Komatsu PC500LC-10R Hydraulic Excavator Shop Manual SEN06722-11 PDF

Description

Komatsu PC500LC-10R Hydraulic Excavator Shop Manual SEN06722-11 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC500LC-10R Hydraulic Excavator Shop Manual SEN06722-11 – PDF DOWNLOAD 

Language : English
Pages : 2542
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC500LC-10R Hydraulic Excavator Shop Manual SEN06722-11 – 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.
• 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-10R Hydraulic Excavator Shop Manual SEN06722-11 – PDF DOWNLOAD 

SERIAL NUMBERS 100001 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 16
Foreword, Safety, Basic Information 22
How to Read the Shop Manual 22
Safety Notice for Operation 24
Precautions to Prevent Fire 32
Procedures If Fire Occurs 34
Precautions for Disposing of Waste Materials 35
Precautions When You Handle Hydraulic Equipment 36
Precautions When You Disconnect and Connect Pipings 39
Precautions When You Handle Electrical Equipment 45
Precautions When You Handle Fuel System Equipment 47
Precautions When You Handle Intake System Equipment 48
Practical Use of KOMTRAX 49
Disconnect and Connect Push-Pull Type Coupler 50
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 50
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 51
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 52
Precautions for Disconnection and Connection of Connectors 54
How to Disconnect and Connect Deutsch Connector 58
How to Disconnect and Connect Slide Lock Type Connector 59
How to Disconnect and Connect Connector with Lock to Pull 61
How to Disconnect and Connect Connector with Lock to Push 62
How to Disconnect and Connect Connector with Housing to Rotate 64
How to Read the Codes for Electric Cable 65
Explanation of Terms for Maintenance Standard 69
Standard Tightening Torque Table 72
Conversion Table 79
01 Specifications 85
Table of Contents 86
Abbreviation List 87
Specifications 93
Specification Drawing 93
Specification Drawing: PC500LC-10R 93
Specification Drawing: PC500LC-10R (For SE Spec) 94
Working Range Drawings 95
Working Range: PC500LC-10R 95
Working Range: PC500LC-10R (For SE Spec) 96
Specifications 97
Specifications: PC500LC-10R 97
Specifications: PC500LC-10R (For SE Spec) 100
Weight Table 103
Weight Table: PC500LC-10R 103
Weight Table: PC500LC-10R (For SE Spec) 105
Table of Fuel, Coolant, and Lubricants 107
10 Structure and Function 109
Table of Contents 110
Abbreviation List 113
Boot-up System 119
Layout Drawing of Boot-up System 119
System Operating Lamp System 121
System Diagram of System Operating Lamp System 121
Function of Operation 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
System Diagram of Engine Control 125
Function of Engine Control System 126
Auto-Deceleration System 128
System Diagram of Auto-Deceleration System 128
Function of Auto-Deceleration System 128
Operation of Auto-Deceleration System 129
Engine Automatic Warm-up System 130
System Diagram of Engine Automatic Warm-up System 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
System Diagram of Turbocharger Protection System 134
Function of Turbocharger Protection System 135
Automatic Idle Stop System 136
System Diagram of Automatic Idle Stop System 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
System Diagram of Machine Monitor System 152
Function of Machine Monitor System 152
KOMTRAX System 154
System Diagram of KOMTRAX System 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
System Diagram of One-Touch Power Maximizing System 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
System Diagram of PPC Lock 323
Function of PPC Lock System 323
Work Equipment and Travel Automatic Lock System 324
System Diagram of Lock Lever Automatic Lock System 324
Function of Work Equipment and Travel Automatic Lock System 324
Operation of Lock Lever Automatic Lock System 325
Attachment Oil Flow Adjuster System 326
Attachment Oil Flow Adjuster System Diagram 326
Function of Attachment Oil Flow Adjuster System 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
System Diagram of Travel Control System 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 Related Parts 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
Table of 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 Procedures to Measure Performance 435
30 Testing and Adjusting 439
Table of 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
Examine Engine Speed 456
How to Examine Engine Speed 456
Examine Boost Pressure 459
How to Examine Boost Pressure on Machine Monitor 459
How to Examine Boost Pressure by Testing Tool 460
Examine Exhaust Gas Temperature 462
How to Examine Exhaust Gas Temperature 462
Examine Exhaust Gas Color 464
How to Examine Exhaust Gas Color with the Handy Smoke Checker 464
How to Examine Exhaust Gas Color with Smoke Meter 465
Examine and Adjust Valve Clearance 466
How to Examine Valve Clearance 466
How to Adjust Valve Clearance 468
Examine Compression Pressure 469
How to Examine Compression Pressure 469
Examine Blowby Pressure 472
How to Examine Blowby Pressure on Machine Monitor 472
How to Examine Blowby Pressure by Testing Tool 473
Examine Engine Oil Pressure 474
How to Examine Engine Oil Pressure on Machine Monitor 474
How to Examine Engine Oil Pressure by Testing Tool 474
Examine Fuel Pressure 476
How to Examine Fuel Pressure 476
Examine Fuel Return Rate and Leakage 478
How to Examine Fuel Return Rate and Leakage 478
Bleed Air from Fuel System 481
How to Bleed Air from Fuel System 481
Examine Fuel Circuit for Leakage 484
How to Examine Fuel System for Leakage 484
Handle Cylinder Cut-out Mode Operation 486
Handle No-Injection Cranking Operation 487
Examine Fan Belt 488
How to Examine Fan Belt 488
Examine Alternator Belt 489
How to Examine Alternator Belt 489
Examine Automatic Tensioner 491
How to Examine Automatic Tensioner 491
Examine Cooling Fan Speed 493
How to Examine Cooling Fan Speed 493
Power Train 494
Examine Swing Circle Bearing Clearance 494
How to Examine Swing Circle Bearing Clearance 494
Undercarriage and Frame 495
Examine and Adjust Track Tension 495
How to Examine Track Tension 495
How to Adjust Track Tension 495
Hydraulic System 497
Release Remained Pressure in Hydraulic Circuit 497
How to Release Remained Pressure from Hydraulic Tank 497
How to Release Remained Pressure in Hydraulic Cylinder Circuit 497
How to Release Remained Pressure from Swing Motor Circuit 499
How to Release Remained Pressure from Travel Motor Circuit 499
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 500
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 501
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 508
Examine Oil Pressure of Control Circuit 511
How to Examine Oil Pressure in Control Circuit 511
Examine and adjust oil pressure in pump PC control circuit 513
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 513
Examine PC-EPC Valve Outlet Pressure 514
How to Adjust Oil Pressure in Pump PC Control Circuit 515
Examine and Adjust Oil Pressure in Pump LS Control Circuit 517
How to Examine LS Differential Pressure with Machine Monitor 517
How to Examine LS Differential Pressure by Testing Tool 519
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 520
How to Examine LS-EPC Valve Outlet Pressure 521
How to Adjust LS Valve 522
Examine Outlet Pressure of Solenoid Valve 523
How to Examine Outlet Pressure of Solenoid Valve 523
Operating Condition of Solenoid Valve 524
Examine PPC Valve Outlet Pressure 527
How to Examine Outlet Pressure in PPC Valve 527
Adjust Play of Work Equipment and Swing PPC Valves 530
How to Adjust Play of Work Equipment and Swing PPC Valves 530
Examine Parts Which Cause Hydraulic Drift of Work Equipment 531
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 531
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 531
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 532
Examine Oil Leakage 533
How to Examine Oil Leakage from Boom Cylinder 533
How to Examine Oil Leakage from Arm Cylinder 533
How to Examine Oil Leakage from Bucket Cylinder 534
How to Examine Oil Leakage from Swing Motor 534
How to Examine Oil Leakage from Travel Motor 535
Bleed Air from Hydraulic System 536
How to Bleed Air from Hydraulic System 538
Examine and Charge Accumulator (Made by HYDAC) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 541
How to Examine Accumulator (Made by HYDAC) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 541
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 545
How to Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 545
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 549
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 549
CAB Related Parts 556
Examine CAB Tipping Stopper 556
How to Examine Cab Tipping Stopper 556
How to Adjust Mirrors 557
Procedure to Adjust Machine Left Front Mirror (A) 557
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 558
Procedure to Adjust Machine Right Front Mirror (B) 559
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 560
Procedure to Adjust Machine Right Side Mirror (C) 561
Procedure to Adjust Machine Rear Counterweight Mirror (D) 562
Electrical System 564
Set and Operate Machine Monitor 564
Operator Mode 567
Examine Function by LCD (Liquid Crystal Display) 567
Examine Function of Service Meter 568
Usage Limitation and Maintenance Password Change Function 568
Service Mode 570
How to Operate Service Mode 570
How to See Pre-defined Monitoring Information 573
How to Examine Self-Define Monitor Information 576
Abnormality Record Menu 584
How to See Maintenance Record 588
Maintenance Mode Setting 589
How to Set Phone Number Entry 593
Default Menu 594
Diagnostic Tests Menu 602
Adjustment Menu 604
No-Injection Cranking Operation 617
KOMTRAX Settings Menu 618
How to Show Service Message 621
How to Start Up KOMTRAX Terminal 623
Adjust Rearview Camera Angle 628
How to Adjust Rearview Camera Angle 628
Handle Voltage Circuit of Engine Controller 631
Handle Battery Disconnect Switch 632
Examine Diodes 633
How to Examine Diodes by Digital Tester 633
How to Examine Diodes by Analog Tester 633
Pm Clinic 634
Pm Clinic Service 634
Pm Clinic Check Sheet: PC500LC-10R 635
40 Troubleshooting 649
Table of Contents 650
Abbreviation List 657
Related Information to Troubleshooting 663
General Troubleshooting Points 663
Sequence of Events in Troubleshooting 664
Checks Before Troubleshooting 666
Inspection Procedure Before Troubleshooting 668
Walk-Around Check 668
Test in Accordance with Testing Procedure 670
Examine Fuel Level and Type 670
Examine Fuel Level and Type 671
Examine for Impure Ingredient in Fuel 672
Examine Fuel Prefilter 672
Examine Water Separator, Drain Water and Sediment 672
Examine Water Separator, Drain Water and Sediment 673
Replace Fuel Prefilter Cartridge 674
Replace Fuel Prefilter Cartridge 675
Examine Fuel Main Filter 677
Examine Fuel Main Filter 679
Examine Engine Oil Level (Oil Quantity in Oil Pan) 681
Examine Engine Oil Level (Oil Quantity in Oil Pan) 682
Examine Coolant Level (Reservoir Tank) 683
Examine Coolant Level (Reservoir Tank) 684
Examine Air Cleaner Clogging 685
Examine Air Cleaner Clogging 685
Clean Outer Element 686
Clean Outer Element 688
Replace Element 690
Replace Element 691
Examine Hydraulic Oil Level 693
Examine Hydraulic Oil Level 694
Examine Hydraulic Oil Strainer 695
Examine Hydraulic Oil Strainer 695
Examine Hydraulic Oil Filter 696
Examine Hydraulic Oil Filter 697
Examine Oil Level in Swing Machinery Case 698
Examine Oil Level in Swing Machinery Case 698
Examine Oil Level in Damper Case 699
Examine Oil Level in Damper Case 700
Examine Oil Level in Final Drive Case 700
Examine Oil Level in Final Drive Case 701
Bleed Air from Fuel System 702
Bleed Air from Hydraulic System 702
How to Examine Electric Equipment 702
Preparation for Troubleshooting of Electrical System 707
Preparation for Troubleshooting of Machine Monitor 707
Preparation for Troubleshooting of Engine Controller 707
Preparation for Troubleshooting of Pump Controller 707
Preparation for Troubleshooting of KOMTRAX Terminal 708
How to Disconnect and Connect Connector with a Special Lock 708
Procedure for Troubleshooting 712
Symptom and Troubleshooting Numbers 715
Information Shown in Troubleshooting Table 719
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 721
Connector and Wiring Harness Identification Table 724
Connector Layout 777
Connector Contact Connection Table 783
T-Branch Box and T-Branch Adapter Table 823
Fuse Location Table 829
Fuse Location Table 831
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 833
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 837
Failure Code Table 839
Troubleshooting by Failure Code (Display of Code) 857
Failure Code [602KNX] 857
Failure Code [879AKA] 860
Failure Code [879AKB] 862
Failure Code [879BKA] 864
Failure Code [879BKB] 868
Failure Code [879CKA] 871
Failure Code [879CKB] 873
Failure Code [879DKZ] 875
Failure Code [879EMC] 878
Failure Code [879FMC] 880
Failure Code [879GKX] 882
Failure Code [989L00] 885
Failure Code [989M00] 887
Failure Code [989N00] 889
Failure Code [A900FR] 890
Failure Code [A900N6] 891
Failure Code [A900NY] 892
Failure Code [AA10NX] 893
Failure Code [AB00KE] 895
Failure Code [B@BAZG] 898
Failure Code [B@BAZK] 902
Failure Code [B@BCNS] 904
Failure Code [B@BCQA] 908
Failure Code [B@BCZK] 910
Failure Code [CA111] 912
Failure Code [CA115] 916
Failure Code [CA122] 918
Failure Code [CA123] 921
Failure Code [CA131] 924
Failure Code [CA132] 927
Failure Code [CA135] 930
Failure Code [CA141] 933
Failure Code [CA144] 936
Failure Code [CA145] 939
Failure Code [CA153] 942
Failure Code [CA154] 945
Failure Code [CA187] 948
Failure Code [CA221] 951
Failure Code [CA222] 954
Failure Code [CA227] 957
Failure Code [CA234] 960
Failure Code [CA238] 962
Failure Code [CA263] 965
Failure Code [CA265] 968
Failure Code [CA271] 971
Failure Code [CA272] 974
Failure Code [CA273] 976
Failure Code [CA274] 979
Failure Code [CA322] 981
Failure Code [CA323] 984
Failure Code [CA324] 987
Failure Code [CA325] 990
Failure Code [CA331] 993
Failure Code [CA332] 996
Failure Code [CA342] 999
Failure Code [CA351] 1003
Failure Code [CA352] 1008
Failure Code [CA386] 1011
Failure Code [CA441] 1014
Failure Code [CA442] 1018
Failure Code [CA449] 1022
Failure Code [CA451] 1027
Failure Code [CA452] 1030
Failure Code [CA553] 1033
Failure Code [CA554] 1036
Failure Code [CA559] 1040
Failure Code [CA689] 1047
Failure Code [CA731] 1051
Failure Code [CA757] 1054
Failure Code [CA778] 1058
Failure Code [CA2185] 1062
Failure Code [CA2186] 1064
Failure Code [CA2249] 1067
Failure Code [CA2555] 1074
Failure Code [CA2556] 1077
Failure Code [D110KB] 1081
Failure Code [D19JKZ] 1084
Failure Code [D1N0KA] 1088
Failure Code [D1N0KB] 1090
Failure Code [D1N0KY] 1092
Failure Code [D811MC] 1094
Failure Code [D8ALKA] 1095
Failure Code [D8ALKB] 1098
Failure Code [D8AQKR] 1100
Failure Code [DA20MC] 1107
Failure Code [DA22KK] 1108
Failure Code [DA25KP] 1112
Failure Code [DA26KP] 1118
Failure Code [DA29KQ] 1122
Failure Code [DA2LKA] 1127
Failure Code [DA2LKB] 1130
Failure Code [DA2QKR] 1132
Failure Code [DA2RKR] 1141
Failure Code [DAF0MB] 1149
Failure Code [DAF0MC] 1150
Failure Code [DAF8KB] 1151
Failure Code [DAF9KQ] 1155
Failure Code [DAFGMC] 1157
Failure Code [DAFLKA] 1158
Failure Code [DAFLKB] 1161
Failure Code [DAFQKR] 1163
Failure Code [DAZ9KQ] 1171
Failure Code [DAZQKR] 1173
Failure Code [DB2QKR] 1179
Failure Code [DDNRKA] 1187
Failure Code [DDNRKY] 1191
Failure Code [DDNS00] 1194
Failure Code [DDPAKA] 1197
Failure Code [DGH2KA] 1200
Failure Code [DGH2KB] 1203
Failure Code [DHA4KA] 1206
Failure Code [DHE5MA] 1208
Failure Code [DHPAMA] 1211
Failure Code [DHPBMA] 1214
Failure Code [DHS3MA] 1217
Failure Code [DHS4MA] 1220
Failure Code [DHS8MA] 1223
Failure Code [DHS9MA] 1226
Failure Code [DHSAMA] 1229
Failure Code [DHSBMA] 1232
Failure Code [DHSCMA] 1235
Failure Code [DHSDMA] 1238
Failure Code [DHSFMA] 1241
Failure Code [DHSGMA] 1244
Failure Code [DHSHMA] 1247
Failure Code [DHSJMA] 1250
Failure Code [DJG1KX] 1253
Failure Code [DKR2MA] 1256
Failure Code [DKR2NX] 1259
Failure Code [DKULKA] 1261
Failure Code [DKULKB] 1263
Failure Code [DKULKY] 1266
Failure Code [DLM5KA] 1268
Failure Code [DLM5MB] 1271
Failure Code [DR21KX] 1275
Failure Code [DR31KX] 1279
Failure Code [DUMBKA] 1283
Failure Code [DUMBKB] 1286
Failure Code [DV20KB] 1288
Failure Code [DW43KA] 1290
Failure Code [DW43KB] 1292
Failure Code [DW43KY] 1295
Failure Code [DW45KA] 1297
Failure Code [DW45KB] 1301
Failure Code [DW45KY] 1305
Failure Code [DW4CKY] 1308
Failure Code [DW91KA] 1310
Failure Code [DW91KB] 1312
Failure Code [DW91KY] 1315
Failure Code [DWA2KA] 1317
Failure Code [DWA2KB] 1319
Failure Code [DWA2KY] 1322
Failure Code [DWK0KA] 1324
Failure Code [DWK0KB] 1326
Failure Code [DWK0KY] 1329
Failure Code [DWK2KA] 1331
Failure Code [DWK2KB] 1333
Failure Code [DWK2KY] 1336
Failure Code [DWK8KA] 1338
Failure Code [DWK8KB] 1340
Failure Code [DWK8KY] 1343
Failure Code [DWN5KA] 1345
Failure Code [DWN5KB] 1348
Failure Code [DWN5KY] 1350
Failure Code [DXA8KA] 1352
Failure Code [DXA8KB] 1355
Failure Code [DXA9KA] 1359
Failure Code [DXA9KB] 1362
Failure Code [DXE0KA] 1366
Failure Code [DXE0KB] 1368
Failure Code [DXE4KA] 1371
Failure Code [DXE4KB] 1373
Failure Code [DXE4KY] 1376
Failure Code [DXE5KA] 1378
Failure Code [DXE5KB] 1380
Failure Code [DXE6KA] 1383
Failure Code [DXE6KB] 1385
Failure Code [DY20KA] 1388
Failure Code [DY20MA] 1391
Failure Code [DY2CKB] 1394
Failure Code [DY2DKB] 1398
Failure Code [DY2EKB] 1401
Failure Code [F@BBZL] 1404
Troubleshooting of Electrical System (E-Mode) 1406
E-1 Engine Does Not Start (Engine Does Not Crank) 1406
E-2 Manual Preheating System Does Not Operate 1416
E-3 Automatic Preheating System Does Not Operate 1421
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1425
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1430
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1435
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1437
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1439
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1440
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1441
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1443
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1446
E-13 Water Separator Monitor Comes On in Red While Engine Runs 1447
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1448
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1450
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1451
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 1452
E-18 Display of Fuel Gauge is Different from Actual Fuel Level 1455
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1457
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1458
E-21 Some Areas of Machine Monitor Screen are Not Shown 1460
E-22 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 1461
E-23 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1464
E-24 Function Switch Does Not Operate 1466
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 1467
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1469
E-27 Auto-Decelerator is Not Operated or Canceled with Lever 1470
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1472
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1473
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1474
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 1475
E-32 Service Meter is Not Shown, While Starting Switch is in OFF Position 1477
E-33 Service Mode Cannot be Selected 1478
E-34 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 1479
E-35 All Work Equipment, Swing and Travel Do Not Lock 1483
E-36 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 1485
E-37 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 1488
E-38 One-Touch Power Maximizing Function Does Not Operate Correctly, or Indicator Not Shown on Monitor 1490
E-39 One-Touch Power Maximizing Function is Not Cancelled 1494
E-40 Horn Does Not Sound 1496
E-41 Horn Does Not Stop 1499
E-42 Alarm Does Not Sound During Travel 1501
E-43 Travel Alarm Does Not Stop When Machine Stops 1504
E-44 Alarm Buzzer Cannot be Canceled 1506
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 1507
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 1508
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 1511
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 1514
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 1515
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function 1516
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 1517
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 1518
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function 1519
E-54 “Swing” is Not Shown Correctly with Monitoring Function 1520
E-55 “Travel” is Not Shown Correctly with Monitoring Function 1521
E-56 Service is Not Shown Correctly with Monitoring Function 1522
E-57 Attachment Hydraulic Circuit Cannot be Changed 1525
E-58 KOMTRAX System Does Not Operate Correctly 1527
R-55 Machine Push-Up Function is Not Canceled 1529
E-60 Machine Push-Up Function Does Not Operate 1533
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1536
H-1 All Work Equipment, Swing and Travel Do Not Work 1536
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 1538
H-3 Fine Control Performance or Response is Unsatisfactory 1546
H-4 Engine Speed Drops Largely or Engine Stops 1549
H-5 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 1556
H-6 Work Equipment Does Not Move in Single Operation 1558
H-7 Time Lag of Work Equipment is Large 1562
H-8 One-Touch Power Maximizing Function Does Not Operate 1568
H-9 Machine Push-Up Function Does Not Operate 1571
H-10 Attachment Circuit Cannot be Changed 1573
H-11 Oil Flow in Attachment Circuit Cannot be Changed 1575
H-12 In Mixed Operation of Work Equipment, Equipment with Heavier Load Moves Slower 1577
H-13 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely 1579
H-14 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low 1580
H-15 Machine Does Not Travel Straight 1581
H-16 Machine is Not Steered Correctly or Steering Power is Low 1593
H-17 Travel Speed is Low 1608
H-18 One of Tracks Does Not Run 1617
H-19 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 1627
H-20 Upper Structure Does Not Swing to the Right and Left 1630
H-21 Swings Only in One Direction 1634
H-22 Swing Acceleration or Swing Speed is Low in Lateral Directions (Right and Left) 1637
H-23 Swing Acceleration Performance is Unsatisfactory or Swing Speed is Slow in Only One Direction 1643
H-24 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 1647
H-25 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction, Right or Left) 1649
H-26 Shock is Large When Upper Structure Stops Swing Operation 1653
H-27 There is Large Unusual Noise When It Stops Swing Operation 1655
H-28 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 1658
H-29 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 1660
H-30 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1664
H-31 Unusual Noise is Heard from Around Fan 1665
H-32 Unusual Noise is Heard from Around Hydraulic Pump 1666
H-33 Speed or Power of Boom is Low 1668
H-34 Arm Speed or Power is Low 1679
H-35 Bucket Speed or Power is Low 1689
H-36 Hydraulic Drift of Boom is Large 1698
H-37 Hydraulic Drift of Arm is Large 1700
H-38 Hydraulic Drift of Bucket is Large 1704
Troubleshooting of Engine (S-Mode) 1707
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 1707
S-2 Engine Cranks but No Exhaust Smoke Comes Out 1709
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1712
S-4 Engine Startability is Unsatisfactory 1716
S-5 Engine Does Not Pick Up Smoothly 1721
S-6 Engine Stops During Operation 1725
S-7 Engine Runs Rough or is Not Stable 1730
S-8 Engine Lacks Power 1732
S-9 Exhaust is Black (Incomplete Combustion) 1738
S-10 Engine Oil Consumption is Excessive 1742
S-11 Oil Becomes Dirty Quickly 1746
S-12 Fuel Consumption is Excessive 1749
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 1751
S-14 Oil Pressure Drops 1753
S-15 Fuel Mixes Into Engine Oil 1758
S-16 Water Mixes Into Engine Oil (Milky) 1760
S-17 Coolant Temperature Increases Too High (Overheating) 1763
S-18 Unusual Noise is Heard 1766
S-19 Vibration is Excessive 1770
S-20 Air Cannot be Bled from Fuel Circuit 1773
50 Disassembly and Assembly 1775
Table of Contents 1776
Abbreviation List 1780
Related Information on Disassembly and Assembly 1786
How to Read This Manual 1786
Coating Materials List 1787
Special Tool List 1792
Sketches of Special Tools 1803
Engine and Cooling System 1809
Remove and Install Supply Pump Assembly 1809
How to Remove Supply Pump Assembly 1810
How to Install Supply Pump Assembly 1816
Remove and Install Injector Assembly 1824
How to Remove Injector Assembly 1825
How to Install Injector Assembly 1829
Remove and Install Cylinder Head Assembly 1838
How to Remove Cylinder Head Assembly 1839
How to Install Cylinder Head Assembly 1848
Remove and Install Starter Assembly 1862
How to Remove Starting Motor Assembly 1862
How to Install Starting Motor Assembly 1864
How to Install Muffler 1866
How to Remove and Install Muffler 1866
How to Remove Muffler 1868
Remove and Install Alternator Belt 1872
How to Remove Alternator Belt 1872
How to Install Alternator Belt 1874
Remove and Install Fan Belt 1876
How to Remove Fan Belt 1876
How to Install Fan Belt 1878
Remove and Install Radiator Assembly 1881
How to Remove Radiator Assembly 1882
How to Install Radiator Assembly 1886
Remove and Install Hydraulic Oil Cooler Assembly 1890
How to Remove Hydraulic Oil Cooler Assembly 1890
How to Install Hydraulic Oil Cooler Assembly 1894
Remove and Install Aftercooler Assembly 1897
How to Remove Aftercooler Assembly 1897
How to Install Aftercooler Assembly 1900
Remove and Install Fan Clutch Assembly 1904
Remove Fan Clutch Assembly 1904
Install Fan Clutch Assembly 1909
Remove and Install Fan 1914
How to Remove Fan 1914
How to Install Fan 1914
Remove and Install Engine and Main Pump Assembly 1915
How to Remove Engine and Main Pump Assembly 1917
How to Install Engine and Main Pump Assembly 1932
Remove and Install Engine Front Oil Seal 1948
How to Remove Engine Front Oil Seal 1949
How to Install Engine Front Oil Seal 1951
Remove and Install Engine Rear Oil Seal 1954
How to Remove Engine Rear Oil Seal 1955
How to Install Engine Rear Oil Seal 1958
Remove and Install Engine Hood Assembly 1963
How to Remove Engine Hood Assembly 1963
How to Install Engine Hood Assembly 1967
Remove and Install Fuel Tank Assembly 1971
How to Remove Fuel Tank Assembly 1972
How to Install Fuel Tank Assembly 1976
Remove and Install Air Cleaner Assembly 1981
How to Remove Air Cleaner Assembly 1981
How to Install Air Cleaner Assembly 1983
Remove and Install Air Conditioner Condenser Assembly 1985
How to Remove Air Conditioner Condenser Assembly 1985
How to Install Air Conditioner Condenser Assembly 1987
Power Train 1989
Remove and Install Travel Motor and Final Drive Assembly 1989
How to Remove Travel Motor and Final Drive Assembly 1990
How to Install Travel Motor and Final Drive Assembly 1992
Disassemble and Assemble Final Drive Assembly 1994
How to Disassemble Final Drive Assembly 1995
How to Assemble Final Drive Assembly 1999
Remove and Install Swing Motor and Swing Machinery Assembly 2008
How to Remove Swing Motor and Swing Machinery Assembly 2009
How to Install Swing Motor and Swing Machinery Assembly 2011
Disassemble and Assemble Swing Machinery Assembly 2013
How to Disassemble Swing Machinery Assembly 2014
How to Assemble Swing Machinery Assembly 2018
Remove and Install Swing Circle Assembly 2026
How to Remove Swing Circle Assembly 2026
How to Install Swing Circle Assembly 2027
Undercarriage and Frame 2028
Separate and Connect Track Assembly 2028
How to Separate Track Assembly 2028
How to Install Track Assembly 2031
Remove and Install Sprocket 2034
How to Remove Sprocket 2034
How to Install Sprocket 2035
Remove and Install Idler and Idler Cushion Assembly 2036
How to Remove Idler and Idler Cushion Assembly 2036
How to Install Idler and Idler Cushion Assembly 2037
Disassemble and Assemble Idler Assembly 2039
How to Disassemble Idler Assembly 2039
How to Assemble Idler Assembly 2040
Disassemble and Assemble Idler Cushion Assembly 2044
How to Disassemble Idler Cushion Assembly 2045
How to Assemble Idler Cushion Assembly 2046
Disassemble and Assemble Track Roller Assembly 2048
How to Disassemble Track Roller Assembly 2049
How to Assemble Track Roller Assembly 2050
Disassemble and Assemble Carrier Roller Assembly 2052
How to Disassemble Carrier Roller Assembly 2052
How to Assemble Carrier Roller Assembly 2054
Remove and Install Revolving Frame Assembly 2057
How to Remove Revolving Frame Assembly 2058
How to Install Revolving Frame Assembly 2061
Remove and Install Counterweight Assembly 2064
How to Remove Counterweight Assembly 2064
How to Install Counterweight Assembly 2066
Hydraulic System 2068
Remove and Install Center Swivel Joint Assembly 2068
How to Remove Center Swivel Joint Assembly 2069
How to Install Center Swivel Joint Assembly 2072
Disassemble and Assemble Center Swivel Joint Assembly 2075
How to Disassemble Center Swivel Joint Assembly 2076
How to Assemble Center Swivel Joint Assembly 2076
Remove and Install Hydraulic Tank Assembly 2078
How to Remove Hydraulic Tank Assembly 2079
How to Install Hydraulic Tank Assembly 2085
Remove and Install Main Pump Assembly 2091
How to Remove Main Pump Assembly 2092
How to Install Main Pump Assembly 2097
Remove and Install Control Valve Assembly 2103
How to Remove Control Valve Assembly 2104
How to Install Control Valve Assembly 2113
Disassemble and Assemble Control Valve Assembly 2122
How to Replace Pressure Compensation Valve Seal Ring 2123
How to Assemble Control Valve Assembly 2124
Disassemble and Assemble Work Equipment PPC Valve Assembly 2129
How to Disassemble Work Equipment PPC Valve Assembly 2130
How to Assemble Work Equipment PPC Valve Assembly 2130
Disassemble and Assemble Travel PPC Valve Assembly 2132
How to Disassemble Travel PPC Valve Assembly 2132
How to Assemble Travel PPC Valve Assembly 2133
Work Equipment 2135
Remove and Install Work Equipment Assembly 2135
How to Remove Work Equipment Assembly 2137
How to Install Work Equipment Assembly 2140
Disassemble and Assemble Work Equipment Cylinder Assembly 2144
How to Disassemble Work Equipment Cylinder Assembly 2145
How to Assemble Work Equipment Cylinder Assembly 2148
CAB Related Parts 2154
Remove and Install Operator Cab Assembly 2154
How to Remove Operator Cab Assembly 2155
How to Install Operator Cab Assembly 2162
Remove and Install Operator Cab Glass (Adhered Glass) 2170
How to Remove Operator Cab Glass (Adhered Glass) 2172
How to Install Operator Cab Glass (Adhered Glass) 2172
Remove and Install Front Window Assembly 2183
How to Remove Front Window Assembly 2183
How to Install Front Window Assembly 2186
Remove and Install Floor Frame Assembly 2192
How to Remove Floor Frame Assembly 2193
How to Install Floor Frame Assembly 2198
Remove and Install Air Conditioner Unit Assembly 2205
How to Remove Air Conditioner Unit Assembly 2206
How to Install Air Conditioner Unit Assembly 2212
Remove and Install Operator Seat 2218
How to Remove Operator Seat 2218
How to Install Operator Seat 2221
How to Remove and Install Seat Belt 2224
How to Remove Seat Belt 2224
How to Install Seatbelt 2225
Remove and Install Work Equipment Control Lever Assembly 2226
How to Remove Work Equipment Control Lever Assembly 2226
How to Install Work Equipment Control Lever Assembly 2231
Remove and Install Front Wiper Assembly 2239
How to Remove Front Wiper Assembly 2240
How to Install Front Wiper Assembly 2246
Electrical System 2255
Remove and Install Engine Controller Assembly 2255
How to Remove Engine Controller Assembly 2255
How to Install Engine Controller Assembly 2257
Remove and Install Pump Controller Assembly 2258
How to Remove Pump Controller Assembly 2258
How to Install Pump Controller Assembly 2261
Remove and Install Machine Monitor Assembly 2264
How to Remove Machine Monitor Assembly 2264
How to Install Machine Monitor Assembly 2268
Remove and Install KOMTRAX Terminal Assembly 2272
How to Remove KOMTRAX Terminal Assembly 2272
How to Install KOMTRAX Terminal Assembly 2274
60 Maintenance Standard 2277
Table of Contents 2278
Abbreviation List 2279
Engine and Cooling System 2285
Maintenance Standard for Engine Mount 2285
Maintenance Standard for Cooling System 2286
Power Train 2287
Maintenance Standard for Swing Circle 2287
Maintenance Standard for Swing Machinery 2289
Maintenance Standard for Final Drive 2291
Maintenance Standard for Sprocket 2293
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2294
Undercarriage and Frame 2295
Maintenance Standard for Track Frame and Idler Cushion 2295
Maintenance Standard for Idler 2297
Maintenance Standard for Track Roller 2299
Maintenance Standard for Carrier Roller 2301
Maintenance Standard for Track Shoes 2302
Maintenance Standard for Triple Shoes 2305
Hydraulic System 2306
Maintenance Standard for Main Pump 2306
Maintenance Standard for Swing Motor 2308
Maintenance Standard for Travel Motor 2311
Maintenance Standard for Control Valve 2314
Maintenance Standard for Work Equipment and Swing PPC Valve 2325
Maintenance Standard for Travel PPC Valve 2328
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2331
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2333
Maintenance Standard for Solenoid Valve 2334
Maintenance Standard for Attachment Circuit Selector Valve 2335
Maintenance Standard for Center Swivel Joint 2336
Work Equipment 2337
Maintenance Standard for Work Equipment Linkage 2337
Dimensions of Arm 2342
Dimensions of Bucket 2344
Maintenance Standard for Work Equipment Linkage (SE Specification) 2346
Dimension of Arm (SE Specification) 2351
Dimensions of Bucket (SE Specification) 2353
Maintenance Standard for Boom Cylinder 2355
Maintenance Standard for Arm Cylinder 2356
Maintenance Standard for Bucket Cylinder 2357
Maintenance Standard for Bucket Cylinder (SE Specification) 2358
80 Appendix 2359
Table of Contents 2360
Abbreviation List 2362
Air Conditioner System 2368
Precautions for Refrigerant 2368
Air Conditioner Component 2369
Specifications of Air Conditioner 2371
Structure and Function of Refrigeration Cycle 2372
Outline of Refrigeration Cycle 2373
Component Parts of Air Conditioner System 2375
Air Conditioner Unit 2375
Configuration Diagram of Air Conditioner Unit 2375
Function of Air Conditioner Unit 2377
Component Parts of Air Conditioner Unit 2379
Function of Evaporator as Air Conditioner Unit Component 2380
Function of Heater Core as Air Conditioner Unit Component 2380
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2380
Function of Servo Motor as Air Conditioner Unit Component 2380
Structure of Expansion Valve as Air Conditioner Unit Component 2381
Function of Expansion Valve as Air Conditioner Unit Component 2381
Operate Expansion Valve as Air Conditioner Unit Component 2381
Function of Dual Pressure Switch 2382
Air Conditioner Controller 2383
Structure of Air Conditioner Controller 2383
Compressor 2384
Structure of Compressor 2384
Specifications of Compressor 2384
Function of Compressor 2384
Condenser 2385
Structure of Condenser 2385
Specifications of Condenser 2385
Function of Condenser 2385
Receiver Drier 2386
Structure of Receiver Dryer 2386
Specifications of Receiver Dryer 2386
Function of Receiver Dryer 2386
Air Conditioner Related Sensors 2387
Structure of Sunlight Sensor 2387
Function of Sunlight Sensor 2387
Structure of Outside Temperature Sensor 2387
Function of Outside Air Temperature Sensor 2387
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2389
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2391
System Diagram of Air Conditioner 2393
Input and Output Signals of Air Conditioner Controller 2394
Function of Air Conditioner Controller 2395
Locations of Air Conditioner Parts and Layout of Connectors 2396
Examine Air Leakage (Duct) 2400
How to Examine Air Leakage (Duct) 2400
Examine Air Conditioner with Self-Diagnosis Function 2402
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2403
Examine Vent (Mode) Changeover 2404
How to Examine Vent (Mode) Changeover 2404
Examine Fresh/Recirc Air Changeover 2406
How to Examine Fresh/Recirc Air Changeover 2406
Examine Sunlight Sensor 2407
How to Examine Sunlight Sensor 2407
Examine Refrigerant (Dual) Pressure Switch 2408
How to Examine Refrigerant (Dual) Pressure Switch 2408
Examine Relay 2409
How to Examine Relay 2409
Air Conditioner Troubleshooting Chart 1 2410
Air Conditioner Troubleshooting Chart 2 2411
Information Shown in Troubleshooting Table 2414
Failure Code [879AKA] 2415
Failure Code [879AKB] 2417
Failure Code [879CKA] 2419
Failure Code [879CKB] 2421
Failure Code [879FMC] 2423
Failure Code [879GKX] 2425
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2428
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2431
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2437
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2441
Troubleshooting by Gauge Pressure 2445
Connect Service Tool 2448
How to Connect Service Tool 2448
Precautions for Disconnection and Connection of Air Conditioner Piping 2450
Handle Compressor Oil 2452
90 Circuit Diagrams 2455
Table of Contents 2456
Abbreviation List 2457
Hydraulic Circuit Diagram 2463
Symbols Used in Hydraulic Circuit Diagram 2463
Hydraulic Circuit Diagram (at Boom RAISE Operation) 2467
Hydraulic Circuit Diagram (at Left Swing Operation) 2469
Hydraulic Circuit Diagram (at Boom RAISE and Left Swing Operation) 2471
Hydraulic Circuit Diagram (1/2) 2473
Hydraulic Circuit Diagram (2/2) 2475
Electrical Circuit Diagram 2477
Symbols Used in Electric Circuit Diagram 2477
Electrical Circuit Diagram (1/7) 2481
Electrical Circuit Diagram (2/7) 2483
Electrical Circuit Diagram (3/7) 2485
Electrical Circuit Diagram (4/7) 2487
Electrical Circuit Diagram (5/7) 2489
Electrical Circuit Diagram (6/7) 2491
Electrical Circuit Diagram (7/7) 2493
Connector and Wiring Harness Chart 2495
Wiring Harness Diagram (1/15) 2497
Wiring Harness Diagram (2/15) 2499
Wiring Harness Diagram (3/15) 2501
Wiring Harness Diagram (4/15) 2503
Wiring Harness Diagram (5/15) 2505
Wiring Harness Diagram (6/15) 2507
Wiring Harness Diagram (7/15) 2509
Wiring Harness Diagram (8/15) 2511
Wiring Harness Diagram (9/15) 2513
Wiring Harness Diagram (10/15) 2515
Wiring Harness Diagram (11/15) 2517
Wiring Harness Diagram (12/15) 2519
Wiring Harness Diagram (13/15) 2521
Wiring Harness Diagram (14/15) 2523
Wiring Harness Diagram (15/15) 2525
Index 2527

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