Komatsu PC450LC-8 Hydraulic Excavator Shop Manual CEBM007602 PDF

Description

Komatsu PC450LC-8 Hydraulic Excavator Shop Manual CEBM007602 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC450LC-8 Hydraulic Excavator Shop Manual CEBM007602 – PDF DOWNLOAD 

Language : English
Pages : 1129
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC450LC-8 Hydraulic Excavator Shop Manual CEBM007602 – PDF DOWNLOAD 

SERIAL NUMBERS

PC450LC-8 A10001 and UP
ENGINE SAA6D125E-5

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

Komatsu PC450LC-8 Hydraulic Excavator Shop Manual CEBM007602 – PDF DOWNLOAD 

SERIAL NUMBERS

PC450LC-8 A10001 and UP
ENGINE SAA6D125E-5

CEBM007602 – PC450LC-8 sn A10001 and up 1
CONTENTS 2
REVISED PAGES 3
SAFETY 13
Safety Notice 13
Important Safety Notice 13
General Precautions 13
Preparations For Work 13
Precautions During Work 13
GENERAL 16
HOW TO READ THE SHOP MANUAL 17
Volumes 17
Distribution And Updating 17
Filing Method 17
Revised Edition Mark 17
Revisions 17
Symbols 17
HOISTING INSTRUCTIONS 18
Hoisting 18
Wire Ropes 18
PUSH PULL COUPLER 19
Type 1 19
Disconnection 19
Connection 19
Type 2 20
Disconnection 20
Connection 20
Type 3 21
Disconnection 21
Connection 21
EXPLANATION OF MAINTENANCE STANDARD TERMS 22
STANDARD TIGHTENING TORQUE 24
Bolts And Nuts 24
Tightening Torque Of Hose Nuts 25
Tightening Torque Of Split Flange Bolts 25
Tightening Torque For Flared Nuts 25
Tightening Torques For O-ring Boss Piping Joints 26
Table Of Tightening Torques For O-ring Boss Plugs 26
Torque Table For Hoses (Taper Seal Type And Face Seal Type) 26
ELECTRIC WIRE CODE 27
Classification By Thickness 27
Classification By Color And Code 27
How To Read Electric Wire Code 28
CONVERSION TABLES 31
Method Of Using The Conversion Table 31
COATING MATERIALS 37
01 GENERAL 39
SPECIFICATION DIMENSION DRAWINGS 40
Dimensions 40
Working Ranges 41
SPECIFICATIONS 42
WEIGHT TABLE 46
FUEL, COOLANT AND LUBRICANTS 48
Lubrication Chart 50
10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD 51
ENGINE AND COOLING SYSTEM 54
Engine Related Parts 54
Radiator, Oil Cooler and Aftercooler 55
POWER TRAIN 57
Power Train 57
Final Drive 58
Sprocket 60
Swing Machinery 62
Swing Circle 64
UNDERCARRIAGE AND FRAME 66
Track Frame and Recoil Spring 66
Idler 68
Carrier Roller 70
Track Roller 72
Track Shoe 74
Triple Grouser Shoe 76
HYDRAULIC SYSTEM 78
Hydraulic Piping Drawing 78
Hydraulic Tank and Filter 80
Hydraulic Pump 82
LS Valve 88
PC Valve 93
LS(PC)-EPC Valve 101
Variable Volume Valve 104
Control Valve 106
CLSS (Closed Center Load Sensing System) 118
Functions and Operation by Valve 122
Unload Valve 124
LS Bypass Valve 127
Pressure Compensation Valve 128
Pressure Compensation Valve Inner Shuttle Valve 131
Boom Regeneration Circuit 133
Arm Regeneration Circuit 135
Merge-Divider Valve 137
LS Select Valve 139
Self Pressure Reducing Valve 140
Travel Junction Valve 143
Travel PPC Shuttle Valve 145
Boom Drift Preventive Valve 147
Arm Drift Preventive Valve 150
Quick Return Valve 154
Lift Check Valve 156
Main Relief Valve 157
2-Stage Safety-Suction Valve 158
Variable Pressure Compensation Valve 160
Attachment Circuit Selector Valve 162
Holding Valve 164
Valve Control 169
PPC Valve 170
Travel PPC Valve 176
Service PPC Valve (With EPC Valve) 186
Solenoid Valve 188
PPC Accumulator 190
Return Oil Filter 191
Center Swivel Joint 192
Travel Motor 194
Brake Valve 202
Swing Motor 208
Reverse Prevention Valve 214
Hydraulic Cylinder 218
Boom Cylinder 218
Arm Cylinder 218
Bucket Cylinder 218
WORK EQUIPMENT 220
Work Equipment 220
Dimensions Of Components 222
Dimension Of Arm 222
Dimension Of Bucket 224
AIR CONDITIONER PIPING 226
ELECTRICAL SYSTEM 227
Engine Control 227
Fuel Control Dial 229
Engine Controller 230
Sensors 234
Rotation Sensor 234
Oil Pressure Switch 234
Ambient Pressure Sensor 235
Boost Pressure Sensor 235
Boost Temperature Sensor 236
Coolant Temperature Sensor 236
Hydraulic Oil Temperature Sensor 236
EGR Valve Stroke Sensor 237
Engine Oil Level Sensor 238
ELECTRONIC CONTROL SYSTEM 239
Engine And Pump Composite Control Function 242
Pump and Valve Control 248
2-Stage Relief Function 249
Power Maximizing and Machine Push-up 250
Auto-Deceleration 252
Auto-Warm-Up and Overheat Prevention 254
Swing Control 256
Travel Control 258
Attachment Flow Control and Circuit Selector 260
System Component Parts 261
PPC Oil Pressure Switch 261
Oil Pressure Sensor 262
Pump Pressure Sensor (High Pressure) 263
Pump Controller 264
MONITOR SYSTEM 267
Machine Monitor 268
Monitor Control, Display Portion 272
Monitor Items And Display 274
Switches 278
Komtrax Logic 289
Sensors 296
KOMTRAX TERMINAL SYSTEM 299
Komtrax Communication Modem – TH300 300
20 STANDARD VALUE TABLES 303
STANDARD VALUE TABLES 304
Engine Related 304
Chassis Related 305
30 TESTING AND ADJUSTING 313
SERVICE TOOLS 315
Sketches of Special Tools 320
ENGINE 321
Engine Speed 321
Air Boost Pressure 323
Exhaust Temperature 324
Exhaust Gas Color 325
Valve Clearance 327
Compression Pressure 329
Blow-By Pressure 332
Engine Oil Pressure 333
EGR Valve Drive Pressure 334
Handling Fuel System Parts 335
Releasing Residual Pressure From Fuel System 335
Fuel Pressure 336
Cylinder Cut-Out Operation 337
No Injection Cranking Operation 337
Fuel Return Rate and Leakage 338
Bleeding Air from Fuel Circuit 341
Fuel Circuit, Checking for Leakage 343
FAN BELT AND ALTERNATOR BELT TENSION 344
AIR CONDITIONER COMPRESSOR BELT TENSION 345
SWING CIRCLE BEARING CLEARANCE 346
TRACK SHOE TENSION 347
OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 348
CONTROL CIRCUIT – BASIC PRESSURE 354
PUMP PC CONTROL CIRCUIT 355
PUMP LS CONTROL CIRCUIT 359
SOLENOID VALVE – OUTPUT PRESSURE 364
PPC VALVE – OUTPUT PRESSURE 367
WORK EQUIPMENT PPC VALVE AND SWING PPC VALVE – PLAY ADJUSTMENT 369
WORK EQUIPMENT – HYDRAULIC DRIFT – CAUSE 370
HYDRAULIC CIRCUIT – RELEASING REMAINING PRESSURE 372
Oil Leakage Measurement 373
BLEEDING AIR FROM VARIOUS PARTS 376
MACHINE MONITOR – SPECIAL FUNCTIONS 379
Ordinary Functions and Special Functions of Machine Monitor 381
Operator Mode (Outline) 383
Display of Komatsu Logo 384
Display of Inputting Password 384
Display of Check of Breaker Mode 385
Display of Check Before Starting 385
Display of Warning after Check Before Starting 385
Display of Ending of Maintenance Interval 386
Display of Check of Working Mode and Travel Speed 386
Display of Ordinary Screen 386
Display of End Screen 387
Selection of Auto-Deceleration 387
Selection of Working Mode 387
Selection of Travel Speed 388
Operation to stop Alarm Buzzer 388
Operation of Windshield Wiper 389
Operation of Window Washer 389
Operation of Air Conditioner/Heater 389
Operation to Display Camera Mode (If camera is installed) 390
Operation to Display Clock and Service Meter 391
Check of Maintenance Information 391
Setting and Display of User Mode 391
KOMTRAX Message 392
Display of Energy-Saving Guidance 392
Display of Caution Monitor 392
Display of Automatic Judgment of Breaker 393
Display of User Code and Failure Code 393
Function of Checking Display of LCD (Liquid Crystal Display) 395
Function of Checking Service Meter 395
Function of Changing Attachment/Maintenance Password 396
Service Mode 399
Monitoring 401
Abnormality Record (Mechanical Systems) 405
Abnormality Record (Electrical Systems) 406
Abnormality Record (Air-Conditioning System/Heater System) 412
Maintenance Record 413
Maintenance Mode Change 414
Phone Number Entry 417
Default (Key-On Mode) 418
Default (Unit) 419
Default (With/Without Attachment) 420
Default (Attachment/Maintenance Password) 421
Default (Camera) 422
Default (ECO Display) 423
Default (Breaker Detect) 425
Adjustment (Pump Absorption Torque (F)) 426
Adjustment (Low Speed) 427
Adjustment (Attachment Flow Adjustment) 428
Determining a Defective Cylinder 429
Cylinder Cut-Out 430
No Injection 431
Fuel Consumption 433
KOMTRAX Settings (Terminal Status) 434
Long Distance Transport Mode 435
KOMTRAX Settings (GPS & Communication Status) 437
KOMTRAX Setting (Modem S/N: TH300) 438
Display of KOMTRAX Message 439
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER 440
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 441
DIODE INSPECTION PROCEDURES 446
PM CLINIC SERVICE 447
40 TROUBLESHOOTING 457
FAILURE CODES TABLE 461
FUSE LOCATIONS 464
Connection Table of Fuse Box 464
Location of Fuse Box and Fuse Numbers 465
GENERAL INFORMATION 468
Points to Remember when Troubleshooting 468
Sequence of Events in Troubleshooting 470
Handling Electric Equipment and Hydraulic Components 471
Connectors newly used for Tier 3 Engines 479
Checks before Troubleshooting 483
Classification and Troubleshooting Steps 484
Classification of Troubleshooting 484
Information in Troubleshooting Table 486
Possible Problems and Troubleshooting No 488
Connection Table for Connector Pin Numbers 491
T-adapter Box and T-adapter Table 526
FAILURE CODE (DISPLAY OF CODE) 529
989L00 – Engine Controller Lock Caution 1 529
989M00 – Engine Controller Lock Caution 2 529
989N00 – Engine Controller Lock Caution 3 530
AA10NX – Air Cleaner Clogging 532
AB00KE – Charge Voltage Low 534
B@BAZG – Engine Oil Pressure Low 536
B@BAZK – Engine Oil Level Low 538
B@BCNS – Engine Coolant Overheat 540
B@BCZK – Engine Coolant Level Low 542
B@HANS – Hydraulic Oil Overheat 544
CA111 – EMC Critical Internal Failure 546
CA115 – Engine Ne And Bkup Speed Sensor Error 548
CA122 – Charge Air Pressure Sensor High Error 550
CA123 – Charge Air Pressure Sensor Low Error 552
CA131 – Throttle Sensor High Error 554
CA132 – Throttle Sensor Low Error 556
CA135 – Engine Oil Pressure Sensor High Error 558
CA141 – Engine Oil Pressure Sensor Low Error 560
CA144 – Coolant Temperature Sensor High Error 562
CA145 – Coolant Temperature Sensor Low Error 564
CA153 – Charge Air Temperature Sensor High Error 566
CA154 – Charge Air Temperature Sensor Low Error 568
CA187 – Sensor Power Supply 2 Volt Low Error 570
CA221 – Ambient Pressure Sensor High Error 572
CA222 – Ambient Pressure Sensor Low Error 574
CA227 – Sensor Supply 2 Volt High Error 576
CA234 – Engine Overspeed 578
CA238 – NE Speed Sensor Supply Voltage Error 579
CA263 – Fuel Temperature Sensor High Error 580
CA265 – Fuel Temperature Sensor Low Error 582
CA271 – IMV/PCV1 Short Error 583
CA272 – IMV/PCV1 Open Error 584
CA273 – PCV2 Short Error 585
CA274 – PCV2 Open Error 586
CA322 – Injector #1 Open/short Error 588
CA323 – Injector #5 Open/short Error 590
CA324 – Injector #3 Open/short Error 592
CA325 – Injector #6 Open/short Error 594
CA331 – Injector #2 Open/short Error 596
CA332 – Injector #4 Open/short Error 598
CA342 – Calibration Code Incompatibility 600
CA351 – Injectors Drive Circuit Error 602
CA352 – Sensor Supply 1 Volt Low Error 604
CA386 – Sensor Supply 1 Volt High Error 606
CA441 – Battery Voltage Low Error 608
CA442 – Battery Voltage High Error 610
CA449 – Rail Pressure Very High Error 612
CA451 – Rail Pressure Sensor High Error 616
CA452 – Rail Pressure Sensor Low Error 618
CA553 – Rail Pressure High Error 620
CA554 – Rail Pressure Sensor In Range Error 621
CA559 – Rail Pressure Low Error 622
CA689 – Engine Ne Speed Sensor Error 626
CA731 – Engine Bkup Speed Sensor Phase Error 628
CA757 – All Persistent Data Lost Error 630
CA778 – Engine Bkup Speed Sensor Error 632
CA1228 – EGR Valve Servo Error 1 634
CA1625 – EGR Valve Servo Error 2 635
CA1633 – KOMNET Datalink Timeout Error 636
CA2185 – Throttle Sensor Supply Volt High Error 638
CA2186 – Throttle Sensor Supply Volt Low Error 640
CA2249 – Rail Pressure Very Low Error 641
CA2272 – EGR Valve Lift Sensor Low Error 644
CA2351 – EGR Valve Solenoid Operation Short Circuit 646
CA2555 – Grid Htr Relay Volt High Error 650
CA2556 – Grid Htr Relay Volt Low Error 652
D110KB – Battery Relay Drive Short Circuit 654
D19JKZ – Personal Code Relay Abnormality 656
D862KA – GPS Antenna Discon 658
DA22KK – Pump Solenoid Power Low Error 660
DA25KP – 5 V Sensor Power Supply Output 1 Abnormality 662
DA29KQ – Model Selection Abnormality 666
DA2RMC – CAN Discon (Pump Con Detected) 668
DAF8KB – Short circuit in camera power supply 670
DAFGMC – GPS Module Error 672
DAFRMC – CAN Discon (Monitor Detected) 674
DGH2KB – Hyd Oil Sensor Short 676
DHPAMA – F Pump Pressure Sensor Abnormality 678
DHPBMA – R Pump Pressure Sensor Abnormality 681
DHS3MA – Arm Curl In PPC Sensor Abnormality 684
DHS4MA – Bucket Curl PPC Pressure Sensor Abnormality 686
DHX1MA – Overload Sensor Abnormality (Analog) 688
DW43KA – Travel Speed Solenoid Disconnection 690
DW43KB – Travel Speed Solenoid Short Circuit 692
DW45KA – Swing Brake Solenoid Disconnection 694
DW45KB – Swing Brake Solenoid Short Circuit 698
DW91KA – Travel Junction Solenoid Disconnection 700
DW91KB – Travel Junction Solenoid Short Circuit 702
DWA2KA – Attachment Sol Open Circuit 704
DWA2KB – Attachment Sol Short Circuit 706
DWJ0KA – Merge-divider Solenoid Disconnection 708
DWJ0KB – Merge-divider Solenoid Short Circuit 710
DWK0KA – 2-stage Relief Solenoid Disconnection 712
DWK0KB – 2-stage Relief Solenoid Short Circuit 714
DXA0KA – PC-EPC Solenoid Disconnection 716
DXA0KB – PC-EPC Solenoid Short Circuit 718
DXE0KA – LS-EPC Solenoid Disconnection 720
DXE0KB – LS-EPC Solenoid Short Circuit 722
DXE4KA – Service Current EPC Disconnection 724
DXE4KB – Service Current EPC Short Circuit 725
DY20KA – Wiper Working Abnormality 726
DY20MA – Wiper Parking Abnormality 728
DY2CKA – Washer Drive Open Circuit 730
DY2CKB – Washer Drive Short Circuit 732
DY2DKB – Wiper Drive (Fwd) Short Circuit 734
DY2EKB – Wiper Drive (Rev) Short Circuit 736
E-MODE (ELECTRICAL SYSTEM) 738
Before Carrying Out Troubleshooting Of Electrical System 738
Information Contained In Troubleshooting Table 740
E-1 Engine Does Not Start 742
E-2 Auto-decelerator Does Not Operate 746
E-3 Automatic Warming-up System Does Not Operate 748
E-4 Preheater Does Not Operate 750
E-5 All Work Equipment, Swing, And Travel Mechanism Do Not Move 752
E-6 Power Maximizing Function Does Not Operate 754
E-7 Machine Monitor Does Not Display At All 756
E-8 Machine Monitor Does Not Display Some Items 758
E-9 Contents Of Display By Machine Monitor Are Different From Applicable Machine 758
E-10 Fuel Level Monitor Was Lighted In Red While Engine Running 759
E-11 Engine Coolant Temperature Gauge Does Not Indicate Normally 760
E-12 Hydraulic Oil Temperature Gauge Does Not Indicate Normally 762
E-13 Fuel Level Gauge Does Not Indicate Normally 763
E-14 Swing Lock Monitor Does Not Indicate Normally 764
E-15 When Monitor Switch Is Operated, Monitor Displays Nothing 766
E-16 Windshield Wiper And Window Washer Do Not Operate 768
E-17 Machine Push-up Function Does Not Operate Normally 772
E-18 Monitoring Function Fails To Display “Boom Raise” Normally 774
E-19 Monitoring Function Fails To Display “Boom Lower” Normally 776
E-20 Monitoring Function Fails To Display “Arm In” Normally 778
E-21 Monitoring Function Fails To Display “Arm OUT” Normally 780
E-22 Monitoring Function Fails To Display “Bucket CURL” Normally 782
E-23 Monitoring Function Fails To Display “Bucket DUMP” Normally 784
E-24 Monitoring Function Fails To Display “Swing” Normally 786
E-25 Monitoring Function Fails To Display “Travel” Normally 788
E-26 Monitoring Function Fails To Display “Travel Differential Pressure” Normally 790
E-27 Monitoring Function Fails To Display “Service” Normally 792
E-28 KOMTRAX System Does Not Operate Normally 794
E-29 Air Conditioner Does Not Operate 796
E-30 Travel Alarm Does Not Sound Or Does Not Stop Sounding 798
E-31 Horn Does Not Sound 800
H-MODE (HYDRAULIC AND MECHANICAL SYSTEMS) 802
System Chart For Hydraulic And Mechanical System 802
Information Contained In Troubleshooting Table 804
H-1 All Work Equipment Lack Power, Or Travel And Swing Speeds Are Slow 806
H-2 Engine Speed Sharply Drops Or Engine Stalls 808
H-3 No Work Equipment, Swing Or Travel Move 809
H-4 Abnormal Noise Is Heard From Around Hydraulic Pump 809
H-5 Auto-decelerator Does Not Work 810
H-6 Fine Control Mode Does Not Function Or Responds Slow 810
H-7 Boom Moves Slowly Or Lacks Power 811
H-8 Arm Moves Slowly Or Lacks Power 812
H-9 Bucket Moves Slowly Or Lacks Power 813
H-10 Work Equipment Does Not Move In Individual Operation 813
H-11 Work Equipment Has A Bit Too Fast Hydraulic Drift 814
H-12 Work Equipment Has Long Time Lag 816
H-13 Other Work Equipment Moves When Relieving Single Circuit 816
H-14 Power Max Switch Does Not Operate 817
H-15 Machine Push-up Function Does Not Operate 817
H-16 In Compound Operation Of Work Equipment, Speed Of Part Loaded More Is Low 818
H-17 In Swing + Boom Raise Operation, Boom Moves Slowly 818
H-18 In Swing + Travel Operation, Travel Speed Drops Sharply 818
H-19 Machine Swerves In Travel 819
H-20 Machine Travels Slowly 820
H-21 Machine Cannot Be Easily Steered Or Lacks Power 821
H-22 Travel Speed Does Not Shift, Or It Is Too Slow Or Fast 822
H-23 Travel System Does Not Turn (On One Side Only) 823
H-24 Machine Does Not Swing 824
H-25 Swing Acceleration Is Poor, Or Swing Speed Is Slow 826
H-26 Excessive Overrun When Stopping Swing 828
H-27 There Is Big Shock When Stopping Swing 829
H-28 Large Sound Is Made When Upper Structure Stops Swinging 829
H-29 Swing Hydraulic Drift Is Too Big 830
H-30 Attachment Circuit Is Not Changed 831
H-31 Oil Flow In Attachment Circuit Cannot Be Controlled 832
50 DISASSEMBLY AND ASSEMBLY 833
HOW TO READ THIS MANUAL 837
SPECIAL TOOLS LIST 840
SKETCHES OF SPECIAL TOOLS 844
CONNECTOR REPAIR PROCEDURES 849
Contact Terminal Removal (HD30 Type) 849
Striping Insulation 850
Crimping Contact Terminal (HD30 Type) 851
Insertion Of Contact Terminal (HD30 Type) 852
Contact Terminal Removal (DT Type) 853
Striping Insulation 854
Crimping Contact Terminal (DT Type) 855
Insertion Of Contact Terminal (DT Type) 856
ENGINE COMPONENTS 857
Fuel Supply Pump 857
Removal 857
Installation 861
Fuel Injector 863
Removal 863
Installation 867
Engine Front Seal 871
Removal 871
Installation 873
Engine Rear Seal 874
Removal 874
Installation 876
Cylinder Head 879
Removal 879
Installation 888
Oil Pan Gasket 892
RADIATOR 893
Removal 893
Installation 894
HYDRAULIC OIL COOLER 895
Removal 895
Installation 896
AFTERCOOLER 897
Removal 897
Installation 898
ENGINE AND HYDRAULIC OIL PUMP 899
Removal 899
Installation 908
DRIVE ASSEMBLY 909
Removal 909
Installation 909
Disassembly 910
Assembly 915
SWING MOTOR AND SWING MACHINERY 921
Removal 921
Installation 922
Disassembly 923
Assembly 927
SWING CIRCLE 933
Removal 933
Installation 933
CARRIER ROLLER 934
Assembly 934
TRACK ROLLER 936
Assembly 936
IDLER 937
Disassembly 937
ASSEMBLY 938
RECOIL SPRING 941
Disassembly 941
Assembly 942
SPROCKET 944
Removal 944
Installation 944
TRACK SHOE 945
Expansion of Track Shoe 945
Installation of Track Shoe 946
REVOLVING FRAME 947
Removal 947
Installation 948
COUNTERWEIGHT 950
Removal 950
Installation 951
COUNTERWEIGHT REMOVER 952
Removing 953
Installing 959
CENTER SWIVEL JOINT 961
Removal 961
Installation 962
Disassembly 963
Assembly 964
HYDRAULIC TANK 965
Removal 965
Installation 966
CONTROL VALVE 967
Removal 967
Installation 970
Disassembly 971
Assembly 973
HYDRAULIC PUMP 976
Removal 976
Installation 978
HYDRAULIC PUMP INPUT SHAFT OIL SEAL 979
Removal 979
Installation 979
WORK EQUIPMENT PPC VALVE 980
Disassembly 980
Assembly 980
TRAVEL PPC VALVE 982
Disassembly 982
Assembly 983
HYDRAULIC CYLINDER 985
Disassembly 985
Assembly 988
WORK EQUIPMENT 991
Removal 991
Installation 993
CAB 994
Removal 994
Installation 997
Cab Glass (Stuck Glass) 998
Removal 999
Installation 1000
Front Window 1009
Removal 1009
Installation 1011
Floor Frame 1017
Removal 1017
Installation 1021
ELECTRICAL SYSTEMS 1022
Air Conditioner Unit 1022
Removal 1022
Installation 1026
KOMTRAX Communication Modem 1027
Removal 1027
Installation 1027
Monitor 1028
Removal 1028
Installation 1029
Pump Controller 1030
Removal 1030
Installation 1030
Engine Controller 1033
Removal 1033
Installation 1034
60 AIR CONDITIONER 1035
STRUCTURE AND FUNCTION 1038
Air Conditioner Component 1038
Configuration and Function of Refrigerating cycle 1040
Outline of Refrigerating Cycle 1041
Air Conditioner Unit 1044
Functions of Major Components in the Air Conditioner Unit 1046
Control Plate 1048
Compressor 1051
Condenser and Receiver Drier 1052
TESTING AND ADJUSTING 1053
Caution About Refrigerant 1053
Troubleshooting Procedure 1054
Block Diagram 1055
Circuit Diagram and Arrangement of Connector Pins 1056
Detail of Air Conditioner Unit 1058
Part and Connector Locations 1060
Testing Air Leakage (Ducts) 1064
Testing with Self-diagnosis Function 1066
Testing Temperature Control 1069
Testing Vent (Mode) Changeover 1072
Testing Recirc/Fresh Changeover 1076
Testing Inner Sensor 1078
Testing Evaporator Temperature Sensor 1079
Testing Sunlight Sensor 1081
Testing (Dual) Pressure Switch for Refrigerant 1082
Testing Relays 1084
TROUBLESHOOTING 1086
Troubleshooting Chart 1 1086
Troubleshooting Chart 2 1087
Troubleshooting for Electrical System (E mode) 1090
E-1 Power Supply System (Air Conditioner does not Operate) 1091
E-2 Compressor System (Air is Not Cooled) 1095
E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 1098
E-4 Temperature Cannot be Controlled 1102
E-5 Vent (Mode) Cannot be Changed Over 1105
E-6 Recirc/Fresh Air Cannot be Changed Over 1108
Troubleshooting With Gauge Pressure 1111
Connection of Service Tool 1114
Precautions for connecting air conditioner piping 1116
Handling of Compressor Oil 1117
Control of Compressor Oil 1117
Adding of Compressor Oil 1117
Compressor Replacement 1118
Applying Compressor Oil for O-ring 1118
Desiccant Replacement Procedure 1119
90 OTHERS 1121
Hydraulic circuit diagram 1123
Electrical circuit diagram (1/5) 1124
Electrical circuit diagram (2/5) 1125
Electrical circuit diagram (3/5) 1126
Electrical circuit diagram (4/5) 1127
Electrical circuit diagram (5/5) 1128
Connector list and stereogram 1129

S.V 15/12/24