Komatsu PC500LC-10MO Hydraulic Excavator Shop Manual SEN06813-10

Description

Komatsu PC500LC-10MO Hydraulic Excavator Shop Manual SEN06813-10 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC500LC-10MO Hydraulic Excavator Shop Manual SEN06813-10 – PDF DOWNLOAD

Language : English
Pages : 2524
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC500LC-10MO Hydraulic Excavator Shop Manual SEN06813-10 – PDF DOWNLOAD 

SERIAL NUMBERS 105002 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the 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 Specification
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.

TABLE OF CONTENTS:

Komatsu PC500LC-10MO Hydraulic Excavator Shop Manual SEN06813-10 – PDF DOWNLOAD 

SERIAL NUMBERS 105002 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 17
Foreword, Safety, Basic Information 20
How to Read the Shop Manual 20
Safety Notice for Operation 22
Precautions to Prevent Fire 30
Procedures If Fire Occurs 31
Precautions for Disposing of Waste Materials 31
Precautions When You Handle Hydraulic Equipment 32
Precautions When You Disconnect and Connect Pipings 35
Precautions When You Handle Electrical Equipment 41
Precautions When You Handle Fuel System Equipment 43
Precautions When You Handle Intake System Equipment 44
Practical Use of KOMTRAX 45
Disconnect and Connect Push-Pull Type Coupler 46
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 46
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 47
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 48
Precautions for Disconnection and Connection of Connectors 50
How to Disconnect and Connect Deutsch Connector 54
How to Disconnect and Connect Slide Lock Type Connector 55
How to Disconnect and Connect Connector with Lock to Pull 56
How to Disconnect and Connect Connector with Lock to Push 57
How to Disconnect and Connect Connector with Housing to Rotate 59
How to Read the Codes for Electric Cable 60
Explanation of Terms for Maintenance Standard 64
Standard Tightening Torque Table 67
Conversion Table 74
01 Specifications 79
Table of Contents 80
Specifications 81
Specification Drawing 81
Specification Drawing: PC500LC-10M0 81
Specification Drawing: PC500LC-10M0 (SE Specification) 82
Working Range Drawings 83
Working Range: PC500LC-10M0 83
Working Range: PC500LC-10M0 (SE Specification) 84
Specifications 85
Specifications: PC500LC-10M0 85
Specifications: PC500LC-10M0 (SE Specification) 88
Weight Table 91
Weight Table: PC500LC-10M0 91
Weight Table: PC500LC-10M0 (SE Specification) 93
Table of Fuel, Coolant, and Lubricants 95
10 Structure and Function 97
Table of Contents 98
Boot-up System 101
Layout Drawing of Boot-up System 101
System Operating Lamp System 103
System Diagram of System Operating Lamp System 103
Function of Operation Lamp System 103
Battery Disconnect Switch 104
Function of Battery Disconnect Switch 104
Engine System 105
Layout Drawing of Engine System 105
Specifications of Engine System 106
Function of Engine System 106
Engine Control System 107
System Diagram of Engine Control 107
Function of Engine Control System 108
Auto-Deceleration System 110
System Diagram of Auto-Deceleration System 110
Function of Auto-Deceleration System 110
Operation of Auto-Deceleration System 111
Engine Automatic Warm-up System 112
System Diagram of Engine Automatic Warm-up System 112
Function of Engine Automatic Warm-up System 113
Overheat Prevention System 114
Overheat Prevention System Diagram 114
Function of Overheat Prevention System 115
Turbocharger Protection System 116
System Diagram of Turbocharger Protection System 116
Function of Turbocharger Protection System 117
Automatic Idle Stop System 118
System Diagram of Automatic Idle Stop System 118
Function of Automatic Idle Stop System 118
Component Parts of Engine System 121
Turbocharger 121
EGR System 123
EGR Valve 125
EGR Cooler 127
Venturi System 129
Blowby Pressure Sensor 130
Cooling System 131
Layout Drawing of Cooling System 131
Specifications of Cooling System 132
Fan Speed Control System of Fan Clutch 133
Fan Speed Control System Diagram of Fan Clutch 133
Function of Fan Speed Control System of Fan Clutch 134
Engine Output Control System of Fan Clutch 135
Engine Output Control System Diagram of Fan Clutch 135
Function of Engine Output Control System of Fan Clutch 135
Component Parts of Cooling System 137
Fan Clutch 137
Control System 138
Layout Drawing of Control System 138
Machine Monitor System 141
System Diagram of Machine Monitor System 141
Function of Machine Monitor System 141
KOMTRAX System 143
System Diagram of KOMTRAX System 143
Function of KOMTRAX System 143
Component Parts of Control System 144
Machine Monitor 144
Rearview Camera 158
KOMTRAX Terminal 159
Pump Controller 161
Resistor for PC-EPC Valve 166
CAN Terminating Resistor 167
Engine Controller 168
Fuel Control Dial 172
Fuel Feed Pump 174
Hydraulic System 175
Layout Drawing of Hydraulic System 175
CLSS 179
Structure of CLSS 179
Operation of Unload Valve and LS Pressure 181
Pump Swash Plate Angle (Oil Flow) Control 182
Pressure Compensation Control 198
Engine and Pump Combined Control System 202
Engine and Pump Combined Control System Diagram 202
Function of Engine and Pump Combined Control System 203
Pump and Valve Control System 208
Pump and Valve Control System Diagram 208
Function of Pump and Valve Control System 209
Component Parts of Hydraulic System 211
Hydraulic Tank 211
Main Pump 214
Control Valve 241
Work Equipment System 304
Layout Drawing of Work Equipment System 304
One-Touch Power Maximizing System 308
System Diagram of One-Touch Power Maximizing System 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
System Diagram of PPC Lock 312
Function of PPC Lock System 312
Work Equipment and Travel Automatic Lock System 313
System Diagram of Lock Lever Automatic Lock System 313
Function of Work Equipment and Travel Automatic Lock System 313
Operation of Lock Lever Automatic Lock System 314
Attachment Oil Flow Adjuster System 315
Attachment Oil Flow Adjuster System Diagram 315
Function of Attachment Oil Flow Adjuster System 316
Component Parts of Work Equipment System 317
Work Equipment and Swing PPC Valve 317
1st-Line Attachment PPC Valve (with EPC Valve) 322
Solenoid Valve 330
Attachment Circuit Selector Valve 333
Pilot Circuit Accumulator 335
Hydraulic Oil Additional Filter with Clogging Switch 336
Hydraulic Oil Additional Filter Clogging Switch 336
Swing System 337
Layout Drawing of Swing System 337
Swing Control System Diagram 341
Function of Swing Control System 341
Component Parts of Swing System 345
Swing Motor 345
Swing Machinery 358
Swing Circle 360
Travel System 363
Layout Drawing of Travel System 363
System Diagram of Travel Control System 367
Function of Travel Control System 367
Component Parts of Travel System 369
Travel Motor 369
Final Drive 382
Travel PPC Valve 384
Center Swivel Joint 388
Undercarriage and Frame 390
Layout Drawing of Undercarriage 390
Specifications of Undercarriage 390
Work Equipment 391
Structure of Work Equipment 391
Function of Work Equipment 391
Work Equipment Clearance Adjustment Shim 392
Function of Work Equipment Clearance Adjustment Shim 392
Bucket Clearance Adjustment Shim 393
Function of Bucket Clearance Adjustment Shim 393
CAB Related Parts 394
CAB 394
Structure of CAB 394
CAB Mount 395
Structure of CAB Mount 395
Function of CAB Mount 395
CAB Tipping Stopper 396
Structure of CAB Tipping Stopper 396
Function of CAB Tipping Stopper 396
20 Standard Value Table 397
Table of Contents 398
Standard Value Table for Engine 399
Standard Value Table for Engine: PC500LC-10M0 399
Standard Value Table for Machine 403
Standard Value Table for Machine: PC500LC-10M0 403
Machine Posture and Procedures to Measure Performance 417
30 Testing and Adjusting 421
Table of Contents 422
Precautions Before Work 425
Related Information on Testing and Adjusting 426
Tools for Testing and Adjusting 426
Sketch of Tools for Testing and Adjusting 431
Engine and Cooling System 433
Examine Engine Speed 433
How to Examine Engine Speed 433
Examine Boost Pressure 436
How to Examine Boost Pressure on Machine Monitor 436
How to Examine Boost Pressure by Testing Tool 437
Examine Exhaust Gas Temperature 439
How to Examine Exhaust Gas Temperature 439
Examine Exhaust Gas Color 441
How to Examine Exhaust Gas Color with the Handy Smoke Checker 441
How to Examine Exhaust Gas Color with Smoke Meter 442
Examine and Adjust Valve Clearance 443
How to Examine Valve Clearance 443
How to Adjust Valve Clearance 445
Examine Compression Pressure 446
How to Examine Compression Pressure 446
Examine Blowby Pressure 449
How to Examine Blowby Pressure on Machine Monitor 449
How to Examine Blowby Pressure by Testing Tool 450
Examine Engine Oil Pressure 451
How to Examine Engine Oil Pressure on Machine Monitor 451
How to Examine Engine Oil Pressure by Testing Tool 451
Examine EGR Valve Driving Oil Pressure 453
How to Examine EGR Valve Driving Oil Pressure 453
Examine Fuel Pressure 455
How to Examine Fuel Pressure 455
Examine Fuel Return Rate and Leakage 457
How to Examine Fuel Return Rate and Leakage 457
Bleed Air from Fuel System 460
How to Bleed Air from Fuel System 460
Examine Fuel Circuit for Leakage 463
How to Examine Fuel System for Leakage 463
Handle Cylinder Cut-out Mode Operation 465
Handle No-Injection Cranking Operation 466
Examine Fan Belt 467
How to Examine Fan Belt 467
Examine Alternator Belt 468
How to Examine Alternator Belt 468
Examine Automatic Tensioner 470
How to Examine Automatic Tensioner 470
Examine Cooling Fan Speed 472
How to Examine Cooling Fan Speed 472
Power Train 473
Examine Swing Circle Bearing Clearance 473
How to Examine Swing Circle Bearing Clearance 473
Undercarriage and Frame 474
Examine and Adjust Track Tension 474
How to Examine Track Tension 474
How to Adjust Track Tension 474
Hydraulic System 476
Release Remained Pressure in Hydraulic Circuit 476
How to Release Remained Pressure from Hydraulic Tank 476
How to Release Remained Pressure in Hydraulic Cylinder Circuit 476
How to Release Remained Pressure from Swing Motor Circuit 478
How to Release Remained Pressure from Travel Motor Circuit 478
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 479
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 480
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 487
Examine Oil Pressure of Control Circuit 490
How to Examine Oil Pressure in Control Circuit 490
Examine and adjust oil pressure in pump PC control circuit 492
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 492
Examine PC-EPC Valve Outlet Pressure 493
How to Adjust Oil Pressure in Pump PC Control Circuit 494
Examine and Adjust Oil Pressure in Pump LS Control Circuit 496
How to Examine LS Differential Pressure with Machine Monitor 496
How to Examine LS Differential Pressure by Testing Tool 498
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 499
How to Examine LS-EPC Valve Outlet Pressure 500
How to Adjust LS Valve 501
Examine Outlet Pressure of Solenoid Valve 502
How to Examine Outlet Pressure of Solenoid Valve 502
Operating Condition of Solenoid Valve 503
Examine PPC Valve Outlet Pressure 506
How to Examine Outlet Pressure in PPC Valve 506
Adjust Play of Work Equipment and Swing PPC Valves 509
How to Adjust Play of Work Equipment and Swing PPC Valves 509
Examine Parts Which Cause Hydraulic Drift of Work Equipment 510
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 510
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 510
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 511
Examine Oil Leakage 512
How to Examine Oil Leakage from Boom Cylinder 512
How to Examine Oil Leakage from Arm Cylinder 512
How to Examine Oil Leakage from Bucket Cylinder 513
How to Examine Oil Leakage from Swing Motor 513
How to Examine Oil Leakage from Travel Motor 514
Bleed Air from Hydraulic System 515
How to Bleed Air from Hydraulic System 517
Examine and Charge Accumulator (Made by HYDAC) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 520
How to Examine Accumulator (Made by HYDAC) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 520
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 524
How to Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 524
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 528
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 528
CAB Related Parts 535
Examine CAB Tipping Stopper 535
How to Examine Cab Tipping Stopper 535
How to Adjust Mirrors 536
Procedure to Adjust Machine Left Front Mirror (A) 536
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 537
Procedure to Adjust Machine Right Front Mirror (B) 538
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 539
Procedure to Adjust Machine Right Side Mirror (C) 540
Procedure to Adjust Machine Rear Counterweight Mirror (D) 541
Electrical System 543
Set and Operate Machine Monitor 543
Operator Mode 546
Examine Function by LCD (Liquid Crystal Display) 546
Examine Function of Service Meter 547
Usage Limitation and Maintenance Password Change Function 547
Service Mode 549
How to Operate Service Mode 549
How to See Pre-defined Monitoring Information 552
How to Examine Self-Define Monitor Information 555
Abnormality Record Menu 563
How to See Maintenance Record 567
Maintenance Mode Setting 568
How to Set Phone Number Entry 572
Default Menu 573
Diagnostic Tests Menu 581
Adjustment Menu 583
No-Injection Cranking Operation 596
KOMTRAX Settings Menu 597
How to Show Service Message 600
How to Start Up KOMTRAX Terminal 602
Adjust Rearview Camera Angle 607
How to Adjust Rearview Camera Angle 607
Handle Voltage Circuit of Engine Controller 610
Handle Battery Disconnect Switch 611
Examine Diodes 612
How to Examine Diodes by Digital Tester 612
How to Examine Diodes by Analog Tester 612
Pm Clinic 613
Pm Clinic Service 613
Pm Clinic Check Sheet: PC500LC-10M0 614
40 Troubleshooting 627
Table of Contents 628
Precautions Before Work 635
Related Information to Troubleshooting 636
General Troubleshooting Points 636
Sequence of Events in Troubleshooting 637
Checks Before Troubleshooting 639
Inspection Procedure Before Troubleshooting 641
Walk-Around Check 641
Test in Accordance with Testing Procedure 643
Examine Fuel Level and Type 643
Examine for Impure Ingredient in Fuel 644
Examine Fuel Prefilter 644
Examine Water Separator, Drain Water and Sediment 645
Replace Fuel Prefilter Cartridge 646
Examine Fuel Main Filter 649
Examine Engine Oil Level (Oil Quantity in Oil Pan) 650
Examine Coolant Level (Reservoir Tank) 651
Examine Air Cleaner Clogging 652
Clean Outer Element 653
Replace Element 655
Examine Hydraulic Oil Level 657
Examine Hydraulic Oil Strainer 658
Examine Hydraulic Oil Filter 658
Examine Oil Level in Swing Machinery Case 660
Examine Oil Level in Damper Case 660
Examine Oil Level in Final Drive Case 661
Bleed Air from Fuel System 661
Bleed Air from Hydraulic System 661
How to Examine Electric Equipment 661
Preparation for Troubleshooting of Electrical System 667
Preparation for Troubleshooting of Machine Monitor 667
Preparation for Troubleshooting of Engine Controller 667
Preparation for Troubleshooting of Pump Controller 667
Preparation for Troubleshooting of KOMTRAX Terminal 668
How to Disconnect and Connect Connector with a Special Lock 668
Procedure for Troubleshooting 672
Symptom and Troubleshooting Numbers 675
Information Shown in Troubleshooting Table 679
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 681
Connector and Wiring Harness Identification Table 684
Connector Layout 737
Connector Contact Connection Table 743
T-Branch Box and T-Branch Adapter Table 783
Fuse Location Table 789
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 791
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 795
Failure Code Table 797
Troubleshooting by Failure Code (Display of Code) 806
Failure Code [602KNX] 806
Failure Code [879AKA] 809
Failure Code [879AKB] 811
Failure Code [879BKA] 813
Failure Code [879BKB] 817
Failure Code [879CKA] 820
Failure Code [879CKB] 822
Failure Code [879DKZ] 824
Failure Code [879EMC] 827
Failure Code [879FMC] 829
Failure Code [879GKX] 831
Failure Code [989L00] 834
Failure Code [989M00] 836
Failure Code [989N00] 838
Failure Code [A900FR] 839
Failure Code [A900N6] 840
Failure Code [A900NY] 841
Failure Code [AA10NX] 842
Failure Code [AB00KE] 844
Failure Code [B@BAZG] 847
Failure Code [B@BAZK] 851
Failure Code [B@BCNS] 853
Failure Code [B@BCQA] 857
Failure Code [B@BCZK] 859
Failure Code [CA111] 861
Failure Code [CA115] 865
Failure Code [CA122] 867
Failure Code [CA123] 870
Failure Code [CA131] 873
Failure Code [CA132] 876
Failure Code [CA135] 879
Failure Code [CA141] 882
Failure Code [CA144] 885
Failure Code [CA145] 888
Failure Code [CA153] 891
Failure Code [CA154] 894
Failure Code [CA187] 897
Failure Code [CA221] 900
Failure Code [CA222] 903
Failure Code [CA227] 906
Failure Code [CA234] 909
Failure Code [CA238] 911
Failure Code [CA263] 914
Failure Code [CA265] 917
Failure Code [CA271] 920
Failure Code [CA272] 923
Failure Code [CA273] 925
Failure Code [CA274] 928
Failure Code [CA322] 930
Failure Code [CA323] 933
Failure Code [CA324] 936
Failure Code [CA325] 939
Failure Code [CA331] 942
Failure Code [CA332] 945
Failure Code [CA342] 948
Failure Code [CA351] 952
Failure Code [CA352] 957
Failure Code [CA386] 960
Failure Code [CA441] 963
Failure Code [CA442] 967
Failure Code [CA449] 971
Failure Code [CA451] 976
Failure Code [CA452] 979
Failure Code [CA553] 982
Failure Code [CA554] 985
Failure Code [CA559] 989
Failure Code [CA689] 996
Failure Code [CA731] 1000
Failure Code [CA757] 1003
Failure Code [CA778] 1007
Failure Code [CA1228] 1011
Failure Code [CA1625] 1016
Failure Code [CA2185] 1020
Failure Code [CA2186] 1022
Failure Code [CA2249] 1025
Failure Code [CA2271] 1032
Failure Code [CA2272] 1035
Failure Code [CA2351] 1038
Failure Code [CA2352] 1041
Failure Code [CA2555] 1043
Failure Code [CA2556] 1046
Failure Code [D110KB] 1050
Failure Code [D19JKZ] 1053
Failure Code [D1N0KA] 1057
Failure Code [D1N0KB] 1059
Failure Code [D1N0KY] 1061
Failure Code [D811MC] 1063
Failure Code [D862KA] 1064
Failure Code [D8ALKA] 1065
Failure Code [D8ALKB] 1068
Failure Code [D8AQKR] 1070
Failure Code [DA20MC] 1077
Failure Code [DA22KK] 1078
Failure Code [DA25KP] 1082
Failure Code [DA26KP] 1088
Failure Code [DA29KQ] 1092
Failure Code [DA2LKA] 1097
Failure Code [DA2LKB] 1100
Failure Code [DA2QKR] 1102
Failure Code [DA2RKR] 1111
Failure Code [DAF0MB] 1119
Failure Code [DAF0MC] 1120
Failure Code [DAF8KB] 1121
Failure Code [DAF9KQ] 1125
Failure Code [DAFGMC] 1127
Failure Code [DAFLKA] 1128
Failure Code [DAFLKB] 1131
Failure Code [DAFQKR] 1133
Failure Code [DAZ9KQ] 1141
Failure Code [DAZQKR] 1143
Failure Code [DB2QKR] 1149
Failure Code [DBP0KM] 1157
Failure Code [DBP0KT] 1158
Failure Code [DBPQKR] 1159
Failure Code [DDNRKA] 1167
Failure Code [DDNRKY] 1171
Failure Code [DDNS00] 1174
Failure Code [DDPAKA] 1177
Failure Code [DGH2KA] 1180
Failure Code [DGH2KB] 1183
Failure Code [DHA4KA] 1186
Failure Code [DHE5MA] 1188
Failure Code [DHPAMA] 1191
Failure Code [DHPBMA] 1194
Failure Code [DHS3MA] 1197
Failure Code [DHS4MA] 1200
Failure Code [DHS8MA] 1203
Failure Code [DHS9MA] 1206
Failure Code [DHSAMA] 1209
Failure Code [DHSBMA] 1212
Failure Code [DHSCMA] 1215
Failure Code [DHSDMA] 1218
Failure Code [DHSFMA] 1221
Failure Code [DHSGMA] 1224
Failure Code [DHSHMA] 1227
Failure Code [DHSJMA] 1230
Failure Code [DJG1KX] 1233
Failure Code [DKR2MA] 1236
Failure Code [DKR2NX] 1239
Failure Code [DKULKA] 1241
Failure Code [DKULKB] 1243
Failure Code [DKULKY] 1246
Failure Code [DLM5KA] 1248
Failure Code [DLM5MB] 1251
Failure Code [DR10KA] 1255
Failure Code [DR21KX] 1265
Failure Code [DR31KX] 1269
Failure Code [DUMBKA] 1273
Failure Code [DUMBKB] 1276
Failure Code [DV20KB] 1278
Failure Code [DW43KA] 1280
Failure Code [DW43KB] 1282
Failure Code [DW43KY] 1285
Failure Code [DW45KA] 1287
Failure Code [DW45KB] 1291
Failure Code [DW45KY] 1295
Failure Code [DW4CKY] 1298
Failure Code [DW91KA] 1300
Failure Code [DW91KB] 1302
Failure Code [DW91KY] 1305
Failure Code [DWA2KA] 1307
Failure Code [DWA2KB] 1309
Failure Code [DWA2KY] 1312
Failure Code [DWK0KA] 1314
Failure Code [DWK0KB] 1316
Failure Code [DWK0KY] 1319
Failure Code [DWK2KA] 1321
Failure Code [DWK2KB] 1323
Failure Code [DWK2KY] 1326
Failure Code [DWK8KA] 1328
Failure Code [DWK8KB] 1330
Failure Code [DWK8KY] 1333
Failure Code [DWN5KA] 1335
Failure Code [DWN5KB] 1338
Failure Code [DWN5KY] 1341
Failure Code [DXA8KA] 1343
Failure Code [DXA8KB] 1346
Failure Code [DXA9KA] 1350
Failure Code [DXA9KB] 1353
Failure Code [DXE0KA] 1357
Failure Code [DXE0KB] 1359
Failure Code [DXE4KA] 1362
Failure Code [DXE4KB] 1364
Failure Code [DXE4KY] 1367
Failure Code [DXE5KA] 1369
Failure Code [DXE5KB] 1371
Failure Code [DXE6KA] 1374
Failure Code [DXE6KB] 1376
Failure Code [DY20KA] 1379
Failure Code [DY20MA] 1382
Failure Code [DY2CKB] 1385
Failure Code [DY2DKB] 1389
Failure Code [DY2EKB] 1392
Failure Code [F@BBZL] 1395
Troubleshooting of Electrical System (E-Mode) 1397
E-1 Engine Does Not Start (Engine Does Not Crank) 1397
E-2 Manual Preheating System Does Not Operate 1407
E-3 Automatic Preheating System Does Not Operate 1412
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1416
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1421
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1426
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1428
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1430
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1431
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1432
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1434
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1437
E-13 Water Separator Monitor Comes On in Red While Engine Runs 1438
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1439
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1441
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1442
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 1443
E-18 Display of Fuel Gauge is Different from Actual Fuel Level 1446
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1448
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1449
E-21 Some Areas of Machine Monitor Screen are Not Shown 1451
E-22 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 1452
E-23 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1455
E-24 Function Switch Does Not Operate 1457
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 1458
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1460
E-27 Auto-Decelerator is Not Operated or Canceled with Lever 1461
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1463
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1464
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1465
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 1466
E-32 Service Meter is Not Shown, While Starting Switch is in OFF Position 1468
E-33 Service Mode Cannot be Selected 1469
E-34 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 1470
E-35 All Work Equipment, Swing and Travel Do Not Lock 1474
E-36 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 1476
E-37 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 1479
E-38 One-Touch Power Maximizing Function Does Not Operate Correctly, or Indicator Not Shown on Monitor 1481
E-39 One-Touch Power Maximizing Function is Not Cancelled 1485
E-40 Horn Does Not Sound 1487
E-41 Horn Does Not Stop 1490
E-42 Alarm Does Not Sound During Travel 1492
E-43 Travel Alarm Does Not Stop When Machine Stops 1495
E-44 Alarm Buzzer Cannot be Canceled 1497
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 1498
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 1499
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 1502
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 1505
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 1506
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function 1507
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 1508
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 1509
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function 1510
E-54 “Swing” is Not Shown Correctly with Monitoring Function 1511
E-55 “Travel” is Not Shown Correctly with Monitoring Function 1512
E-56 Service is Not Shown Correctly with Monitoring Function 1513
E-57 Attachment Hydraulic Circuit Cannot be Changed 1516
E-58 KOMTRAX System Does Not Operate Correctly 1518
R-55 Machine Push-Up Function is Not Canceled 1520
E-60 Machine Push-Up Function Does Not Operate 1524
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1527
H-1 All Work Equipment, Swing and Travel Do Not Work 1527
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 1529
H-3 Fine Control Performance or Response is Unsatisfactory 1537
H-4 Engine Speed Drops Largely or Engine Stops 1540
H-5 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 1547
H-6 Work Equipment Does Not Move in Single Operation 1549
H-7 Time Lag of Work Equipment is Large 1553
H-8 One-Touch Power Maximizing Function Does Not Operate 1559
H-9 Machine Push-Up Function Does Not Operate 1562
H-10 Attachment Circuit Cannot be Changed 1564
H-11 Oil Flow in Attachment Circuit Cannot be Changed 1566
H-12 In Mixed Operation of Work Equipment, Equipment with Heavier Load Moves Slower 1568
H-13 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely 1570
H-14 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low 1571
H-15 Machine Does Not Travel Straight 1572
H-16 Machine is Not Steered Correctly or Steering Power is Low 1584
H-17 Travel Speed is Low 1599
H-18 One of Tracks Does Not Run 1608
H-19 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 1618
H-20 Upper Structure Does Not Swing to the Right and Left 1621
H-21 Swings Only in One Direction 1625
H-22 Swing Acceleration or Swing Speed is Low in Lateral Directions (Right and Left) 1628
H-23 Swing Acceleration Performance is Unsatisfactory or Swing Speed is Slow in Only One Direction 1634
H-24 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 1638
H-25 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction, Right or Left) 1640
H-26 Shock is Large When Upper Structure Stops Swing Operation 1644
H-27 There is Large Unusual Noise When It Stops Swing Operation 1646
H-28 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 1649
H-29 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 1651
H-30 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1655
H-31 Unusual Noise is Heard from Around Fan 1656
H-32 Unusual Noise is Heard from Around Hydraulic Pump 1657
H-33 Speed or Power of Boom is Low 1659
H-34 Arm Speed or Power is Low 1670
H-35 Bucket Speed or Power is Low 1680
H-36 Hydraulic Drift of Boom is Large 1689
H-37 Hydraulic Drift of Arm is Large 1691
H-38 Hydraulic Drift of Bucket is Large 1695
Troubleshooting of Engine (S-Mode) 1698
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 1698
S-2 Engine Cranks but No Exhaust Smoke Comes Out 1700
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1703
S-4 Engine Startability is Unsatisfactory 1707
S-5 Engine Does Not Pick Up Smoothly 1712
S-6 Engine Stops During Operation 1716
S-7 Engine Runs Rough or is Not Stable 1721
S-8 Engine Lacks Power 1723
S-9 Exhaust is Black (Incomplete Combustion) 1729
S-10 Engine Oil Consumption is Excessive 1733
S-11 Oil Becomes Dirty Quickly 1737
S-12 Fuel Consumption is Excessive 1740
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 1742
S-14 Oil Pressure Drops 1744
S-15 Fuel Mixes Into Engine Oil 1749
S-16 Water Mixes Into Engine Oil (Milky) 1751
S-17 Coolant Temperature Increases Too High (Overheating) 1754
S-18 Unusual Noise is Heard 1757
S-19 Vibration is Excessive 1761
S-20 Air Cannot be Bled from Fuel Circuit 1764
50 Disassembly and Assembly 1767
Table of Contents 1768
Precautions Before Work 1772
Related Information on Disassembly and Assembly 1773
How to Read This Manual 1773
Coating Materials List 1774
Special Tool List 1779
Sketches of Special Tools 1790
Engine and Cooling System 1796
Remove and Install Supply Pump Assembly 1796
How to Remove Supply Pump Assembly 1797
How to Install Supply Pump Assembly 1803
Remove and Install Injector Assembly 1811
How to Remove Injector Assembly 1812
How to Install Injector Assembly 1816
Remove and Install Cylinder Head Assembly 1825
How to Remove Cylinder Head Assembly 1826
How to Install Cylinder Head Assembly 1835
Remove and Install EGR Valve Assembly 1849
How to Remove EGR Valve Assembly 1849
How to Install EGR Valve Assembly 1852
Remove and Install EGR Cooler Assembly 1856
How to Remove EGR Cooler Assembly 1856
How to Install EGR Cooler Assembly 1858
Remove and Install Starter Assembly 1861
How to Remove Starting Motor Assembly 1861
How to Install Starting Motor Assembly 1863
How to Install Muffler 1865
How to Remove and Install Muffler 1865
How to Remove Muffler 1867
Remove and Install Alternator Belt 1871
How to Remove Alternator Belt 1871
How to Install Alternator Belt 1873
Remove and Install Fan Belt 1875
How to Remove Fan Belt 1875
How to Install Fan Belt 1877
Remove and Install Radiator Assembly 1880
How to Remove Radiator Assembly 1881
How to Install Radiator Assembly 1885
Remove and Install Hydraulic Oil Cooler Assembly 1889
How to Remove Hydraulic Oil Cooler Assembly 1889
How to Install Hydraulic Oil Cooler Assembly 1893
Remove and Install Aftercooler Assembly 1896
How to Remove Aftercooler Assembly 1896
How to Install Aftercooler Assembly 1899
Remove and Install Fan Clutch Assembly 1903
Remove Fan Clutch Assembly 1903
Install Fan Clutch Assembly 1908
Remove and Install Fan 1913
How to Remove Fan 1913
How to Install Fan 1913
Remove and Install Engine and Main Pump Assembly 1914
How to Remove Engine and Main Pump Assembly 1916
How to Install Engine and Main Pump Assembly 1931
Remove and Install Engine Front Oil Seal 1947
How to Remove Engine Front Oil Seal 1948
How to Install Engine Front Oil Seal 1950
Remove and Install Engine Rear Oil Seal 1953
How to Remove Engine Rear Oil Seal 1954
How to Install Engine Rear Oil Seal 1957
Remove and Install Engine Hood Assembly 1962
How to Remove Engine Hood Assembly 1962
How to Install Engine Hood Assembly 1966
Remove and Install Fuel Tank Assembly 1970
How to Remove Fuel Tank Assembly 1971
How to Install Fuel Tank Assembly 1975
Remove and Install Air Cleaner Assembly 1980
How to Remove Air Cleaner Assembly 1980
How to Install Air Cleaner Assembly 1982
Remove and Install Air Conditioner Condenser Assembly 1984
How to Remove Air Conditioner Condenser Assembly 1984
How to Install Air Conditioner Condenser Assembly 1986
Power Train 1988
Remove and Install Travel Motor and Final Drive Assembly 1988
How to Remove Travel Motor and Final Drive Assembly 1989
How to Install Travel Motor and Final Drive Assembly 1991
Disassemble and Assemble Final Drive Assembly 1993
How to Disassemble Final Drive Assembly 1994
How to Assemble Final Drive Assembly 1998
Remove and Install Swing Motor and Swing Machinery Assembly 2007
How to Remove Swing Motor and Swing Machinery Assembly 2008
How to Install Swing Motor and Swing Machinery Assembly 2010
Disassemble and Assemble Swing Machinery Assembly 2012
How to Disassemble Swing Machinery Assembly 2013
How to Assemble Swing Machinery Assembly 2017
Remove and Install Swing Circle Assembly 2025
How to Remove Swing Circle Assembly 2025
How to Install Swing Circle Assembly 2026
Undercarriage and Frame 2027
Separate and Connect Track Assembly 2027
How to Separate Track Assembly 2028
How to Install Track Assembly 2030
Remove and Install Sprocket 2033
How to Remove Sprocket 2033
How to Install Sprocket 2034
Remove and Install Idler and Idler Cushion Assembly 2035
How to Remove Idler and Idler Cushion Assembly 2035
How to Install Idler and Idler Cushion Assembly 2036
Disassemble and Assemble Idler Assembly 2038
How to Disassemble Idler Assembly 2038
How to Assemble Idler Assembly 2039
Disassemble and Assemble Idler Cushion Assembly 2043
How to Disassemble Idler Cushion Assembly 2044
How to Assemble Idler Cushion Assembly 2045
Disassemble and Assemble Track Roller Assembly 2047
How to Disassemble Track Roller Assembly 2048
How to Assemble Track Roller Assembly 2049
Disassemble and Assemble Carrier Roller Assembly 2051
How to Disassemble Carrier Roller Assembly 2051
How to Assemble Carrier Roller Assembly 2053
Remove and Install Revolving Frame Assembly 2056
How to Remove Revolving Frame Assembly 2057
How to Install Revolving Frame Assembly 2060
Remove and Install Counterweight Assembly 2063
How to Remove Counterweight Assembly 2063
How to Install Counterweight Assembly 2065
Hydraulic System 2067
Remove and Install Center Swivel Joint Assembly 2067
How to Remove Center Swivel Joint Assembly 2068
How to Install Center Swivel Joint Assembly 2071
Disassemble and Assemble Center Swivel Joint Assembly 2074
How to Disassemble Center Swivel Joint Assembly 2075
How to Assemble Center Swivel Joint Assembly 2075
Remove and Install Hydraulic Tank Assembly 2077
How to Remove Hydraulic Tank Assembly 2078
How to Install Hydraulic Tank Assembly 2084
Remove and Install Main Pump Assembly 2090
How to Remove Main Pump Assembly 2091
How to Install Main Pump Assembly 2096
Remove and Install Control Valve Assembly 2102
How to Remove Control Valve Assembly 2103
How to Install Control Valve Assembly 2112
Disassemble and Assemble Control Valve Assembly 2121
How to Replace Pressure Compensation Valve Seal Ring 2122
How to Assemble Control Valve Assembly 2123
Disassemble and Assemble Work Equipment PPC Valve Assembly 2128
How to Disassemble Work Equipment PPC Valve Assembly 2129
How to Assemble Work Equipment PPC Valve Assembly 2129
Disassemble and Assemble Travel PPC Valve Assembly 2131
How to Disassemble Travel PPC Valve Assembly 2131
How to Assemble Travel PPC Valve Assembly 2132
Work Equipment 2134
Remove and Install Work Equipment Assembly 2134
How to Remove Work Equipment Assembly 2136
How to Install Work Equipment Assembly 2139
Disassemble and Assemble Work Equipment Cylinder Assembly 2143
How to Disassemble Work Equipment Cylinder Assembly 2144
How to Assemble Work Equipment Cylinder Assembly 2147
CAB Related Parts 2153
Remove and Install Operator Cab Assembly 2153
How to Remove Operator Cab Assembly 2154
How to Install Operator Cab Assembly 2161
Remove and Install Operator Cab Glass (Adhered Glass) 2169
How to Remove Operator Cab Glass (Adhered Glass) 2171
How to Install Operator Cab Glass (Adhered Glass) 2171
Remove and Install Front Window Assembly 2182
How to Remove Front Window Assembly 2182
How to Install Front Window Assembly 2185
Remove and Install Floor Frame Assembly 2191
How to Remove Floor Frame Assembly 2192
How to Install Floor Frame Assembly 2197
Remove and Install Air Conditioner Unit Assembly 2204
How to Remove Air Conditioner Unit Assembly 2205
How to Install Air Conditioner Unit Assembly 2211
Remove and Install Operator Seat 2217
How to Remove Operator Seat 2217
How to Install Operator Seat 2220
How to Remove and Install Seat Belt 2223
How to Remove Seat Belt 2223
How to Install Seatbelt 2224
Remove and Install Work Equipment Control Lever Assembly 2225
How to Remove Work Equipment Control Lever Assembly 2225
How to Install Work Equipment Control Lever Assembly 2230
Remove and Install Front Wiper Assembly 2238
How to Remove Front Wiper Assembly 2239
How to Install Front Wiper Assembly 2245
Electrical System 2254
Remove and Install Engine Controller Assembly 2254
How to Remove Engine Controller Assembly 2254
How to Install Engine Controller Assembly 2256
Remove and Install Pump Controller Assembly 2257
How to Remove Pump Controller Assembly 2257
How to Install Pump Controller Assembly 2260
Remove and Install Machine Monitor Assembly 2263
How to Remove Machine Monitor Assembly 2264
How to Install Machine Monitor Assembly 2267
Remove and Install KOMTRAX Terminal Assembly 2271
How to Remove KOMTRAX Terminal Assembly 2271
How to Install KOMTRAX Terminal Assembly 2273
60 Maintenance Standard 2277
Table of Contents 2278
Engine and Cooling System 2279
Maintenance Standard for Engine Mount 2279
Maintenance Standard for Cooling System 2280
Power Train 2281
Maintenance Standard for Swing Circle 2281
Maintenance Standard for Swing Machinery 2283
Maintenance Standard for Final Drive 2285
Maintenance Standard for Sprocket 2287
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2288
Undercarriage and Frame 2289
Maintenance Standard for Track Frame and Idler Cushion 2289
Maintenance Standard for Idler 2291
Maintenance Standard for Track Roller 2293
Maintenance Standard for Carrier Roller 2295
Maintenance Standard for Track Shoes 2296
Maintenance Standard for Triple Shoes 2299
Hydraulic System 2300
Maintenance Standard for Main Pump 2300
Maintenance Standard for Swing Motor 2302
Maintenance Standard for Travel Motor 2305
Maintenance Standard for Control Valve 2308
Maintenance Standard for Work Equipment and Swing PPC Valve 2319
Maintenance Standard for Travel PPC Valve 2322
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2325
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2327
Maintenance Standard for Solenoid Valve 2328
Maintenance Standard for Attachment Circuit Selector Valve 2329
Maintenance Standard for Center Swivel Joint 2330
Work Equipment 2331
Maintenance Standard for Work Equipment Linkage 2331
Dimensions of Arm 2336
Dimensions of Bucket 2338
Maintenance Standard for Work Equipment Linkage (SE Specification) 2340
Dimension of Arm (SE Specification) 2345
Dimensions of Bucket (SE Specification) 2347
Maintenance Standard for Boom Cylinder 2349
Maintenance Standard for Arm Cylinder 2350
Maintenance Standard for Bucket Cylinder 2351
Maintenance Standard for Bucket Cylinder (SE Specification) 2352
80 Appendix 2353
Table of Contents 2354
Precautions Before Work 2356
Air Conditioner System 2357
Precautions for Refrigerant 2357
Air Conditioner Component 2358
Specifications of Air Conditioner 2360
Structure and Function of Refrigeration Cycle 2361
Outline of Refrigeration Cycle 2362
Component Parts of Air Conditioner System 2364
Air Conditioner Unit 2364
Configuration Diagram of Air Conditioner Unit 2364
Function of Air Conditioner Unit 2366
Component Parts of Air Conditioner Unit 2368
Function of Evaporator as Air Conditioner Unit Component 2369
Function of Heater Core as Air Conditioner Unit Component 2369
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2369
Function of Servo Motor as Air Conditioner Unit Component 2369
Structure of Expansion Valve as Air Conditioner Unit Component 2370
Function of Expansion Valve as Air Conditioner Unit Component 2370
Operate Expansion Valve as Air Conditioner Unit Component 2370
Function of Dual Pressure Switch 2371
Air Conditioner Controller 2372
Structure of Air Conditioner Controller 2372
Compressor 2373
Structure of Compressor 2373
Specifications of Compressor 2373
Function of Compressor 2373
Condenser 2374
Structure of Condenser 2374
Specifications of Condenser 2374
Function of Condenser 2374
Receiver Drier 2375
Structure of Receiver Dryer 2375
Specifications of Receiver Dryer 2375
Function of Receiver Dryer 2375
Air Conditioner Related Sensors 2376
Structure of Sunlight Sensor 2376
Function of Sunlight Sensor 2376
Structure of Outside Temperature Sensor 2376
Function of Outside Air Temperature Sensor 2376
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2378
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2380
System Diagram of Air Conditioner 2382
Input and Output Signals of Air Conditioner Controller 2383
Function of Air Conditioner Controller 2384
Locations of Air Conditioner Parts and Layout of Connectors 2385
Examine Air Leakage (Duct) 2389
How to Examine Air Leakage (Duct) 2389
Examine Air Conditioner with Self-Diagnosis Function 2391
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2392
Examine Vent (Mode) Changeover 2393
How to Examine Vent (Mode) Changeover 2393
Examine Fresh/Recirc Air Changeover 2395
How to Examine Fresh/Recirc Air Changeover 2395
Examine Sunlight Sensor 2396
How to Examine Sunlight Sensor 2396
Examine Refrigerant (Dual) Pressure Switch 2397
How to Examine Refrigerant (Dual) Pressure Switch 2397
Examine Relay 2398
How to Examine Relay 2398
Air Conditioner Troubleshooting Chart 1 2399
Air Conditioner Troubleshooting Chart 2 2400
Information Shown in Troubleshooting Table 2403
Failure Code [879AKA] 2404
Failure Code [879AKB] 2406
Failure Code [879CKA] 2408
Failure Code [879CKB] 2410
Failure Code [879FMC] 2412
Failure Code [879GKX] 2414
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2417
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2420
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2426
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2430
Troubleshooting by Gauge Pressure 2434
Connect Service Tool 2437
How to Connect Service Tool 2437
Precautions for Disconnection and Connection of Air Conditioner Piping 2439
Handle Compressor Oil 2441
90 Circuit Diagrams 2443
Table of Contents 2444
Hydraulic Circuit Diagram 2445
Symbols Used in Hydraulic Circuit Diagram 2445
Hydraulic Circuit Diagram (at Boom RAISE Operation) 2449
Hydraulic Circuit Diagram (at Left Swing Operation) 2451
Hydraulic Circuit Diagram (at Boom RAISE and Left Swing Operation) 2453
Hydraulic Circuit Diagram (1/2) 2455
Hydraulic Circuit Diagram (2/2) 2457
Electrical Circuit Diagram 2459
Symbols Used in Electric Circuit Diagram 2459
Electrical Circuit Diagram (1/7) 2463
Electrical Circuit Diagram (2/7) 2465
Electrical Circuit Diagram (3/7) 2467
Electrical Circuit Diagram (4/7) 2469
Electrical Circuit Diagram (5/7) 2471
Electrical Circuit Diagram (6/7) 2473
Electrical Circuit Diagram (7/7) 2475
Connector and Wiring Harness Chart 2477
Wiring Harness Diagram (1/15) 2479
Wiring Harness Diagram (2/15) 2481
Wiring Harness Diagram (3/15) 2483
Wiring Harness Diagram (4/15) 2485
Wiring Harness Diagram (5/15) 2487
Wiring Harness Diagram (6/15) 2489
Wiring Harness Diagram (7/15) 2491
Wiring Harness Diagram (8/15) 2493
Wiring Harness Diagram (9/15) 2495
Wiring Harness Diagram (10/15) 2497
Wiring Harness Diagram (11/15) 2499
Wiring Harness Diagram (12/15) 2501
Wiring Harness Diagram (13/15) 2503
Wiring Harness Diagram (14/15) 2505
Wiring Harness Diagram (15/15) 2507
Index 2509

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