEL SYSTEM 803
BLEED AIR FROM HYDRAULIC SYSTEM 803
ELECTRICAL EQUIPMENT – CHECK METHOD 803
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 811
PROCEDURE FOR TESTING AND TROUBLESHOOTING 821
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 824
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 828
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 830
CONNECTOR LIST AND LAYOUT 833
CONNECTOR CONTACT IDENTIFICATION 846
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 886
FUSE LOCATION TABLE 892
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 894
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 898
FAILURE CODES TABLE 900
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 917
FAILURE CODE [879AKA] 917
FAILURE CODE [879AKB] 918
FAILURE CODE [879BKA] 919
FAILURE CODE [879BKB] 921
FAILURE CODE [879CKA] 923
FAILURE CODE [879CKB] 924
FAILURE CODE [879DKZ] 925
FAILURE CODE [879EMC] 927
FAILURE CODE [879FMC] 928
FAILURE CODE [879GKX] 929
FAILURE CODE [989L00] 931
FAILURE CODE [989M00] 932
FAILURE CODE [989N00] 933
FAILURE CODE [A1U0N3] 934
FAILURE CODE [A1U0N4] 936
FAILURE CODE [A900FR] 938
FAILURE CODE [A900N6] 939
FAILURE CODE [A900NY] 940
FAILURE CODE [AA10NX] 941
FAILURE CODE [AB00KE] 943
FAILURE CODE [AQ10N3] 946
FAILURE CODE [AS00N3] 948
FAILURE CODE [AS00R2] 950
FAILURE CODE [AS00R3] 951
FAILURE CODE [AS00R4] 952
FAILURE CODE [AS00R5] 953
FAILURE CODE [AS00R6] 954
FAILURE CODE [AS00ZK] 955
FAILURE CODE [AS10KM] 956
FAILURE CODE [AS10NR] 957
FAILURE CODE [AS10NT] 958
FAILURE CODE [B@BAZG] 959
FAILURE CODE [B@BAZK] 960
FAILURE CODE [B@BCNS] 962
FAILURE CODE [B@BCQA] 963
FAILURE CODE [B@BCZK] 965
FAILURE CODE [B@HANS] 967
FAILURE CODE [CA115] 968
FAILURE CODE [CA122] 969
FAILURE CODE [CA123] 971
FAILURE CODE [CA131] 973
FAILURE CODE [CA132] 975
FAILURE CODE [CA144] 977
FAILURE CODE [CA145] 979
FAILURE CODE [CA153] 981
FAILURE CODE [CA154] 984
FAILURE CODE [CA187] 986
FAILURE CODE [CA221] 988
FAILURE CODE [CA222] 990
FAILURE CODE [CA227] 992
FAILURE CODE [CA234] 993
FAILURE CODE [CA238] 994
FAILURE CODE [CA239] 996
FAILURE CODE [CA249] 998
FAILURE CODE [CA256] 1000
FAILURE CODE [CA271] 1002
FAILURE CODE [CA272] 1004
FAILURE CODE [CA322] 1006
FAILURE CODE [CA323] 1008
FAILURE CODE [CA324] 1010
FAILURE CODE [CA325] 1012
FAILURE CODE [CA331] 1014
FAILURE CODE [CA332] 1016
FAILURE CODE [CA343] 1018
FAILURE CODE [CA351] 1019
FAILURE CODE [CA352] 1020
FAILURE CODE [CA356] 1023
FAILURE CODE [CA357] 1025
FAILURE CODE [CA386] 1027
FAILURE CODE [CA428] 1028
FAILURE CODE [CA429] 1030
FAILURE CODE [CA435] 1032
FAILURE CODE [CA441] 1034
FAILURE CODE [CA442] 1036
FAILURE CODE [CA449] 1037
FAILURE CODE [CA451] 1038
FAILURE CODE [CA452] 1040
FAILURE CODE [CA488] 1042
FAILURE CODE [CA515] 1043
FAILURE CODE [CA516] 1045
FAILURE CODE [CA553] 1047
FAILURE CODE [CA555] 1048
FAILURE CODE [CA556] 1049
FAILURE CODE [CA559] 1050
FAILURE CODE [CA595] 1053
FAILURE CODE [CA687] 1054
FAILURE CODE [CA689] 1056
FAILURE CODE [CA691] 1059
FAILURE CODE [CA692] 1061
FAILURE CODE [CA697] 1063
FAILURE CODE [CA698] 1064
FAILURE CODE [CA731] 1065
FAILURE CODE [CA778] 1067
FAILURE CODE [CA1117] 1072
FAILURE CODE [CA1664] 1073
FAILURE CODE [CA1669] 1075
FAILURE CODE [CA1673] 1076
FAILURE CODE [CA1677] 1077
FAILURE CODE [CA1678] 1078
FAILURE CODE [CA1682] 1079
FAILURE CODE [CA1683] 1081
FAILURE CODE [CA1684] 1083
FAILURE CODE [CA1686] 1085
FAILURE CODE [CA1691] 1086
FAILURE CODE [CA1694] 1089
FAILURE CODE [CA1695] 1092
FAILURE CODE [CA1696] 1093
FAILURE CODE [CA1712] 1095
FAILURE CODE [CA1713] 1098
FAILURE CODE [CA1714] 1100
FAILURE CODE [CA1715] 1101
FAILURE CODE [CA1776] 1102
FAILURE CODE [CA1777] 1105
FAILURE CODE [CA1843] 1108
FAILURE CODE [CA1844] 1110
FAILURE CODE [CA1879] 1113
FAILURE CODE [CA1881] 1115
FAILURE CODE [CA1883] 1117
FAILURE CODE [CA1885] 1120
FAILURE CODE [CA1887] 1122
FAILURE CODE [CA1921] 1124
FAILURE CODE [CA1922] 1127
FAILURE CODE [CA1942] 1132
FAILURE CODE [CA1993] 1133
FAILURE CODE [CA2185] 1136
FAILURE CODE [CA2186] 1137
FAILURE CODE [CA2249] 1139
FAILURE CODE [CA2271] 1140
FAILURE CODE [CA2272] 1143
FAILURE CODE [CA2288] 1146
FAILURE CODE [CA2311] 1147
FAILURE CODE [CA2349] 1148
FAILURE CODE [CA2353] 1151
FAILURE CODE [CA2357] 1153
FAILURE CODE [CA2381] 1154
FAILURE CODE [CA2382] 1157
FAILURE CODE [CA2383] 1160
FAILURE CODE [CA2386] 1163
FAILURE CODE [CA2387] 1165
FAILURE CODE [CA2555] 1166
FAILURE CODE [CA2556] 1169
FAILURE CODE [CA2637] 1172
FAILURE CODE [CA2639] 1174
FAILURE CODE [CA2771] 1177
FAILURE CODE [CA2777] 1183
FAILURE CODE [CA2976] 1186
FAILURE CODE [CA3133] 1188
FAILURE CODE [CA3134] 1191
FAILURE CODE [CA3135] 1193
FAILURE CODE [CA3142] 1196
FAILURE CODE [CA3143] 1197
FAILURE CODE [CA3144] 1198
FAILURE CODE [CA3146] 1200
FAILURE CODE [CA3147] 1201
FAILURE CODE [CA3148] 1202
FAILURE CODE [CA3151] 1204
FAILURE CODE [CA3165] 1210
FAILURE CODE [CA3229] 1212
FAILURE CODE [CA3231] 1214
FAILURE CODE [CA3232] 1216
FAILURE CODE [CA3235] 1220
FAILURE CODE [CA3239] 1222
FAILURE CODE [CA3241] 1225
FAILURE CODE [CA3242] 1228
FAILURE CODE [CA3251] 1231
FAILURE CODE [CA3253] 1233
FAILURE CODE [CA3254] 1236
FAILURE CODE [CA3255] 1239
FAILURE CODE [CA3256] 1243
FAILURE CODE [CA3311] 1245
FAILURE CODE [CA3312] 1247
FAILURE CODE [CA3313] 1250
FAILURE CODE [CA3314] 1251
FAILURE CODE [CA3315] 1252
FAILURE CODE [CA3316] 1254
FAILURE CODE [CA3317] 1255
FAILURE CODE [CA3318] 1256
FAILURE CODE [CA3319] 1258
FAILURE CODE [CA3321] 1259
FAILURE CODE [CA3322] 1261
FAILURE CODE [CA3419] 1263
FAILURE CODE [CA3421] 1265
FAILURE CODE [CA3497] 1267
FAILURE CODE [CA3498] 1268
FAILURE CODE [CA3543] 1269
FAILURE CODE [CA3545] 1276
FAILURE CODE [CA3547] 1278
FAILURE CODE [CA3558] 1279
FAILURE CODE [CA3559] 1281
FAILURE CODE [CA3562] 1283
FAILURE CODE [CA3563] 1285
FAILURE CODE [CA3567] 1288
FAILURE CODE [CA3568] 1291
FAILURE CODE [CA3571] 1295
FAILURE CODE [CA3572] 1297
FAILURE CODE [CA3574] 1299
FAILURE CODE [CA3575] 1301
FAILURE CODE [CA3577] 1303
FAILURE CODE [CA3578] 1305
FAILURE CODE [CA3582] 1307
FAILURE CODE [CA3583] 1313
FAILURE CODE [CA3596] 1315
FAILURE CODE [CA3649] 1317
FAILURE CODE [CA3681] 1319
FAILURE CODE [CA3682] 1324
FAILURE CODE [CA3713] 1330
FAILURE CODE [CA3717] 1333
FAILURE CODE [CA3718] 1334
FAILURE CODE [CA3725] 1335
FAILURE CODE [CA3741] 1338
FAILURE CODE [CA3748] 1339
FAILURE CODE [CA3751] 1341
FAILURE CODE [CA3755] 1343
FAILURE CODE [CA3866] 1345
FAILURE CODE [CA3867] 1349
FAILURE CODE [CA3868] 1352
FAILURE CODE [CA3899] 1356
FAILURE CODE [CA3911] 1358
FAILURE CODE [CA3912] 1362
FAILURE CODE [CA3932] 1364
FAILURE CODE [CA3933] 1366
FAILURE CODE [CA3934] 1368
FAILURE CODE [CA3935] 1371
FAILURE CODE [CA3936] 1373
FAILURE CODE [CA4151] 1375
FAILURE CODE [CA4152] 1379
FAILURE CODE [CA4155] 1383
FAILURE CODE [CA4156] 1385
FAILURE CODE [CA4157] 1388
FAILURE CODE [CA4158] 1390
FAILURE CODE [CA4159] 1391
FAILURE CODE [CA4161] 1392
FAILURE CODE [CA4162] 1395
FAILURE CODE [CA4163] 1398
FAILURE CODE [CA4164] 1399
FAILURE CODE [CA4165] 1401
FAILURE CODE [CA4166] 1403
FAILURE CODE [CA4168] 1404
FAILURE CODE [CA4169] 1407
FAILURE CODE [CA4171] 1409
FAILURE CODE [CA4249] 1412
FAILURE CODE [CA4251] 1414
FAILURE CODE [CA4259] 1416
FAILURE CODE [CA4261] 1419
FAILURE CODE [CA4277] 1422
FAILURE CODE [CA4281] 1425
FAILURE CODE [CA4459] 1428
FAILURE CODE [CA4461] 1431
FAILURE CODE [CA4658] 1434
FAILURE CODE [CA4731] 1438
FAILURE CODE [CA4732] 1439
FAILURE CODE [CA4739] 1440
FAILURE CODE [CA4768] 1441
FAILURE CODE [CA4769] 1443
FAILURE CODE [CA4842] 1446
FAILURE CODE [CA4952] 1450
FAILURE CODE [CA5115] 1452
FAILURE CODE [CA5179] 1455
FAILURE CODE [CA5181] 1457
FAILURE CODE [CA5383] 1459
FAILURE CODE [D110KB] 1461
FAILURE CODE [D19JKZ] 1463
FAILURE CODE [D811MC] 1466
FAILURE CODE [D862KA] 1467
FAILURE CODE [D8ALKA] 1468
FAILURE CODE [D8ALKB] 1470
FAILURE CODE [D8AQKR] 1472
FAILURE CODE [DA20MC] 1474
FAILURE CODE [DA22KK] 1475
FAILURE CODE [DA25KP] 1478
FAILURE CODE [DA26KP] 1481
FAILURE CODE [DA29KQ] 1483
FAILURE CODE [DA2LKA] 1485
FAILURE CODE [DA2LKB] 1487
FAILURE CODE [DA2QKR] 1489
FAILURE CODE [DA2RKR] 1492
FAILURE CODE [DAF0MB] 1493
FAILURE CODE [DAF0MC] 1494
FAILURE CODE [DAF8KB] 1495
FAILURE CODE [DAF9KQ] 1497
FAILURE CODE [DAFGMC] 1498
FAILURE CODE [DAFLKA] 1499
FAILURE CODE [DAFLKB] 1501
FAILURE CODE [DAFQKR] 1503
FAILURE CODE [DAZ9KQ] 1504
FAILURE CODE [DAZQKR] 1505
FAILURE CODE [DB2QKR] 1510
FAILURE CODE [DB2RKR] 1515
FAILURE CODE [DDNRKA] 1520
FAILURE CODE [DDNRKY] 1522
FAILURE CODE [DDNS00] 1524
FAILURE CODE [DGH2KA] 1526
FAILURE CODE [DGH2KB] 1528
FAILURE CODE [DHA4KA] 1530
FAILURE CODE [DHAAMA] 1532
FAILURE CODE [DHACMA] 1534
FAILURE CODE [DHPAMA] 1536
FAILURE CODE [DHPBMA] 1539
FAILURE CODE [DHS3MA] 1542
FAILURE CODE [DHS4MA] 1545
FAILURE CODE [DHS8MA] 1548
FAILURE CODE [DHS9MA] 1551
FAILURE CODE [DHSAMA] 1554
FAILURE CODE [DHSBMA] 1557
FAILURE CODE [DHSCMA] 1560
FAILURE CODE [DHSDMA] 1563
FAILURE CODE [DHSFMA] 1566
FAILURE CODE [DHSGMA] 1569
FAILURE CODE [DHSHMA] 1572
FAILURE CODE [DHSJMA] 1575
FAILURE CODE [DKR0MA] 1578
FAILURE CODE [DKR1MA] 1581
FAILURE CODE [DKULKA] 1584
FAILURE CODE [DKULKB] 1586
FAILURE CODE [DKULKY] 1588
FAILURE CODE [DLM5KA] 1590
FAILURE CODE [DLM5MB] 1592
FAILURE CODE [DR21KX] 1594
FAILURE CODE [DR31KX] 1596
FAILURE CODE [DV20KB] 1598
FAILURE CODE [DW43KA] 1600
FAILURE CODE [DW43KB] 1602
FAILURE CODE [DW43KY] 1604
FAILURE CODE [DW45KA] 1606
FAILURE CODE [DW45KB] 1609
FAILURE CODE [DW45KY] 1612
FAILURE CODE [DW4CKY] 1614
FAILURE CODE [DW91KA] 1616
FAILURE CODE [DW91KB] 1618
FAILURE CODE [DW91KY] 1620
FAILURE CODE [DWA2KA] 1622
FAILURE CODE [DWA2KB] 1624
FAILURE CODE [DWA2KY] 1626
FAILURE CODE [DWK0KA] 1628
FAILURE CODE [DWK0KB] 1630
FAILURE CODE [DWK0KY] 1632
FAILURE CODE [DWK2KA] 1634
FAILURE CODE [DWK2KB] 1636
FAILURE CODE [DWK2KY] 1638
FAILURE CODE [DWK8KA] 1640
FAILURE CODE [DWK8KB] 1642
FAILURE CODE [DWK8KY] 1644
FAILURE CODE [DWN5KA] 1646
FAILURE CODE [DWN5KB] 1648
FAILURE CODE [DWN5KY] 1650
FAILURE CODE [DXA8KA] 1652
FAILURE CODE [DXA8KB] 1654
FAILURE CODE [DXA9KA] 1656
FAILURE CODE [DXA9KB] 1658
FAILURE CODE [DXE0KA] 1660
FAILURE CODE [DXE0KB] 1661
FAILURE CODE [DXE4KA] 1663
FAILURE CODE [DXE4KB] 1665
FAILURE CODE [DXE4KY] 1667
FAILURE CODE [DXE5KA] 1669
FAILURE CODE [DXE5KB] 1671
FAILURE CODE [DXE6KA] 1673
FAILURE CODE [DXE6KB] 1675
FAILURE CODE [DXE7KA] 1677
FAILURE CODE [DXE7KB] 1679
FAILURE CODE [DXE7KY] 1681
FAILURE CODE [DXE8KA] 1683
FAILURE CODE [DXE8KB] 1685
FAILURE CODE [DXE8KY] 1687
FAILURE CODE [DXE9KA] 1689
FAILURE CODE [DXE9KB] 1691
FAILURE CODE [DXE9KY] 1693
FAILURE CODE [DXEAKA] 1695
FAILURE CODE [DXEAKB] 1697
FAILURE CODE [DXEAKY] 1699
FAILURE CODE [DY20KA] 1701
FAILURE CODE [DY20MA] 1703
FAILURE CODE [DY2CKB] 1705
FAILURE CODE [DY2DKB] 1708
FAILURE CODE [DY2EKB] 1710
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1712
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1712
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1718
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1721
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1723
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1725
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1728
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1729
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1730
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1731
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1732
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1733
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1734
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1735
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1736
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1737
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1738
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1739
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 1741
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1742
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1743
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1744
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 1746
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 1747
E-24 FUNCTION SWITCH DOES NOT OPERATE 1748
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 1749
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1750
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1751
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 1752
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1753
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 1754
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1755
E-32 ALARM BUZZER CANNOT BE CANCELED 1757
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 1758
E-34 SERVICE MODE CANNOT BE SELECTED 1759
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1760
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 1763
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 1765
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 1768
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 1770
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 1773
E-41 ALARM DOES NOT SOUND DURING TRAVEL 1774
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1776
E-43 HORN DOES NOT SOUND 1777
E-44 HORN DOES NOT STOP SOUNDING 1780
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 1782
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 1783
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1785
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1786
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1787
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1788
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1789
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1790
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1791
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1792
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1793
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1794
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED 1796
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1797
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1798
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1798
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1799
FAILURE MODE AND CAUSE TABLE 1801
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1813
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 1814
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1817
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 1818
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1819
H-6 SPEED OR POWER OF BOOM IS LOW 1821
H-7 ARM SPEED OR POWER IS LOW 1825
H-8 BUCKET SPEED OR POWER IS LOW 1830
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1833
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE 1834
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1836
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE 1838
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 1839
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1840
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 1841
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED 1842
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 1843
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1844
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1845
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1846
H-21 MACHINE DOES NOT TRAVEL STRAIGHT 1847
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 1849
H-23 TRAVEL SPEED IS LOW 1852
H-24 ONE OF TRACKS DOES NOT RUN 1854
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1855
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1856
H-27 SWINGS ONLY IN ONE DIRECTION 1857
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 1858
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1859
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1860
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1861
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 1862
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 1863
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 1864
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1865
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 1866
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN 1867
TROUBLESHOOTING OF ENGINE (S-MODE) 1868
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1868
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1869
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1870
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1871
S-4 ENGINE STARTABILITY IS POOR 1873
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1875
S-6 ENGINE STOPS DURING OPERATION 1877
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1879
S-8 ENGINE LACKS POWER 1880
S-9 KDPF GETS CLOGGED IN A SHORT TIME 1882
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1884
S-11 OIL BECOMES CONTAMINATED QUICKLY 1885
S-12 FUEL CONSUMPTION IS EXCESSIVE 1886
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1887
S-14 OIL PRESSURE DROPS 1888
S-15 FUEL MIXES INTO ENGINE OIL 1890
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1891
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 1892
S-18 UNUSUAL NOISE IS HEARD 1893
S-19 VIBRATION IS EXCESSIVE 1894
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 1895
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 1896
S-22 ACTIVE REGENERATION TAKES TIME 1898
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1899
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1900
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 1902
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1903
50 DISASSEMBLY AND ASSEMBLY 1905
CONTENTS 1906
ABBREVIATION LIST 1911
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1917
HOW TO READ THIS MANUAL 1917
COATING MATERIALS LIST 1919
SPECIAL TOOLS LIST 1923
SKETCHES OF SPECIAL TOOLS 1935
ENGINE AND COOLING SYSTEM 1941
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1941
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1941
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1944
REMOVE AND INSTALL INJECTOR ASSEMBLY 1947
METHOD FOR REMOVING INJECTOR ASSEMBLY 1947
METHOD FOR INSTALLING INJECTOR ASSEMBLY 1952
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 1960
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1961
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1970
REMOVE AND INSTALL EGR VALVE ASSEMBLY 1986
METHOD FOR REMOVING EGR VALVE ASSEMBLY 1986
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 1987
REMOVE AND INSTALL EGR COOLER ASSEMBLY 1989
METHOD FOR REMOVING EGR COOLER ASSEMBLY 1989
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 1993
REMOVE AND INSTALL STARTER ASSEMBLY 1998
METHOD FOR REMOVING STARTER ASSEMBLY 1998
METHOD FOR INSTALLING STARTER ASSEMBLY 1999
REMOVE AND INSTALL ALTERNATOR BELT 2002
METHOD FOR REMOVING ALTERNATOR BELT 2002
METHOD FOR INSTALLING ALTERNATOR BELT 2004
REMOVE AND INSTALL RADIATOR ASSEMBLY 2006
METHOD FOR REMOVING RADIATOR ASSEMBLY 2006
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2008
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2011
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2011
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2014
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2017
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2017
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2019
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2021
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY 2021
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY 2025
REMOVE AND INSTALL FAN 2029
METHOD FOR INSTALLING FAN 2029
METHOD FOR REMOVING FAN 2029
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2030
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY 2030
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY 2039
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2051
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2051
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2054
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2058
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2058
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2059
REMOVE AND INSTALL FUEL COOLER ASSEMBLY 2062
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2062
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2062
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2064
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2064
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2066
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2071
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2071
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2075
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2079
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2079
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2085
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2091
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2091
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2097
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2103
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2103
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2103
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2105
METHOD FOR REMOVING AdBlue/DEF STRAINER 2105
METHOD FOR INSTALLING AdBlue/DEF STRAINER 2105
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2106
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2106
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2108
REMOVE AND INSTALL KDPF ASSEMBLY 2111
METHOD FOR REMOVING KDPF ASSEMBLY 2111
METHOD FOR INSTALLING KDPF ASSEMBLY 2113
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2115
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2116
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2119
REMOVE AND INSTALL SCR ASSEMBLY 2124
METHOD FOR REMOVING SCR ASSEMBLY 2124
METHOD FOR INSTALLING SCR ASSEMBLY 2126
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2128
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2128
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2134
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET 2140
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2140
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2148
REMOVE AND INSTALL KCCV ASSEMBLY 2156
METHOD FOR REMOVING KCCV ASSEMBLY 2156
METHOD FOR INSTALLING KCCV ASSEMBLY 2158
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2163
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2163
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2169
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2175
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2175
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2178
REMOVE AND INSTALL AdBlue/DEF PUMP 2181
METHOD FOR REMOVING AdBlue/DEF PUMP 2181
METHOD FOR INSTALLING AdBlue/DEF PUMP 2184
REMOVE AND INSTALL AdBlue/DEF HOSE 2187
METHOD FOR REMOVING AdBlue/DEF HOSE 2187
METHOD FOR INSTALLING AdBlue/DEF HOSE 2194
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2200
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2200
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2201
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2203
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2203
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2205
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2208
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2208
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2209
POWER TRAIN 2210
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2210
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2210
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2211
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2213
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2213
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2217
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2226
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2226
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2228
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2232
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 2232
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2236
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2243
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 2243
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 2243
UNDERCARRIAGE AND FRAME 2245
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2245
METHOD FOR SEPARATING TRACK ASSEMBLY 2245
METHOD FOR INSTALLING TRACK ASSEMBLY 2247
REMOVE AND INSTALL SPROCKET 2250
METHOD FOR REMOVING SPROCKET 2250
METHOD FOR INSTALLING SPROCKET 2250
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2252
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2252
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2253
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2254
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2254
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2255
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2259
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 2259
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2260
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2262
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2263
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2264
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 2266
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2266
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2267
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2270
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2270
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2272
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2275
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2275
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2278
HYDRAULIC SYSTEM 2282
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2282
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2282
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2284
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2287
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2287
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2288
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2290
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2290
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2292
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 2295
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2295
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2298
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2301
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2301
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2308
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 2316
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2316
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2317
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2321
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2321
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2321
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2323
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2323
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2324
WORK EQUIPMENT 2326
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2326
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2326
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2330
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 2335
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM 2335
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM 2337
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM 2338
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM 2338
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM 2340
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY 2341
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY 2341
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY 2341
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2342
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2342
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2345
CAB AND ITS ATTACHMENTS 2351
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2351
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY 2351
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY 2357
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 2364
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2366
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2366
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2376
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 2376
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 2379
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 2385
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2385
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2392
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2399
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2399
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2404
REMOVE AND INSTALL OPERATOR’S SEAT 2410
METHOD FOR REMOVING OPERATOR’S SEAT 2410
METHOD FOR INSTALLING OPERATOR’S SEAT 2412
REMOVE AND INSTALL SEAT BELT 2415
METHOD FOR REMOVING SEAT BELT 2415
METHOD FOR INSTALLING SEAT BELT 2416
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 2417
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2417
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2422
ELECTRICAL SYSTEM 2431
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2431
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2431
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2432
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 2434
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2434
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2438
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2443
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2443
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2446
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2450
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR 2450
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR 2451
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2452
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2452
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2452
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2454
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2454
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2455
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2456
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2456
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2458
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2460
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2460
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2463
60 MAINTENANCE STANDARD 2467
CONTENTS 2468
ABBREVIATION LIST 2469
ENGINE AND COOLING SYSTEM 2475
MAINTENANCE STANDARD OF ENGINE MOUNT 2475
MAINTENANCE STANDARD OF COOLING SYSTEM 2476
POWER TRAIN 2478
MAINTENANCE STANDARD OF SWING CIRCLE 2478
MAINTENANCE STANDARD OF SWING MACHINERY 2479
MAINTENANCE STANDARD OF FINAL DRIVE 2481
MAINTENANCE STANDARD OF SPROCKET 2483
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 2484
UNDERCARRIAGE AND FRAME 2486
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2486
MAINTENANCE STANDARD OF IDLER 2488
MAINTENANCE STANDARD OF TRACK ROLLER 2490
MAINTENANCE STANDARD OF CARRIER ROLLER 2491
MAINTENANCE STANDARD OF TRACK SHOE 2492
MAINTENANCE STANDARD OF TRIPLE SHOE 2495
MAINTENANCE STANDARD OF SWAMP SHOE 2496
MAINTENANCE STANDARD OF ROAD LINER 2497
HYDRAULIC SYSTEM 2498
MAINTENANCE STANDARD OF HYDRAULIC TANK 2498
MAINTENANCE STANDARD OF MAIN PUMP 2499
MAINTENANCE STANDARD OF LS-EPC VALVE 2500
MAINTENANCE STANDARD OF PC-EPC VALVE 2501
MAINTENANCE STANDARD OF SWING MOTOR 2502
MAINTENANCE STANDARD OF TRAVEL MOTOR 2505
MAINTENANCE STANDARD OF CONTROL VALVE 2508
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2518
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM 2520
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2522
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2525
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2528
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2530
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE 2531
MAINTENANCE STANDARD OF SOLENOID VALVE 2533
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 2534
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2535
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 2536
WORK EQUIPMENT 2537
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2537
DIMENSION OF ARM 2542
DIMENSIONS OF BUCKET 2544
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) 2546
MAINTENANCE STANDARD OF ARM CYLINDER 2547
MAINTENANCE STANDARD OF BUCKET CYLINDER 2548
80 APPENDIX 2549
CONTENTS 2550
ABBREVIATION LIST 2552
AIR CONDITIONER SYSTEM 2558
PRECAUTIONS FOR REFRIGERANT 2558
AIR CONDITIONER COMPONENT 2559
SPECIFICATIONS OF AIR CONDITIONER 2561
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2562
OUTLINE OF REFRIGERATION CYCLE 2563
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2565
AIR CONDITIONER UNIT 2565
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2565
FUNCTION OF AIR CONDITIONER UNIT 2567
COMPONENT PARTS OF AIR CONDITIONER UNIT 2569
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2570
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2570
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2570
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 2570
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2571
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2571
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2571
FUNCTION OF DUAL PRESSURE SWITCH 2572
AIR CONDITIONER CONTROLLER 2573
STRUCTURE OF AIR CONDITIONER CONTROLLER 2573
COMPRESSOR 2574
STRUCTURE OF COMPRESSOR 2574
SPECIFICATIONS OF COMPRESSOR 2574
FUNCTION OF COMPRESSOR 2574
CONDENSER 2575
STRUCTURE OF CONDENSER 2575
SPECIFICATIONS OF CONDENSER 2575
FUNCTION OF CONDENSER 2575
SENSORS FOR AIR CONDITIONER SYSTEM 2577
STRUCTURE OF SUNLIGHT SENSOR 2577
FUNCTION OF SUNLIGHT SENSOR 2577
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 2577
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2577
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2579
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2581
AIR CONDITIONER SYSTEM DIAGRAM 2583
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2584
FUNCTION OF AIR CONDITIONER CONTROLLER 2585
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2586
TESTING AIR LEAKAGE (DUCT) 2590
METHOD FOR TESTING AIR LEAKAGE (DUCT) 2590
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2592
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2593
TEST VENT (MODE) CHANGEOVER 2594
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2594
TESTING FRESH/RECIRC AIR CHANGEOVER 2596
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2596
TEST SUNLIGHT SENSOR 2597
METHOD FOR TESTING SUNLIGHT SENSOR 2597
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2598
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2598
TEST RELAYS 2599
METHOD FOR TESTING RELAYS 2599
AIR CONDITIONER TROUBLESHOOTING CHART 1 2600
AIR CONDITIONER TROUBLESHOOTING CHART 2 2601
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2604
FAILURE CODE [879AKA] 2606
FAILURE CODE [879AKB] 2607
FAILURE CODE [879BKA] 2608
FAILURE CODE [879BKB] 2610
FAILURE CODE [879CKA] 2612
FAILURE CODE [879CKB] 2613
FAILURE CODE [879DKZ] 2614
FAILURE CODE [879EMC] 2616
FAILURE CODE [879FMC] 2617
FAILURE CODE [879GKX] 2618
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2620
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2622
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2625
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 2627
TROUBLESHOOTING USING GAUGE PRESSURE 2629
CONNECTION OF SERVICE TOOL 2632
METHOD FOR CONNECTING SERVICE TOOL 2632
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2634
HANDLE COMPRESSOR OIL 2636
METHOD FOR REPLACING DESICCANT 2638
90 CIRCUIT DIAGRAMS 2641
CONTENTS 2642
ABBREVIATION LIST 2643
HYDRAULIC CIRCUIT DIAGRAM 2649
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2649
HYDRAULIC CIRCUIT DIAGRAM 2653
ELECTRICAL CIRCUIT DIAGRAM 2655
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2655
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(1/8) 2659
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(2/8) 2661
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(3/8) 2663
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(4/8) 2665
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(5/8) 2667
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(6/8) 2669
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(7/8) 2671
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(8/8) 2673
INDEX 2675

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24