Komatsu PC500LC-10R Hydraulic Excavator Shop Manual SEN06722-08 – PDF DOWNLOAD

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Komatsu PC500LC-10R Hydraulic Excavator Shop Manual SEN06722-08 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu PC500LC-10R Hydraulic Excavator Shop Manual SEN06722-08 – PDF DOWNLOAD

SERIAL NUMBERS 100001 and up

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

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TABLE OF CONTENTS:

Komatsu PC500LC-10R Hydraulic Excavator Shop Manual SEN06722-08 – PDF DOWNLOAD

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-10R 93
SPECIFICATION DRAWING: PC500LC-10R (SE SPECIFICATION) 94
WORKING RANGE DRAWINGS 95
WORKING RANGE: PC500LC-10R 95
WORKING RANGE: PC500LC-10R (SE SPECIFICATION) 96
SPECIFICATIONS 97
SPECIFICATIONS: PC500LC-10R 97
SPECIFICATIONS: PC500LC-10R (SE SPECIFICATION) 100
WEIGHT TABLE 103
WEIGHT TABLE: PC500LC-10R 103
WEIGHT TABLE: PC500LC-10R (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
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
BLOWBY PRESSURE SENSOR 141
COOLING SYSTEM 142
LAYOUT DRAWING OF COOLING SYSTEM 142
SPECIFICATIONS OF COOLING SYSTEM 143
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 144
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 144
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 145
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 146
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 146
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 146
COMPONENT PARTS OF COOLING SYSTEM 148
FAN CLUTCH 148
CONTROL SYSTEM 149
LAYOUT DRAWING OF CONTROL SYSTEM 149
MACHINE MONITOR SYSTEM 152
MACHINE MONITOR SYSTEM DIAGRAM 152
FUNCTION OF MACHINE MONITOR SYSTEM 152
KOMTRAX SYSTEM 154
KOMTRAX SYSTEM DIAGRAM 154
FUNCTION OF KOMTRAX SYSTEM 154
COMPONENT PARTS OF CONTROL SYSTEM 155
MACHINE MONITOR 155
REARVIEW CAMERA 169
KOMTRAX TERMINAL 170
PUMP CONTROLLER 172
RESISTOR FOR PC-EPC VALVE 177
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 209
ENGINE AND PUMP COMBINED CONTROL SYSTEM 213
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 213
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 214
PUMP AND VALVE CONTROL SYSTEM 219
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 219
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 220
COMPONENT PARTS OF HYDRAULIC SYSTEM 222
HYDRAULIC TANK 222
MAIN PUMP 225
CONTROL VALVE 252
WORK EQUIPMENT SYSTEM 315
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 315
ONE-TOUCH POWER MAXIMIZING SYSTEM 319
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 319
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 320
MACHINE PUSH-UP SYSTEM 321
MACHINE PUSH-UP SYSTEM DIAGRAM 321
FUNCTION OF MACHINE PUSH-UP SYSTEM 322
PPC LOCK SYSTEM 323
PPC LOCK SYSTEM DIAGRAM 323
FUNCTION OF PPC LOCK SYSTEM 323
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 324
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 324
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 324
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 325
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 326
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT 326
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 327
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 328
WORK EQUIPMENT AND SWING PPC VALVE 328
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 333
SOLENOID VALVE 341
ATTACHMENT CIRCUIT SELECTOR VALVE 344
PILOT CIRCUIT ACCUMULATOR 346
HYDRAULIC OIL ADDITIONAL FILTER WITH CLOGGING SWITCH 347
HYDRAULIC OIL ADDITIONAL FILTER CLOGGING SWITCH 347
SWING SYSTEM 348
LAYOUT DRAWING OF SWING SYSTEM 348
SWING CONTROL SYSTEM DIAGRAM 352
FUNCTION OF SWING CONTROL SYSTEM 352
COMPONENT PARTS OF SWING SYSTEM 356
SWING MOTOR 356
SWING MACHINERY 369
SWING CIRCLE 371
TRAVEL SYSTEM 374
LAYOUT DRAWING OF TRAVEL SYSTEM 374
TRAVEL CONTROL SYSTEM DIAGRAM 378
FUNCTION OF TRAVEL CONTROL SYSTEM 378
COMPONENT PARTS OF TRAVEL SYSTEM 380
TRAVEL MOTOR 380
FINAL DRIVE 393
TRAVEL PPC VALVE 395
CENTER SWIVEL JOINT 399
UNDERCARRIAGE AND FRAME 401
LAYOUT DRAWING OF UNDERCARRIAGE 401
SPECIFICATIONS OF UNDERCARRIAGE 401
WORK EQUIPMENT 402
STRUCTURE OF WORK EQUIPMENT 402
FUNCTION OF WORK EQUIPMENT 403
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 404
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 404
BUCKET CLEARANCE ADJUSTMENT SHIM 405
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 405
CAB AND ITS ATTACHMENTS 406
CAB 406
STRUCTURE OF CAB 406
CAB MOUNT 407
STRUCTURE OF CAB MOUNT 407
FUNCTION OF CAB MOUNT 407
CAB TIPPING STOPPER 408
STRUCTURE OF CAB TIPPING STOPPER 408
FUNCTION OF CAB TIPPING STOPPER 408
20 STANDARD VALUE TABLE 409
CONTENTS 410
ABBREVIATION LIST 411
STANDARD VALUE TABLE FOR ENGINE 417
STANDARD VALUE TABLE FOR ENGINE: PC500LC-10R 417
STANDARD VALUE TABLE FOR MACHINE 421
STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R 421
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 435
30 TESTING AND ADJUSTING 439
CONTENTS 440
ABBREVIATION LIST 443
RELATED INFORMATION ON TESTING AND ADJUSTING 449
TOOLS FOR TESTING AND ADJUSTING 449
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 454
ENGINE AND COOLING SYSTEM 456
TEST ENGINE SPEED 456
METHOD FOR TESTING ENGINE SPEED 456
TEST BOOST PRESSURE 459
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 459
METHOD FOR TESTING BOOST PRESSURE 460
TEST EXHAUST GAS TEMPERATURE 462
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 462
TEST EXHAUST GAS COLOR 464
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 464
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 465
TEST AND ADJUST VALVE CLEARANCE 466
METHOD FOR TESTING VALVE CLEARANCE 466
METHOD FOR ADJUSTING VALVE CLEARANCE 468
TEST COMPRESSION PRESSURE 469
METHOD FOR TESTING COMPRESSION PRESSURE 469
TEST BLOWBY PRESSURE 472
METHOD FOR TESTING BLOWBY PRESSURE ON MACHINE MONITOR 472
METHOD FOR TESTING BLOWBY PRESSURE BY TESTING TOOL 473
TEST ENGINE OIL PRESSURE 475
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 475
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 475
TEST FUEL PRESSURE 477
METHOD FOR TESTING FUEL PRESSURE 477
TEST FUEL RETURN RATE AND LEAKAGE 479
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 479
BLEED AIR FROM FUEL SYSTEM 482
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 482
TEST FUEL CIRCUIT FOR LEAKAGE 485
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 485
HANDLE CYLINDER CUT-OUT MODE OPERATION 487
HANDLE NO-INJECTION CRANKING OPERATION 488
TEST FAN BELT 489
METHOD FOR TESTING OF FAN BELT 489
TEST ALTERNATOR BELT 490
METHOD FOR TESTING ALTERNATOR BELT 490
TEST AUTOMATIC TENSIONER 492
METHOD FOR TESTING AUTOMATIC TENSIONER 492
TEST COOLING FAN SPEED 494
METHOD FOR TESTING COOLING FAN SPEED 494
POWER TRAIN 495
TEST SWING CIRCLE BEARING CLEARANCE 495
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 495
UNDERCARRIAGE AND FRAME 496
TEST AND ADJUST TRACK TENSION 496
METHOD FOR TESTING TRACK TENSION 496
METHOD FOR ADJUSTING TRACK TENSION 496
HYDRAULIC SYSTEM 498
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 498
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 498
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 498
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 500
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 500
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 501
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 502
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 509
TEST OIL PRESSURE OF CONTROL CIRCUIT 512
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 512
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 514
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 514
TEST PC-EPC VALVE OUTLET PRESSURE 515
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 516
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 518
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 518
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE 520
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 521
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 522
METHOD FOR ADJUSTING LS VALVE 523
TEST OUTLET PRESSURE OF SOLENOID VALVE 524
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 524
OPERATING CONDITION OF SOLENOID VALVE 525
TEST PPC VALVE OUTLET PRESSURE 528
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 528
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 531
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 531
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 532
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 532
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 532
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 533
TEST OIL LEAKAGE 534
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 534
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 534
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 535
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 535
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 536
BLEED AIR FROM HYDRAULIC CIRCUIT 537
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 539
TEST AND CHARGE ACCUMULATOR (MANUFACTURED BY HYDAC) NITROGEN GAS PRESSURE FOR ATTACHMENT (LOW PRESSURE SIDE) 542
TEST ACCUMULATOR (MANUFACTURED BY HYDAC) NITROGEN GAS PRESSURE FOR ATTACHMENT (LOW PRESSURE SIDE) 542
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH PRESSURE SIDE) 546
TEST ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH PRESSURE SIDE) 546
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ATTACHMENT PIPING 550
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ATTACHMENT PIPING 550
CAB AND ITS ATTACHMENTS 557
TEST CAB TIPPING STOPPER 557
METHOD FOR TESTING CAB TIPPING STOPPER 557
METHOD FOR ADJUSTING MIRRORS 558
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 558
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 559
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 560
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 561
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 563
PROCEDURE FOR ADJUSTING MACHINE REAR COUNTERWEIGHT MIRROR (D) 564
ELECTRICAL SYSTEM 565
SET AND OPERATE MACHINE MONITOR 565
OPERATOR MODE 568
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 568
CHECKING FUNCTION OF SERVICE METER 569
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 569
SERVICE MODE 571
METHOD FOR OPERATING SERVICE MODE 571
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 574
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 577
ABNORMALITY RECORD MENU 585
METHOD FOR CONFIRMING MAINTENANCE RECORD 589
METHOD FOR OPERATING MAINTENANCE MODE SETTING 591
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 595
DEFAULT MENU 596
DIAGNOSTIC TESTS MENU 604
ADJUSTMENT MENU 606
METHOD FOR PERFORMING NO-INJECTION CRANKING 619
KOMTRAX SETTINGS MENU 620
METHOD FOR DISPLAYING SERVICE MESSAGE 623
METHOD FOR STARTING UP KOMTRAX TERMINAL 625
ADJUST REARVIEW CAMERA ANGLE 630
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 630
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 633
HANDLE BATTERY DISCONNECT SWITCH 634
TEST DIODES 635
METHOD FOR TESTING DIODE USING DIGITAL TESTER 635
METHOD FOR TESTING DIODE USING ANALOG TESTER 635
Pm CLINIC 636
Pm CLINIC SERVICE 636
Pm CLINIC CHECK SHEET: PC500LC-10R 637
40 TROUBLESHOOTING 651
CONTENTS 652
ABBREVIATION LIST 659
RELATED INFORMATION ON TROUBLESHOOTING 665
GENERAL TROUBLESHOOTING POINTS 665
SEQUENCE OF EVENTS IN TROUBLESHOOTING 666
CHECKS BEFORE TROUBLESHOOTING 668
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 670
WALK-AROUND CHECK 670
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 672
CHECK FUEL LEVEL AND TYPE 672
CHECK FUEL LEVEL AND TYPE 673
CHECK IMPURE INGREDIENT IN FUEL 674
CHECK FUEL PREFILTER 674
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 674
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 675
FUEL PREFILTER CARTRIDGE – REPLACE 676
FUEL PREFILTER CARTRIDGE – REPLACE 677
CHECK MAIN FILTER 679
CHECK MAIN FILTER 681
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 683
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 684
CHECK COOLANT LEVEL (RESERVOIR TANK) 685
CHECK COOLANT LEVEL (RESERVOIR TANK) 686
CHECK CLOGGING OF AIR CLEANER 687
CHECK CLOGGING OF AIR CLEANER 687
OUTER ELEMENT – CLEAN 688
OUTER ELEMENT – CLEAN 690
ELEMENTS – REPLACE 692
ELEMENTS – REPLACE 693
CHECK HYDRAULIC OIL LEVEL 695
CHECK HYDRAULIC OIL LEVEL 696
CHECK HYDRAULIC OIL STRAINER 697
CHECK HYDRAULIC OIL STRAINER 697
CHECK HYDRAULIC FILTER 698
CHECK HYDRAULIC FILTER 699
CHECK OIL LEVEL IN SWING MACHINERY CASE 700
CHECK OIL LEVEL IN SWING MACHINERY CASE 700
CHECK OIL LEVEL IN DAMPER CASE 701
CHECK OIL LEVEL IN DAMPER CASE 702
CHECK OIL LEVEL IN FINAL DRIVE CASE 702
CHECK OIL LEVEL IN FINAL DRIVE CASE 703
BLEED AIR FROM FUEL SYSTEM 704
BLEED AIR FROM HYDRAULIC SYSTEM 704
ELECTRICAL EQUIPMENT – CHECK METHOD 704
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 709
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 709
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 709
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 709
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL 710
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 710
PROCEDURE FOR TESTING AND TROUBLESHOOTING 714
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 717
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 721
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 723
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE 726
CONNECTOR LAYOUT 779
CONNECTOR CONTACT IDENTIFICATION 785
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 825
FUSE LOCATION TABLE 831
FUSE LOCATION TABLE 833
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 835
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 839
FAILURE CODES TABLE 841
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 859
FAILURE CODE [602KNX] 859
FAILURE CODE [879AKA] 862
FAILURE CODE [879AKB] 864
FAILURE CODE [879BKA] 866
FAILURE CODE [879BKB] 870
FAILURE CODE [879CKA] 873
FAILURE CODE [879CKB] 875
FAILURE CODE [879DKZ] 877
FAILURE CODE [879EMC] 880
FAILURE CODE [879FMC] 882
FAILURE CODE [879GKX] 884
FAILURE CODE [989L00] 887
FAILURE CODE [989M00] 889
FAILURE CODE [989N00] 891
FAILURE CODE [A900FR] 892
FAILURE CODE [A900N6] 893
FAILURE CODE [A900NY] 894
FAILURE CODE [AA10NX] 895
FAILURE CODE [AB00KE] 897
FAILURE CODE [B@BAZG] 900
FAILURE CODE [B@BAZK] 904
FAILURE CODE [B@BCNS] 906
FAILURE CODE [B@BCQA] 910
FAILURE CODE [B@BCZK] 912
FAILURE CODE [CA111] 914
FAILURE CODE [CA115] 918
FAILURE CODE [CA122] 920
FAILURE CODE [CA123] 923
FAILURE CODE [CA131] 926
FAILURE CODE [CA132] 929
FAILURE CODE [CA135] 932
FAILURE CODE [CA141] 935
FAILURE CODE [CA144] 938
FAILURE CODE [CA145] 941
FAILURE CODE [CA153] 944
FAILURE CODE [CA154] 947
FAILURE CODE [CA187] 950
FAILURE CODE [CA221] 953
FAILURE CODE [CA222] 956
FAILURE CODE [CA227] 959
FAILURE CODE [CA234] 962
FAILURE CODE [CA238] 964
FAILURE CODE [CA263] 967
FAILURE CODE [CA265] 970
FAILURE CODE [CA271] 973
FAILURE CODE [CA272] 976
FAILURE CODE [CA273] 978
FAILURE CODE [CA274] 981
FAILURE CODE [CA322] 983
FAILURE CODE [CA323] 986
FAILURE CODE [CA324] 989
FAILURE CODE [CA325] 992
FAILURE CODE [CA331] 995
FAILURE CODE [CA332] 998
FAILURE CODE [CA342] 1001
FAILURE CODE [CA351] 1005
FAILURE CODE [CA352] 1010
FAILURE CODE [CA386] 1013
FAILURE CODE [CA441] 1016
FAILURE CODE [CA442] 1020
FAILURE CODE [CA449] 1024
FAILURE CODE [CA451] 1029
FAILURE CODE [CA452] 1032
FAILURE CODE [CA553] 1035
FAILURE CODE [CA554] 1038
FAILURE CODE [CA559] 1042
FAILURE CODE [CA689] 1049
FAILURE CODE [CA731] 1053
FAILURE CODE [CA757] 1056
FAILURE CODE [CA778] 1060
FAILURE CODE [CA2185] 1064
FAILURE CODE [CA2186] 1066
FAILURE CODE [CA2249] 1069
FAILURE CODE [CA2555] 1076
FAILURE CODE [CA2556] 1079
FAILURE CODE [D110KB] 1083
FAILURE CODE [D19JKZ] 1086
FAILURE CODE [D1N0KA] 1090
FAILURE CODE [D1N0KB] 1092
FAILURE CODE [D1N0KY] 1094
FAILURE CODE [D811MC] 1096
FAILURE CODE [D8ALKA] 1097
FAILURE CODE [D8ALKB] 1100
FAILURE CODE [D8AQKR] 1102
FAILURE CODE [DA20MC] 1109
FAILURE CODE [DA22KK] 1110
FAILURE CODE [DA25KP] 1114
FAILURE CODE [DA26KP] 1120
FAILURE CODE [DA29KQ] 1124
FAILURE CODE [DA2LKA] 1129
FAILURE CODE [DA2LKB] 1132
FAILURE CODE [DA2QKR] 1134
FAILURE CODE [DA2RKR] 1143
FAILURE CODE [DAF0MB] 1151
FAILURE CODE [DAF0MC] 1152
FAILURE CODE [DAF8KB] 1153
FAILURE CODE [DAF9KQ] 1157
FAILURE CODE [DAFGMC] 1159
FAILURE CODE [DAFLKA] 1160
FAILURE CODE [DAFLKB] 1163
FAILURE CODE [DAFQKR] 1165
FAILURE CODE [DAZ9KQ] 1173
FAILURE CODE [DAZQKR] 1175
FAILURE CODE [DB2QKR] 1181
FAILURE CODE [DDNRKA] 1189
FAILURE CODE [DDNRKY] 1193
FAILURE CODE [DDNS00] 1196
FAILURE CODE [DDPAKA] 1199
FAILURE CODE [DGH2KA] 1202
FAILURE CODE [DGH2KB] 1205
FAILURE CODE [DHA4KA] 1208
FAILURE CODE [DHE5MA] 1210
FAILURE CODE [DHPAMA] 1213
FAILURE CODE [DHPBMA] 1216
FAILURE CODE [DHS3MA] 1219
FAILURE CODE [DHS4MA] 1222
FAILURE CODE [DHS8MA] 1225
FAILURE CODE [DHS9MA] 1228
FAILURE CODE [DHSAMA] 1231
FAILURE CODE [DHSBMA] 1234
FAILURE CODE [DHSCMA] 1237
FAILURE CODE [DHSDMA] 1240
FAILURE CODE [DHSFMA] 1243
FAILURE CODE [DHSGMA] 1246
FAILURE CODE [DHSHMA] 1249
FAILURE CODE [DHSJMA] 1252
FAILURE CODE [DJG1KX] 1255
FAILURE CODE [DKR2MA] 1258
FAILURE CODE [DKR2NX] 1261
FAILURE CODE [DKULKA] 1263
FAILURE CODE [DKULKB] 1265
FAILURE CODE [DKULKY] 1268
FAILURE CODE [DLM5KA] 1270
FAILURE CODE [DLM5MB] 1273
FAILURE CODE [DR21KX] 1277
FAILURE CODE [DR31KX] 1281
FAILURE CODE [DUMBKA] 1285
FAILURE CODE [DUMBKB] 1288
FAILURE CODE [DV20KB] 1290
FAILURE CODE [DW43KA] 1292
FAILURE CODE [DW43KB] 1294
FAILURE CODE [DW43KY] 1297
FAILURE CODE [DW45KA] 1299
FAILURE CODE [DW45KB] 1303
FAILURE CODE [DW45KY] 1307
FAILURE CODE [DW4CKY] 1310
FAILURE CODE [DW91KA] 1312
FAILURE CODE [DW91KB] 1314
FAILURE CODE [DW91KY] 1317
FAILURE CODE [DWA2KA] 1319
FAILURE CODE [DWA2KB] 1321
FAILURE CODE [DWA2KY] 1324
FAILURE CODE [DWK0KA] 1326
FAILURE CODE [DWK0KB] 1328
FAILURE CODE [DWK0KY] 1331
FAILURE CODE [DWK2KA] 1333
FAILURE CODE [DWK2KB] 1335
FAILURE CODE [DWK2KY] 1338
FAILURE CODE [DWK8KA] 1340
FAILURE CODE [DWK8KB] 1342
FAILURE CODE [DWK8KY] 1345
FAILURE CODE [DWN5KA] 1347
FAILURE CODE [DWN5KB] 1350
FAILURE CODE [DWN5KY] 1352
FAILURE CODE [DXA8KA] 1354
FAILURE CODE [DXA8KB] 1357
FAILURE CODE [DXA9KA] 1361
FAILURE CODE [DXA9KB] 1364
FAILURE CODE [DXE0KA] 1368
FAILURE CODE [DXE0KB] 1370
FAILURE CODE [DXE4KA] 1373
FAILURE CODE [DXE4KB] 1375
FAILURE CODE [DXE4KY] 1378
FAILURE CODE [DXE5KA] 1380
FAILURE CODE [DXE5KB] 1382
FAILURE CODE [DXE6KA] 1385
FAILURE CODE [DXE6KB] 1387
FAILURE CODE [DY20KA] 1390
FAILURE CODE [DY20MA] 1393
FAILURE CODE [DY2CKB] 1396
FAILURE CODE [DY2DKB] 1400
FAILURE CODE [DY2EKB] 1403
FAILURE CODE [F@BBZL] 1406
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1408
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1408
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1418
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1423
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1427
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1432
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1437
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1439
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1441
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1442
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1443
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1445
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1448
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1449
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1450
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1452
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1453
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1454
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 1457
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1459
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1460
E-21 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 1462
E-22 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1463
E-23 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 1466
E-24 FUNCTION SWITCH DOES NOT OPERATE 1468
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 1469
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1471
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1472
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 1474
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1475
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 1476
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1477
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 1479
E-33 SERVICE MODE CANNOT BE SELECTED 1480
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1481
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 1485
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 1487
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 1490
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 1492
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 1496
E-40 HORN DOES NOT SOUND 1498
E-41 HORN DOES NOT STOP SOUNDING 1501
E-42 ALARM DOES NOT SOUND DURING TRAVEL 1503
E-43 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1506
E-44 ALARM BUZZER CANNOT BE CANCELED 1508
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 1509
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 1510
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1513
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1516
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1517
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1518
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1519
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1520
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1521
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1522
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1523
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1524
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED 1527
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1529
E-59 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 1531
E-60 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1535
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1538
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1538
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 1540
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1548
H-4 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1551
H-5 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 1558
H-6 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1560
H-7 TIME LAG OF WORK EQUIPMENT IS LARGE 1564
H-8 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 1570
H-9 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1573
H-10 ATTACHMENT CIRCUIT CANNOT BE CHANGED 1575
H-11 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 1577
H-12 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1579
H-13 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1581
H-14 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1582
H-15 MACHINE DOES NOT TRAVEL STRAIGHT 1583
H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 1595
H-17 TRAVEL SPEED IS LOW 1610
H-18 ONE OF TRACKS DOES NOT RUN 1619
H-19 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1629
H-20 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1632
H-21 SWINGS ONLY IN ONE DIRECTION 1636
H-22 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 1639
H-23 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1645
H-24 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1649
H-25 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1651
H-26 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 1655
H-27 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 1657
H-28 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 1660
H-29 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1662
H-30 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 1666
H-31 UNUSUAL NOISE IS HEARD FROM AROUND FAN 1667
H-32 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 1668
H-33 SPEED OR POWER OF BOOM IS LOW 1670
H-34 ARM SPEED OR POWER IS LOW 1681
H-35 BUCKET SPEED OR POWER IS LOW 1691
H-36 HYDRAULIC DRIFT OF BOOM IS LARGE 1700
H-37 HYDRAULIC DRIFT OF ARM IS LARGE 1702
H-38 HYDRAULIC DRIFT OF BUCKET IS LARGE 1706
TROUBLESHOOTING OF ENGINE (S-MODE) 1709
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1709
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1711
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1714
S-4 ENGINE STARTABILITY IS POOR 1718
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1723
S-6 ENGINE STOPS DURING OPERATION 1727
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1732
S-8 ENGINE LACKS POWER 1734
S-9 EXHAUST IS BLACK (INCOMPLETE COMBUSTION) 1740
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1744
S-11 OIL BECOMES CONTAMINATED QUICKLY 1748
S-12 FUEL CONSUMPTION IS EXCESSIVE 1751
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1753
S-14 OIL PRESSURE DROPS 1755
S-15 FUEL MIXES INTO ENGINE OIL 1760
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1762
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 1765
S-18 UNUSUAL NOISE IS HEARD 1768
S-19 VIBRATION IS EXCESSIVE 1772
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 1775
50 DISASSEMBLY AND ASSEMBLY 1777
CONTENTS 1778
ABBREVIATION LIST 1782
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1788
HOW TO READ THIS MANUAL 1788
COATING MATERIALS LIST 1790
SPECIAL TOOLS LIST 1794
SKETCHES OF SPECIAL TOOLS 1805
ENGINE AND COOLING SYSTEM 1811
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1811
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1812
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1818
REMOVE AND INSTALL INJECTOR ASSEMBLY 1826
METHOD FOR REMOVING INJECTOR ASSEMBLY 1827
METHOD FOR INSTALLING INJECTOR ASSEMBLY 1831
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 1840
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1841
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1850
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 1864
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 1864
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 1866
METHOD FOR INSTALLING MUFFLER 1868
REMOVE AND INSTALL MUFFLER 1868
METHOD FOR REMOVING MUFFLER 1870
REMOVE AND INSTALL ALTERNATOR BELT 1874
METHOD FOR REMOVING ALTERNATOR BELT 1874
METHOD FOR INSTALLING ALTERNATOR BELT 1876
REMOVE AND INSTALL FAN BELT 1878
METHOD FOR REMOVING FAN BELT 1878
METHOD FOR INSTALLING FAN BELT 1880
REMOVE AND INSTALL RADIATOR ASSEMBLY 1883
METHOD FOR REMOVING RADIATOR ASSEMBLY 1884
METHOD FOR INSTALLING RADIATOR ASSEMBLY 1888
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1892
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 1892
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 1896
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 1899
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 1899
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 1902
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 1906
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY 1906
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY 1911
REMOVE AND INSTALL FAN 1916
METHOD FOR INSTALLING FAN 1916
METHOD FOR REMOVING FAN 1916
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 1917
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY 1919
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY 1934
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 1950
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 1951
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 1953
REMOVE AND INSTALL ENGINE REAR OIL SEAL 1956
METHOD FOR REMOVING ENGINE REAR OIL SEAL 1957
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 1960
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 1965
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 1965
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 1969
REMOVE AND INSTALL FUEL TANK ASSEMBLY 1973
METHOD FOR REMOVING FUEL TANK ASSEMBLY 1974
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 1978
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 1983
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 1983
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 1985
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 1987
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 1987
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 1989
POWER TRAIN 1991
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1991
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1992
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1994
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 1996
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 1997
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2001
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2010
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2011
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2013
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2015
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 2016
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2020
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2028
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 2028
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 2029
UNDERCARRIAGE AND FRAME 2030
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2030
METHOD FOR SEPARATING TRACK ASSEMBLY 2030
METHOD FOR INSTALLING TRACK ASSEMBLY 2033
REMOVE AND INSTALL SPROCKET 2036
METHOD FOR REMOVING SPROCKET 2036
METHOD FOR INSTALLING SPROCKET 2037
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2038
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2038
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2039
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2041
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2041
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2042
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2046
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 2047
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2048
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2050
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2051
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2052
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 2054
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2054
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2056
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2059
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2060
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2063
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2066
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2066
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2068
HYDRAULIC SYSTEM 2070
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2070
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2071
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2074
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2077
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2078
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2078
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2080
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2081
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2087
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 2093
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2094
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2099
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2105
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2106
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2115
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 2124
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2125
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2126
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2131
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2132
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2132
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2134
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2134
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2135
WORK EQUIPMENT 2137
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2137
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2139
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2142
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2146
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2147
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2150
CAB AND ITS ATTACHMENTS 2156
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2156
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY 2157
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY 2164
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 2172
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2174
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2174
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2185
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 2185
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 2188
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 2194
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2195
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2200
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2207
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2208
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2214
REMOVE AND INSTALL OPERATOR’S SEAT 2220
METHOD FOR REMOVING OPERATOR’S SEAT 2220
METHOD FOR INSTALLING OPERATOR’S SEAT 2223
REMOVE AND INSTALL SEAT BELT 2226
METHOD FOR REMOVING SEAT BELT 2226
METHOD FOR INSTALLING SEAT BELT 2227
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 2228
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2229
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2235
ELECTRICAL SYSTEM 2244
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2244
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2244
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2246
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 2247
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2247
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2250
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2253
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2253
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2257
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2261
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2261
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2263
60 MAINTENANCE STANDARD 2267
CONTENTS 2268
ABBREVIATION LIST 2269
ENGINE AND COOLING SYSTEM 2275
MAINTENANCE STANDARD OF ENGINE MOUNT 2275
MAINTENANCE STANDARD OF COOLING SYSTEM 2276
POWER TRAIN 2277
MAINTENANCE STANDARD OF SWING CIRCLE 2277
MAINTENANCE STANDARD OF SWING MACHINERY 2279
MAINTENANCE STANDARD OF FINAL DRIVE 2281
MAINTENANCE STANDARD OF SPROCKET 2283
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 2284
UNDERCARRIAGE AND FRAME 2286
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2286
MAINTENANCE STANDARD OF IDLER 2288
MAINTENANCE STANDARD OF TRACK ROLLER 2290
MAINTENANCE STANDARD OF CARRIER ROLLER 2292
MAINTENANCE STANDARD OF TRACK SHOE 2293
MAINTENANCE STANDARD OF TRIPLE SHOE 2296
HYDRAULIC SYSTEM 2297
MAINTENANCE STANDARD OF MAIN PUMP 2297
MAINTENANCE STANDARD OF SWING MOTOR 2299
MAINTENANCE STANDARD OF TRAVEL MOTOR 2302
MAINTENANCE STANDARD OF CONTROL VALVE 2305
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2316
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2319
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2322
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2324
MAINTENANCE STANDARD OF SOLENOID VALVE 2326
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE 2327
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 2328
WORK EQUIPMENT 2329
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2329
DIMENSION OF ARM 2334
DIMENSIONS OF BUCKET 2336
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE (SE SPECIFICATION) 2338
DIMENSION OF ARM (SE SPECIFICATION) 2343
DIMENSIONS OF BUCKET (SE SPECIFICATION) 2345
MAINTENANCE STANDARD OF BOOM CYLINDER 2347
MAINTENANCE STANDARD OF ARM CYLINDER 2348
MAINTENANCE STANDARD OF BUCKET CYLINDER 2349
MAINTENANCE STANDARD OF BUCKET CYLINDER (SE SPECIFICATION) 2350
80 APPENDIX 2351
CONTENTS 2352
ABBREVIATION LIST 2354
AIR CONDITIONER SYSTEM 2360
PRECAUTIONS FOR REFRIGERANT 2360
AIR CONDITIONER COMPONENT 2361
SPECIFICATIONS OF AIR CONDITIONER 2363
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2364
OUTLINE OF REFRIGERATION CYCLE 2365
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2367
AIR CONDITIONER UNIT 2367
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2367
FUNCTION OF AIR CONDITIONER UNIT 2369
COMPONENT PARTS OF AIR CONDITIONER UNIT 2371
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2372
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2372
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2372
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 2372
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2373
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2373
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2373
FUNCTION OF DUAL PRESSURE SWITCH 2374
AIR CONDITIONER CONTROLLER 2375
STRUCTURE OF AIR CONDITIONER CONTROLLER 2375
COMPRESSOR 2376
STRUCTURE OF COMPRESSOR 2376
SPECIFICATIONS OF COMPRESSOR 2376
FUNCTION OF COMPRESSOR 2376
CONDENSER 2377
STRUCTURE OF CONDENSER 2377
SPECIFICATIONS OF CONDENSER 2377
FUNCTION OF CONDENSER 2377
RECEIVER DRIER 2378
STRUCTURE OF RECEIVER DRIER 2378
SPECIFICATIONS OF RECEIVER DRIER 2378
FUNCTION OF RECEIVER DRIER 2378
SENSORS FOR AIR CONDITIONER SYSTEM 2379
STRUCTURE OF SUNLIGHT SENSOR 2379
FUNCTION OF SUNLIGHT SENSOR 2379
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 2379
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2379
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2381
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2383
AIR CONDITIONER SYSTEM DIAGRAM 2385
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2386
FUNCTION OF AIR CONDITIONER CONTROLLER 2387
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2388
TESTING AIR LEAKAGE (DUCT) 2392
METHOD FOR TESTING AIR LEAKAGE (DUCT) 2392
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2394
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2395
TEST VENT (MODE) CHANGEOVER 2396
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2396
TESTING FRESH/RECIRC AIR CHANGEOVER 2398
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2398
TEST SUNLIGHT SENSOR 2399
METHOD FOR TESTING SUNLIGHT SENSOR 2399
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2400
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2400
TEST RELAYS 2401
METHOD FOR TESTING RELAYS 2401
AIR CONDITIONER TROUBLESHOOTING CHART 1 2402
AIR CONDITIONER TROUBLESHOOTING CHART 2 2403
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2406
FAILURE CODE [879AKA] 2408
FAILURE CODE [879AKB] 2410
FAILURE CODE [879CKA] 2412
FAILURE CODE [879CKB] 2414
FAILURE CODE [879FMC] 2416
FAILURE CODE [879GKX] 2418
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2421
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2424
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2430
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 2434
TROUBLESHOOTING USING GAUGE PRESSURE 2438
CONNECTION OF SERVICE TOOL 2441
METHOD FOR CONNECTING SERVICE TOOL 2441
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2443
HANDLE COMPRESSOR OIL 2445
90 CIRCUIT DIAGRAMS 2447
CONTENTS 2448
ABBREVIATION LIST 2449
HYDRAULIC CIRCUIT DIAGRAM 2455
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2455
HYDRAULIC CIRCUIT DIAGRAM (WHEN BOOM IS RAISED) 2459
HYDRAULIC CIRCUIT DIAGRAM (WHEN UPPER STRUCTURE IS SWING TO LEFT) 2461
HYDRAULIC CIRCUIT DIAGRAM (WHEN BOOM IS RAISED AND UPPER STRUCTURE IS SWUNG TO LEFT) 2463
HYDRAULIC CIRCUIT DIAGRAM (1/2) 2465
HYDRAULIC CIRCUIT DIAGRAM (2/2) 2467
ELECTRICAL CIRCUIT DIAGRAM 2469
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2469
ELECTRICAL CIRCUIT DIAGRAM (1/7) 2473
ELECTRICAL CIRCUIT DIAGRAM (2/7) 2475
ELECTRICAL CIRCUIT DIAGRAM (3/7) 2477
ELECTRICAL CIRCUIT DIAGRAM (4/7) 2479
ELECTRICAL CIRCUIT DIAGRAM (5/7) 2481
ELECTRICAL CIRCUIT DIAGRAM (6/7) 2483
ELECTRICAL CIRCUIT DIAGRAM (7/7) 2485
CONNECTOR AND WIRING HARNESS CHART 2487
CONNECTOR AND WIRING HARNESS CHART (1/15) 2489
CONNECTOR AND WIRING HARNESS CHART (2/15) 2491
CONNECTOR AND WIRING HARNESS CHART (3/15) 2493
CONNECTOR AND WIRING HARNESS CHART (4/15) 2495
CONNECTOR AND WIRING HARNESS CHART (5/15) 2497
CONNECTOR AND WIRING HARNESS CHART (6/15) 2499
CONNECTOR AND WIRING HARNESS CHART (7/15) 2501
CONNECTOR AND WIRING HARNESS CHART (8/15) 2503
CONNECTOR AND WIRING HARNESS CHART (9/15) 2505
CONNECTOR AND WIRING HARNESS CHART (10/15) 2507
CONNECTOR AND WIRING HARNESS CHART (11/15) 2509
CONNECTOR AND WIRING HARNESS CHART (12/15) 2511
CONNECTOR AND WIRING HARNESS CHART (13/15) 2513
CONNECTOR AND WIRING HARNESS CHART (14/15) 2515
CONNECTOR AND WIRING HARNESS CHART (15/15) 2517
INDEX 2519

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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