Komatsu PC500LC-10M0 Hydraulic Excavator Shop Manual SEN06637-03 – PDF DOWNLOAD 

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Komatsu PC500LC-10M0 Hydraulic Excavator Shop Manual SEN06637-03 – PDF DOWNLOAD

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Komatsu PC500LC-10M0 Hydraulic Excavator Shop Manual SEN06637-03 – PDF DOWNLOAD 

Language : English
Pages : 2552
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu PC500LC-10M0 Hydraulic Excavator Shop Manual SEN06637-03 – PDF DOWNLOAD 

SERIAL NUMBERS 95001 and up

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 17
FOREWORD, SAFETY, BASIC INFORMATION 23
HOW TO READ THE SHOP MANUAL 23
SAFETY NOTICE FOR OPERATION 25
PRECAUTIONS TO PREVENT FIRE 33
ACTIONS IF FIRE OCCURS 35
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 36
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 37
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 40
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 46
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 48
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 49
PRACTICAL USE OF KOMTRAX 50
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 51
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 51
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 52
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 53
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 55
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 59
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 60
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 62
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 63
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 65
HOW TO READ ELECTRICAL WIRE CODE 66
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 70
STANDARD TIGHTENING TORQUE TABLE 73
CONVERSION TABLE 80
01 SPECIFICATIONS 85
CONTENTS 86
ABBREVIATION LIST 87
SPECIFICATIONS 93
SPECIFICATION DRAWING 93
SPECIFICATION DRAWING: PC500LC-10M0 93
SPECIFICATION DRAWING: PC500LC-10M0 (SE SPECIFICATION) 94
WORKING RANGE DRAWINGS 95
WORKING RANGE: PC500LC-10M0 95
WORKING RANGE: PC500LC-10M0 (SE SPECIFICATION) 96
SPECIFICATIONS 97
SPECIFICATIONS: PC500LC-10M0 97
SPECIFICATIONS: PC500LC-10M0 (SE SPECIFICATION) 100
WEIGHT TABLE 103
WEIGHT TABLE: PC500LC-10M0 103
WEIGHT TABLE: PC500LC-10M0 (SE SPECIFICATION) 105
TABLE OF FUEL, COOLANT, AND LUBRICANTS 107
10 STRUCTURE AND FUNCTION 109
CONTENTS 110
ABBREVIATION LIST 113
BOOT-UP SYSTEM 119
LAYOUT DRAWING OF BOOT-UP SYSTEM 119
SYSTEM OPERATING LAMP SYSTEM 121
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 121
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 121
BATTERY DISCONNECT SWITCH 122
FUNCTION OF BATTERY DISCONNECT SWITCH 122
ENGINE SYSTEM 123
LAYOUT DRAWING OF ENGINE SYSTEM 123
SPECIFICATIONS OF ENGINE SYSTEM 124
FUNCTION OF ENGINE SYSTEM 124
ENGINE CONTROL SYSTEM 125
ENGINE CONTROL SYSTEM DIAGRAM 125
FUNCTION OF ENGINE CONTROL SYSTEM 126
AUTO-DECELERATION SYSTEM 128
AUTO-DECELERATION SYSTEM DIAGRAM 128
FUNCTION OF AUTO-DECELERATION SYSTEM 128
OPERATION OF AUTO-DECELERATION SYSTEM 129
ENGINE AUTOMATIC WARM-UP SYSTEM 130
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 130
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 131
OVERHEAT PREVENTION SYSTEM 132
OVERHEAT PREVENTION SYSTEM DIAGRAM 132
FUNCTION OF OVERHEAT PREVENTION SYSTEM 133
TURBOCHARGER PROTECTION SYSTEM 134
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 134
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 135
AUTOMATIC IDLE STOP SYSTEM 136
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 136
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 136
COMPONENT PARTS OF ENGINE SYSTEM 139
TURBOCHARGER 139
EGR SYSTEM 140
EGR VALVE 142
EGR COOLER 143
VENTURI SYSTEM 144
BLOWBY PRESSURE SENSOR 145
COOLING SYSTEM 146
LAYOUT DRAWING OF COOLING SYSTEM 146
SPECIFICATIONS OF COOLING SYSTEM 147
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 148
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 148
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 149
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 150
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 150
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 150
COMPONENT PARTS OF COOLING SYSTEM 152
FAN CLUTCH 152
CONTROL SYSTEM 153
LAYOUT DRAWING OF CONTROL SYSTEM 153
MACHINE MONITOR SYSTEM 156
MACHINE MONITOR SYSTEM DIAGRAM 156
FUNCTION OF MACHINE MONITOR SYSTEM 156
KOMTRAX SYSTEM 158
KOMTRAX SYSTEM DIAGRAM 158
FUNCTION OF KOMTRAX SYSTEM 158
COMPONENT PARTS OF CONTROL SYSTEM 159
MACHINE MONITOR 159
REARVIEW CAMERA 170
KOMTRAX TERMINAL 171
PUMP CONTROLLER 174
RESISTOR FOR PC-EPC VALVE 178
CAN TERMINATING RESISTOR 178
ENGINE CONTROLLER 179
FUEL CONTROL DIAL 183
FUEL FEED PUMP 185
HYDRAULIC SYSTEM 186
LAYOUT DRAWING OF HYDRAULIC SYSTEM 186
CLSS 190
STRUCTURE OF CLSS 190
OPERATION OF UNLOAD VALVE AND LS PRESSURE 192
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 193
PRESSURE COMPENSATION CONTROL 206
ENGINE AND PUMP COMBINED CONTROL SYSTEM 209
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 209
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 210
PUMP AND VALVE CONTROL SYSTEM 215
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 215
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 216
COMPONENT PARTS OF HYDRAULIC SYSTEM 218
HYDRAULIC TANK 218
MAIN PUMP 221
CONTROL VALVE 247
WORK EQUIPMENT SYSTEM 304
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 304
ONE-TOUCH POWER MAXIMIZING SYSTEM 308
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 308
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 309
MACHINE PUSH-UP SYSTEM 310
MACHINE PUSH-UP SYSTEM DIAGRAM 310
FUNCTION OF MACHINE PUSH-UP SYSTEM 311
PPC LOCK SYSTEM 312
PPC LOCK SYSTEM DIAGRAM 312
FUNCTION OF PPC LOCK SYSTEM 312
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 313
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 313
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 313
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 314
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 315
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT 315
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 316
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 317
WORK EQUIPMENT AND SWING PPC VALVE 317
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 321
SOLENOID VALVE 328
ATTACHMENT CIRCUIT SELECTOR VALVE 330
PILOT CIRCUIT ACCUMULATOR 332
HYDRAULIC OIL ADDITIONAL FILTER WITH CLOGGING SWITCH 333
HYDRAULIC OIL ADDITIONAL FILTER CLOGGING SWITCH 333
SWING SYSTEM 335
LAYOUT DRAWING OF SWING SYSTEM 335
SWING CONTROL SYSTEM DIAGRAM 339
FUNCTION OF SWING CONTROL SYSTEM 339
COMPONENT PARTS OF SWING SYSTEM 343
SWING MOTOR 343
SWING MACHINERY 356
SWING CIRCLE 357
TRAVEL SYSTEM 361
LAYOUT DRAWING OF TRAVEL SYSTEM 361
TRAVEL CONTROL SYSTEM DIAGRAM 365
FUNCTION OF TRAVEL CONTROL SYSTEM 365
COMPONENT PARTS OF TRAVEL SYSTEM 367
TRAVEL MOTOR 367
FINAL DRIVE 380
TRAVEL PPC VALVE 381
CENTER SWIVEL JOINT 386
UNDERCARRIAGE AND FRAME 388
LAYOUT DRAWING OF UNDERCARRIAGE 388
SPECIFICATIONS OF UNDERCARRIAGE 388
WORK EQUIPMENT 389
STRUCTURE OF WORK EQUIPMENT 389
FUNCTION OF WORK EQUIPMENT 390
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 391
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 391
BUCKET CLEARANCE ADJUSTMENT SHIM 392
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 392
CAB AND ITS ATTACHMENTS 393
ROPS CAB 393
STRUCTURE OF ROPS CAB 393
FUNCTION OF ROPS CAB 393
CAB MOUNT 394
STRUCTURE OF CAB MOUNT 394
FUNCTION OF CAB MOUNT 394
CAB TIPPING STOPPER 395
STRUCTURE OF CAB TIPPING STOPPER 395
FUNCTION OF CAB TIPPING STOPPER 395
20 STANDARD VALUE TABLE 397
CONTENTS 398
ABBREVIATION LIST 399
STANDARD VALUE TABLE FOR ENGINE 405
STANDARD VALUE TABLE FOR ENGINE: PC500LC-10M0 405
STANDARD VALUE TABLE FOR MACHINE 409
STANDARD VALUE TABLE FOR MACHINE: PC500LC-10M0 409
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 423
30 TESTING AND ADJUSTING 427
CONTENTS 428
ABBREVIATION LIST 431
RELATED INFORMATION ON TESTING AND ADJUSTING 437
TOOLS FOR TESTING AND ADJUSTING 437
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 442
ENGINE AND COOLING SYSTEM 444
TEST ENGINE SPEED 444
METHOD FOR TESTING ENGINE SPEED 444
TEST BOOST PRESSURE 447
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 447
METHOD FOR TESTING BOOST PRESSURE 448
TEST EXHAUST GAS TEMPERATURE 450
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 450
TEST EXHAUST GAS COLOR 452
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 452
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 453
TEST AND ADJUST VALVE CLEARANCE 454
METHOD FOR TESTING VALVE CLEARANCE 454
METHOD FOR ADJUSTING VALVE CLEARANCE 456
TEST COMPRESSION PRESSURE 457
METHOD FOR TESTING COMPRESSION PRESSURE 457
TEST BLOWBY PRESSURE 460
METHOD FOR TESTING BLOWBY PRESSURE ON MACHINE MONITOR 460
METHOD FOR TESTING BLOWBY PRESSURE BY TESTING TOOL 461
TEST ENGINE OIL PRESSURE 463
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 463
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 463
TEST EGR VALVE DRIVING OIL PRESSURE 465
METHOD FOR TESTING OF EGR VALVE DRIVING OIL PRESSURE 465
TEST FUEL PRESSURE 467
METHOD FOR TESTING FUEL PRESSURE 467
TEST FUEL RETURN RATE AND LEAKAGE 469
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 469
BLEED AIR FROM FUEL SYSTEM 472
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 472
TEST FUEL CIRCUIT FOR LEAKAGE 475
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 475
HANDLE CYLINDER CUT-OUT MODE OPERATION 477
HANDLE NO-INJECTION CRANKING OPERATION 478
TEST FAN BELT 479
METHOD FOR TESTING OF FAN BELT 479
TEST ALTERNATOR BELT 480
METHOD FOR TESTING ALTERNATOR BELT 480
TEST AUTOMATIC TENSIONER 482
METHOD FOR TESTING AUTOMATIC TENSIONER 482
TEST COOLING FAN SPEED 484
METHOD FOR TESTING COOLING FAN SPEED 484
POWER TRAIN 485
TEST SWING CIRCLE BEARING CLEARANCE 485
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 485
UNDERCARRIAGE AND FRAME 486
TEST AND ADJUST TRACK TENSION 486
METHOD FOR TESTING TRACK TENSION 486
METHOD FOR ADJUSTING TRACK TENSION 486
HYDRAULIC SYSTEM 488
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 488
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 488
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 488
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 490
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 490
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 491
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 492
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 499
TEST OIL PRESSURE OF CONTROL CIRCUIT 502
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 502
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 504
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 504
TEST PC-EPC VALVE OUTLET PRESSURE 505
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 506
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 508
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 508
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE 510
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 511
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 512
METHOD FOR ADJUSTING LS VALVE 513
TEST OUTLET PRESSURE OF SOLENOID VALVE 514
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 514
OPERATING CONDITION OF SOLENOID VALVE 515
TEST PPC VALVE OUTLET PRESSURE 518
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 518
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 521
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 521
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 522
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 522
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 522
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 523
TEST OIL LEAKAGE 524
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 524
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 524
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 525
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 525
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 526
BLEED AIR FROM HYDRAULIC CIRCUIT 527
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 529
TEST AND CHARGE ACCUMULATOR (MANUFACTURED BY HYDAC) NITROGEN GAS PRESSURE FOR ATTACHMENT (LOW PRESSURE SIDE) 532
TEST ACCUMULATOR (MANUFACTURED BY HYDAC) NITROGEN GAS PRESSURE FOR ATTACHMENT (LOW PRESSURE SIDE) 532
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH PRESSURE SIDE) 536
TEST ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH PRESSURE SIDE) 536
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ACCUMULATOR PIPING 540
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ACCUMULATOR PIPING 540
CAB AND ITS ATTACHMENTS 547
TEST CAB TIPPING STOPPER 547
METHOD FOR TESTING CAB TIPPING STOPPER 547
METHOD FOR ADJUSTING MIRRORS 548
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 548
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 549
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 550
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 551
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 553
PROCEDURE FOR ADJUSTING MACHINE REAR COUNTERWEIGHT MIRROR (D) 554
ELECTRICAL SYSTEM 555
SET AND OPERATE MACHINE MONITOR 555
OPERATOR MODE 558
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 559
CHECKING FUNCTION OF SERVICE METER 559
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 559
SERVICE MODE 562
METHOD FOR OPERATING SERVICE MODE 562
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 564
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 567
ABNORMALITY RECORD MENU 575
METHOD FOR CONFIRMING MAINTENANCE RECORD 579
METHOD FOR OPERATING MAINTENANCE MODE SETTING 581
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 585
DEFAULT MENU 586
DIAGNOSTIC TESTS MENU 594
ADJUSTMENT MENU 596
METHOD FOR PERFORMING NO-INJECTION CRANKING 609
KOMTRAX SETTINGS MENU 610
METHOD FOR DISPLAYING SERVICE MESSAGE 613
METHOD FOR STARTING UP KOMTRAX TERMINAL 615
ADJUST REARVIEW CAMERA ANGLE 620
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 620
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 623
HANDLE BATTERY DISCONNECT SWITCH 624
TEST DIODES 625
METHOD FOR TESTING DIODE USING DIGITAL TESTER 625
METHOD FOR TESTING DIODE USING ANALOG TESTER 625
Pm CLINIC 626
Pm CLINIC SERVICE 626
Pm CLINIC CHECK SHEET: PC500LC-10M0 627
40 TROUBLESHOOTING 641
CONTENTS 642
ABBREVIATION LIST 649
RELATED INFORMATION ON TROUBLESHOOTING 655
GENERAL TROUBLESHOOTING POINTS 655
SEQUENCE OF EVENTS IN TROUBLESHOOTING 656
CHECKS BEFORE TROUBLESHOOTING 658
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 660
WALK-AROUND CHECK 660
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 662
CHECK FUEL LEVEL AND TYPE 662
CHECK IMPURE INGREDIENT IN FUEL 663
CHECK FUEL PREFILTER 663
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 664
FUEL PREFILTER CARTRIDGE – REPLACE 665
CHECK MAIN FILTER 668
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 669
CHECK COOLANT LEVEL (RESERVOIR TANK) 670
CHECK CLOGGING OF AIR CLEANER 671
OUTER ELEMENT – CLEAN 672
ELEMENTS – REPLACE 674
CHECK HYDRAULIC OIL LEVEL 676
CHECK HYDRAULIC OIL STRAINER 677
CHECK HYDRAULIC FILTER 677
CHECK OIL LEVEL IN SWING MACHINERY CASE 679
CHECK OIL LEVEL IN DAMPER CASE 679
CHECK OIL LEVEL IN FINAL DRIVE CASE 680
BLEED AIR FROM FUEL SYSTEM 680
BLEED AIR FROM HYDRAULIC SYSTEM 680
ELECTRICAL EQUIPMENT – CHECK METHOD 680
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 686
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 686
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 686
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 686
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL 686
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK 687
PROCEDURE FOR TESTING AND TROUBLESHOOTING 691
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 694
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 698
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 700
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE 703
CONNECTOR LAYOUT 756
CONNECTOR CONTACT IDENTIFICATION 762
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 802
FUSE LOCATION TABLE 808
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 810
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 814
FAILURE CODES TABLE 816
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 825
FAILURE CODE [602KNX] 825
FAILURE CODE [879AKA] 828
FAILURE CODE [879AKB] 830
FAILURE CODE [879BKA] 832
FAILURE CODE [879BKB] 836
FAILURE CODE [879CKA] 839
FAILURE CODE [879CKB] 841
FAILURE CODE [879DKZ] 843
FAILURE CODE [879EMC] 846
FAILURE CODE [879FMC] 848
FAILURE CODE [879GKX] 850
FAILURE CODE [989L00] 853
FAILURE CODE [989M00] 855
FAILURE CODE [989N00] 857
FAILURE CODE [A900FR] 858
FAILURE CODE [A900N6] 859
FAILURE CODE [A900NY] 860
FAILURE CODE [AA10NX] 861
FAILURE CODE [AB00KE] 863
FAILURE CODE [B@BAZG] 866
FAILURE CODE [B@BAZK] 870
FAILURE CODE [B@BCNS] 872
FAILURE CODE [B@BCQA] 876
FAILURE CODE [B@BCZK] 878
FAILURE CODE [CA111] 880
FAILURE CODE [CA115] 884
FAILURE CODE [CA122] 886
FAILURE CODE [CA123] 889
FAILURE CODE [CA131] 892
FAILURE CODE [CA132] 895
FAILURE CODE [CA135] 898
FAILURE CODE [CA141] 901
FAILURE CODE [CA144] 904
FAILURE CODE [CA145] 907
FAILURE CODE [CA153] 910
FAILURE CODE [CA154] 913
FAILURE CODE [CA187] 916
FAILURE CODE [CA221] 919
FAILURE CODE [CA222] 922
FAILURE CODE [CA227] 925
FAILURE CODE [CA234] 928
FAILURE CODE [CA238] 930
FAILURE CODE [CA263] 933
FAILURE CODE [CA265] 936
FAILURE CODE [CA271] 939
FAILURE CODE [CA272] 942
FAILURE CODE [CA273] 944
FAILURE CODE [CA274] 947
FAILURE CODE [CA322] 949
FAILURE CODE [CA323] 952
FAILURE CODE [CA324] 955
FAILURE CODE [CA325] 958
FAILURE CODE [CA331] 961
FAILURE CODE [CA332] 964
FAILURE CODE [CA342] 967
FAILURE CODE [CA351] 971
FAILURE CODE [CA352] 976
FAILURE CODE [CA386] 979
FAILURE CODE [CA441] 982
FAILURE CODE [CA442] 986
FAILURE CODE [CA449] 990
FAILURE CODE [CA451] 995
FAILURE CODE [CA452] 998
FAILURE CODE [CA553] 1001
FAILURE CODE [CA554] 1004
FAILURE CODE [CA559] 1008
FAILURE CODE [CA689] 1015
FAILURE CODE [CA731] 1019
FAILURE CODE [CA757] 1022
FAILURE CODE [CA778] 1026
FAILURE CODE [CA1228] 1030
FAILURE CODE [CA1625] 1035
FAILURE CODE [CA2185] 1039
FAILURE CODE [CA2186] 1041
FAILURE CODE [CA2249] 1044
FAILURE CODE [CA2271] 1051
FAILURE CODE [CA2272] 1054
FAILURE CODE [CA2351] 1057
FAILURE CODE [CA2352] 1060
FAILURE CODE [CA2555] 1062
FAILURE CODE [CA2556] 1065
FAILURE CODE [D110KB] 1069
FAILURE CODE [D19JKZ] 1072
FAILURE CODE [D1N0KA] 1076
FAILURE CODE [D1N0KB] 1078
FAILURE CODE [D1N0KY] 1080
FAILURE CODE [D811MC] 1082
FAILURE CODE [D862KA] 1083
FAILURE CODE [D8ALKA] 1085
FAILURE CODE [D8ALKB] 1088
FAILURE CODE [D8AQKR] 1090
FAILURE CODE [DA20MC] 1097
FAILURE CODE [DA22KK] 1098
FAILURE CODE [DA25KP] 1102
FAILURE CODE [DA26KP] 1108
FAILURE CODE [DA29KQ] 1112
FAILURE CODE [DA2LKA] 1117
FAILURE CODE [DA2LKB] 1120
FAILURE CODE [DA2QKR] 1122
FAILURE CODE [DA2RKR] 1131
FAILURE CODE [DAF0MB] 1139
FAILURE CODE [DAF0MC] 1140
FAILURE CODE [DAF8KB] 1141
FAILURE CODE [DAF9KQ] 1145
FAILURE CODE [DAFGMC] 1147
FAILURE CODE [DAFLKA] 1148
FAILURE CODE [DAFLKB] 1151
FAILURE CODE [DAFQKR] 1153
FAILURE CODE [DAZ9KQ] 1161
FAILURE CODE [DAZQKR] 1163
FAILURE CODE [DB2QKR] 1169
FAILURE CODE [DBP0KM] 1177
FAILURE CODE [DBP0KT] 1178
FAILURE CODE [DBPQKR] 1179
FAILURE CODE [DDNRKA] 1187
FAILURE CODE [DDNRKY] 1191
FAILURE CODE [DDNS00] 1194
FAILURE CODE [DDPAKA] 1197
FAILURE CODE [DGH2KA] 1200
FAILURE CODE [DGH2KB] 1203
FAILURE CODE [DHA4KA] 1206
FAILURE CODE [DHE5MA] 1208
FAILURE CODE [DHPAMA] 1211
FAILURE CODE [DHPBMA] 1214
FAILURE CODE [DHS3MA] 1217
FAILURE CODE [DHS4MA] 1220
FAILURE CODE [DHS8MA] 1223
FAILURE CODE [DHS9MA] 1226
FAILURE CODE [DHSAMA] 1229
FAILURE CODE [DHSBMA] 1232
FAILURE CODE [DHSCMA] 1235
FAILURE CODE [DHSDMA] 1238
FAILURE CODE [DHSFMA] 1241
FAILURE CODE [DHSGMA] 1244
FAILURE CODE [DHSHMA] 1247
FAILURE CODE [DHSJMA] 1250
FAILURE CODE [DJG1KX] 1253
FAILURE CODE [DKR2MA] 1256
FAILURE CODE [DKR2NX] 1259
FAILURE CODE [DKULKA] 1261
FAILURE CODE [DKULKB] 1263
FAILURE CODE [DKULKY] 1266
FAILURE CODE [DLM5KA] 1268
FAILURE CODE [DLM5MB] 1271
FAILURE CODE [DR10KA] 1275
FAILURE CODE [DR21KX] 1285
FAILURE CODE [DR31KX] 1289
FAILURE CODE [DUMBKA] 1293
FAILURE CODE [DUMBKB] 1296
FAILURE CODE [DV20KB] 1298
FAILURE CODE [DW43KA] 1300
FAILURE CODE [DW43KB] 1302
FAILURE CODE [DW43KY] 1305
FAILURE CODE [DW45KA] 1307
FAILURE CODE [DW45KB] 1311
FAILURE CODE [DW45KY] 1315
FAILURE CODE [DW4CKY] 1318
FAILURE CODE [DW91KA] 1320
FAILURE CODE [DW91KB] 1322
FAILURE CODE [DW91KY] 1325
FAILURE CODE [DWA2KA] 1327
FAILURE CODE [DWA2KB] 1329
FAILURE CODE [DWA2KY] 1332
FAILURE CODE [DWK0KA] 1334
FAILURE CODE [DWK0KB] 1336
FAILURE CODE [DWK0KY] 1339
FAILURE CODE [DWK2KA] 1341
FAILURE CODE [DWK2KB] 1343
FAILURE CODE [DWK2KY] 1346
FAILURE CODE [DWK8KA] 1348
FAILURE CODE [DWK8KB] 1350
FAILURE CODE [DWK8KY] 1353
FAILURE CODE [DWN5KA] 1355
FAILURE CODE [DWN5KB] 1358
FAILURE CODE [DWN5KY] 1360
FAILURE CODE [DXA8KA] 1362
FAILURE CODE [DXA8KB] 1365
FAILURE CODE [DXA9KA] 1369
FAILURE CODE [DXA9KB] 1372
FAILURE CODE [DXE0KA] 1376
FAILURE CODE [DXE0KB] 1378
FAILURE CODE [DXE4KA] 1381
FAILURE CODE [DXE4KB] 1383
FAILURE CODE [DXE4KY] 1386
FAILURE CODE [DXE5KA] 1388
FAILURE CODE [DXE5KB] 1390
FAILURE CODE [DXE6KA] 1393
FAILURE CODE [DXE6KB] 1395
FAILURE CODE [DY20KA] 1398
FAILURE CODE [DY20MA] 1401
FAILURE CODE [DY2CKB] 1404
FAILURE CODE [DY2DKB] 1408
FAILURE CODE [DY2EKB] 1411
FAILURE CODE [F@BBZL] 1414
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1416
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1416
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1426
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1431
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1435
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1440
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1445
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1447
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1449
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1450
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1451
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1453
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1456
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1457
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1458
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1460
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1461
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1462
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 1465
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1467
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1468
E-21 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 1470
E-22 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1471
E-23 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 1474
E-24 FUNCTION SWITCH DOES NOT OPERATE 1476
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 1477
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1479
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1480
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 1482
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1483
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 1484
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1485
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 1487
E-33 SERVICE MODE CANNOT BE SELECTED 1488
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1489
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 1493
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 1495
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 1498
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 1500
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 1504
E-40 HORN DOES NOT SOUND 1506
E-41 HORN DOES NOT STOP SOUNDING 1509
E-42 ALARM DOES NOT SOUND DURING TRAVEL 1511
E-43 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1514
E-44 ALARM BUZZER CANNOT BE CANCELED 1516
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 1517
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 1518
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1521
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1524
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1525
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1526
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1527
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1528
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1529
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1530
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1531
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1532
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED 1535
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1537
E-59 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 1539
E-60 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1543
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1546
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1546
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 1548
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1556
H-4 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1559
H-5 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 1566
H-6 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1568
H-7 TIME LAG OF WORK EQUIPMENT IS LARGE 1572
H-8 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 1578
H-9 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1581
H-10 ATTACHMENT CIRCUIT CANNOT BE CHANGED 1583
H-11 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 1585
H-12 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1587
H-13 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1589
H-14 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1590
H-15 MACHINE DOES NOT TRAVEL STRAIGHT 1591
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 1603
H-17 TRAVEL SPEED IS LOW 1618
H-18 ONE OF TRACKS DOES NOT RUN 1627
H-19 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1637
H-20 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1640
H-21 SWINGS ONLY IN ONE DIRECTION 1644
H-22 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 1647
H-23 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1653
H-24 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1657
H-25 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1659
H-26 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 1663
H-27 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 1665
H-28 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 1668
H-29 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1670
H-30 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 1674
H-31 UNUSUAL NOISE IS HEARD FROM AROUND FAN 1675
H-32 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 1676
H-33 SPEED OR POWER OF BOOM IS LOW 1678
H-34 ARM SPEED OR POWER IS LOW 1689
H-35 BUCKET SPEED OR POWER IS LOW 1699
H-36 HYDRAULIC DRIFT OF BOOM IS LARGE 1708
H-37 HYDRAULIC DRIFT OF ARM IS LARGE 1710
H-38 HYDRAULIC DRIFT OF BUCKET IS LARGE 1714
TROUBLESHOOTING OF ENGINE (S-MODE) 1717
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1717
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1719
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1722
S-4 ENGINE STARTABILITY IS POOR 1726
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1731
S-6 ENGINE STOPS DURING OPERATION 1735
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1740
S-8 ENGINE LACKS POWER 1742
S-9 EXHAUST IS BLACK (INCOMPLETE COMBUSTION) 1748
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1752
S-11 OIL BECOMES CONTAMINATED QUICKLY 1756
S-12 FUEL CONSUMPTION IS EXCESSIVE 1759
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1761
S-14 OIL PRESSURE DROPS 1763
S-15 FUEL MIXES INTO ENGINE OIL 1768
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1770
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 1773
S-18 UNUSUAL NOISE IS HEARD 1776
S-19 VIBRATION IS EXCESSIVE 1780
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 1783
50 DISASSEMBLY AND ASSEMBLY 1785
CONTENTS 1786
ABBREVIATION LIST 1790
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1796
HOW TO READ THIS MANUAL 1796
COATING MATERIALS LIST 1798
SPECIAL TOOLS LIST 1802
SKETCHES OF SPECIAL TOOLS 1813
ENGINE AND COOLING SYSTEM 1819
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1819
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1820
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1826
REMOVE AND INSTALL INJECTOR ASSEMBLY 1834
METHOD FOR REMOVING INJECTOR ASSEMBLY 1835
METHOD FOR INSTALLING INJECTOR ASSEMBLY 1839
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 1848
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1849
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1858
REMOVE AND INSTALL EGR VALVE ASSEMBLY 1872
METHOD FOR REMOVING EGR VALVE ASSEMBLY 1872
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 1875
REMOVE AND INSTALL EGR COOLER ASSEMBLY 1879
METHOD FOR REMOVING EGR COOLER ASSEMBLY 1879
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 1881
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 1884
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 1884
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 1885
METHOD FOR INSTALLING MUFFLER 1887
REMOVE AND INSTALL MUFFLER 1887
METHOD FOR REMOVING MUFFLER 1889
REMOVE AND INSTALL ALTERNATOR BELT 1893
METHOD FOR REMOVING ALTERNATOR BELT 1893
METHOD FOR INSTALLING ALTERNATOR BELT 1895
REMOVE AND INSTALL FAN BELT 1897
METHOD FOR REMOVING FAN BELT 1897
METHOD FOR INSTALLING FAN BELT 1899
REMOVE AND INSTALL RADIATOR ASSEMBLY 1902
METHOD FOR REMOVING RADIATOR ASSEMBLY 1903
METHOD FOR INSTALLING RADIATOR ASSEMBLY 1907
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1911
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 1911
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 1915
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 1918
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 1918
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 1921
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 1925
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY 1925
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY 1930
REMOVE AND INSTALL FAN 1935
METHOD FOR INSTALLING FAN 1935
METHOD FOR REMOVING FAN 1935
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 1936
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY 1938
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY 1953
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 1969
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 1970
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 1971
REMOVE AND INSTALL ENGINE REAR OIL SEAL 1975
METHOD FOR REMOVING ENGINE REAR OIL SEAL 1976
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 1979
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 1984
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 1984
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 1987
REMOVE AND INSTALL FUEL TANK ASSEMBLY 1992
METHOD FOR REMOVING FUEL TANK ASSEMBLY 1993
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 1997
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2001
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2001
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2003
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2005
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2005
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2007
POWER TRAIN 2009
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2009
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2010
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2012
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2014
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2015
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2019
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2028
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2029
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2031
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2033
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 2034
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2038
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2046
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 2046
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 2047
UNDERCARRIAGE AND FRAME 2048
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2048
METHOD FOR SEPARATING TRACK ASSEMBLY 2048
METHOD FOR INSTALLING TRACK ASSEMBLY 2051
REMOVE AND INSTALL SPROCKET 2054
METHOD FOR REMOVING SPROCKET 2054
METHOD FOR INSTALLING SPROCKET 2055
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2056
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2056
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2057
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2059
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2059
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2060
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2064
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 2065
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2066
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2068
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2069
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2070
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 2072
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2072
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2074
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2077
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2078
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2081
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2084
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2084
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2086
HYDRAULIC SYSTEM 2088
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2088
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2089
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2092
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2095
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2096
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2096
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2098
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2099
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2105
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 2111
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2112
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2117
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2123
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2124
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2133
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 2142
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2143
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2144
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2149
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2150
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2150
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2152
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2152
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2153
WORK EQUIPMENT 2155
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2155
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2157
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2160
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2164
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2165
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2168
CAB AND ITS ATTACHMENTS 2174
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2174
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY 2175
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY 2182
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 2190
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2192
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2192
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2203
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 2203
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 2206
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 2212
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2213
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2218
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2225
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2226
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2232
REMOVE AND INSTALL OPERATOR’S SEAT 2238
METHOD FOR REMOVING OPERATOR’S SEAT 2238
METHOD FOR INSTALLING OPERATOR’S SEAT 2241
REMOVE AND INSTALL SEAT BELT 2244
METHOD FOR REMOVING SEAT BELT 2244
METHOD FOR INSTALLING SEAT BELT 2245
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 2246
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2247
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2253
ELECTRICAL SYSTEM 2262
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2262
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2262
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2264
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 2265
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2265
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2268
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2271
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2271
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2275
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2279
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2279
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2281
60 MAINTENANCE STANDARD 2285
CONTENTS 2286
ABBREVIATION LIST 2287
ENGINE AND COOLING SYSTEM 2293
MAINTENANCE STANDARD OF ENGINE MOUNT 2293
MAINTENANCE STANDARD OF COOLING SYSTEM 2294
POWER TRAIN 2295
MAINTENANCE STANDARD OF SWING CIRCLE 2295
MAINTENANCE STANDARD OF SWING MACHINERY 2297
MAINTENANCE STANDARD OF FINAL DRIVE 2299
MAINTENANCE STANDARD OF SPROCKET 2301
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 2302
UNDERCARRIAGE AND FRAME 2304
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2304
MAINTENANCE STANDARD OF IDLER 2306
MAINTENANCE STANDARD OF TRACK ROLLER 2308
MAINTENANCE STANDARD OF CARRIER ROLLER 2310
MAINTENANCE STANDARD OF TRACK SHOE 2311
MAINTENANCE STANDARD OF TRIPLE SHOE 2314
HYDRAULIC SYSTEM 2315
MAINTENANCE STANDARD OF MAIN PUMP 2315
MAINTENANCE STANDARD OF SWING MOTOR 2317
MAINTENANCE STANDARD OF TRAVEL MOTOR 2320
MAINTENANCE STANDARD OF CONTROL VALVE 2323
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2334
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2337
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2340
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2342
MAINTENANCE STANDARD OF SOLENOID VALVE 2344
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE 2345
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 2346
WORK EQUIPMENT 2347
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2347
DIMENSION OF ARM 2352
DIMENSIONS OF BUCKET 2354
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE (SE SPECIFICATION) 2356
DIMENSION OF ARM (SE SPECIFICATION) 2361
DIMENSIONS OF BUCKET (SE SPECIFICATION) 2363
MAINTENANCE STANDARD OF BOOM CYLINDER 2365
MAINTENANCE STANDARD OF ARM CYLINDER 2366
MAINTENANCE STANDARD OF BUCKET CYLINDER 2367
MAINTENANCE STANDARD OF BUCKET CYLINDER (SE SPECIFICATION) 2368
80 APPENDIX 2369
CONTENTS 2370
ABBREVIATION LIST 2372
AIR CONDITIONER SYSTEM 2378
PRECAUTIONS FOR REFRIGERANT 2378
AIR CONDITIONER COMPONENT 2379
SPECIFICATIONS OF AIR CONDITIONER 2381
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2382
OUTLINE OF REFRIGERATION CYCLE 2383
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2385
AIR CONDITIONER UNIT 2385
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2385
FUNCTION OF AIR CONDITIONER UNIT 2387
COMPONENT PARTS OF AIR CONDITIONER UNIT 2389
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2390
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2390
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2390
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 2390
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2391
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2391
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2391
FUNCTION OF DUAL PRESSURE SWITCH 2392
AIR CONDITIONER CONTROLLER 2393
STRUCTURE OF AIR CONDITIONER CONTROLLER 2393
COMPRESSOR 2394
STRUCTURE OF COMPRESSOR 2394
SPECIFICATIONS OF COMPRESSOR 2394
FUNCTION OF COMPRESSOR 2394
CONDENSER 2395
STRUCTURE OF CONDENSER 2395
SPECIFICATIONS OF CONDENSER 2395
FUNCTION OF CONDENSER 2395
RECEIVER DRIER 2396
STRUCTURE OF RECEIVER DRIER 2396
SPECIFICATIONS OF RECEIVER DRIER 2396
FUNCTION OF RECEIVER DRIER 2396
SENSORS FOR AIR CONDITIONER SYSTEM 2397
STRUCTURE OF SUNLIGHT SENSOR 2397
FUNCTION OF SUNLIGHT SENSOR 2397
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 2397
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2397
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2399
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2401
AIR CONDITIONER SYSTEM DIAGRAM 2403
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2404
FUNCTION OF AIR CONDITIONER CONTROLLER 2405
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2406
TESTING AIR LEAKAGE (DUCT) 2410
METHOD FOR TESTING AIR LEAKAGE (DUCT) 2410
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2412
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2413
TEST VENT (MODE) CHANGEOVER 2414
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2414
TESTING FRESH/RECIRC AIR CHANGEOVER 2416
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2416
TEST SUNLIGHT SENSOR 2417
METHOD FOR TESTING SUNLIGHT SENSOR 2417
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2418
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2418
TEST RELAYS 2419
METHOD FOR TESTING RELAYS 2419
AIR CONDITIONER TROUBLESHOOTING CHART 1 2420
AIR CONDITIONER TROUBLESHOOTING CHART 2 2421
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2424
FAILURE CODE [879AKA] 2426
FAILURE CODE [879AKB] 2428
FAILURE CODE [879CKA] 2430
FAILURE CODE [879CKB] 2432
FAILURE CODE [879FMC] 2434
FAILURE CODE [879GKX] 2436
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2439
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2442
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2448
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 2452
TROUBLESHOOTING USING GAUGE PRESSURE 2456
CONNECTION OF SERVICE TOOL 2459
METHOD FOR CONNECTING SERVICE TOOL 2459
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2461
HANDLE COMPRESSOR OIL 2463
90 CIRCUIT DIAGRAMS 2465
CONTENTS 2466
ABBREVIATION LIST 2467
HYDRAULIC CIRCUIT DIAGRAM 2473
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2473
HYDRAULIC CIRCUIT DIAGRAM (WHEN BOOM IS RAISED) 2477
HYDRAULIC CIRCUIT DIAGRAM (WHEN UPPER STRUCTURE IS SWING TO LEFT) 2479
HYDRAULIC CIRCUIT DIAGRAM (WHEN BOOM IS RAISED AND UPPER STRUCTURE IS SWUNG TO LEFT) 2481
HYDRAULIC CIRCUIT DIAGRAM (1/2) 2483
HYDRAULIC CIRCUIT DIAGRAM (2/2) 2485
ELECTRICAL CIRCUIT DIAGRAM 2487
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2487
ELECTRICAL CIRCUIT DIAGRAM (1/7) 2491
ELECTRICAL CIRCUIT DIAGRAM (2/7) 2493
ELECTRICAL CIRCUIT DIAGRAM (3/7) 2495
ELECTRICAL CIRCUIT DIAGRAM (4/7) 2497
ELECTRICAL CIRCUIT DIAGRAM (5/7) 2499
ELECTRICAL CIRCUIT DIAGRAM (6/7) 2501
ELECTRICAL CIRCUIT DIAGRAM (7/7) 2503
CONNECTOR AND WIRING HARNESS CHART 2505
CONNECTOR AND WIRING HARNESS CHART (1/15) 2507
CONNECTOR AND WIRING HARNESS CHART (2/15) 2509
CONNECTOR AND WIRING HARNESS CHART (3/15) 2511
CONNECTOR AND WIRING HARNESS CHART (4/15) 2513
CONNECTOR AND WIRING HARNESS CHART (5/15) 2515
CONNECTOR AND WIRING HARNESS CHART (6/15) 2517
CONNECTOR AND WIRING HARNESS CHART (7/15) 2519
CONNECTOR AND WIRING HARNESS CHART (8/15) 2521
CONNECTOR AND WIRING HARNESS CHART (9/15) 2523
CONNECTOR AND WIRING HARNESS CHART (10/15) 2525
CONNECTOR AND WIRING HARNESS CHART (11/15) 2527
CONNECTOR AND WIRING HARNESS CHART (12/15) 2529
CONNECTOR AND WIRING HARNESS CHART (13/15) 2531
CONNECTOR AND WIRING HARNESS CHART (14/15) 2533
CONNECTOR AND WIRING HARNESS CHART (15/15) 2535
INDEX 2537

DESCRIPTION:

Komatsu PC500LC-10M0 Hydraulic Excavator Shop Manual SEN06637-03 – PDF DOWNLOAD 

SERIAL NUMBERS 95001 and up

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.

IMAGES PREVIEW OF THE MANUAL:

S.V 28/12/24