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KOMATSU PC650LC-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06603-07 – PDF DOWNLOAD
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KOMATSU PC650LC-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06603-07 – PDF DOWNLOAD
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KOMATSU PC650LC-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06603-07 – PDF DOWNLOAD
Language : English
Pages : 2692
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC650LC-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06603-07 – PDF DOWNLOAD
COVER.................................................................................................................................... 1 00 INDEX AND FOREWORD................................................................................................................... 3 INDEX............................................................................................................................... 4 ABBREVIATION LIST................................................................................................................... 21 FOREWORD, SAFETY, BASIC INFORMATION................................................................................................. 27 HOW TO READ THE SHOP MANUAL..................................................................................................... 27 SAFETY NOTICE FOR OPERATION..................................................................................................... 29 PRECAUTIONS TO PREVENT FIRE..................................................................................................... 37 ACTIONS IF FIRE OCCURS.......................................................................................................... 39 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS.................................................................................... 40 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS................................................................................... 41 PRECAUTIONS FOR DEF............................................................................................................. 42 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING.............................................................................. 42 PRECAUTIONS FOR ADDING...................................................................................................... 42 PRECAUTIONS FOR STORING..................................................................................................... 42 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE..................................................................................... 42 THE OTHER PRECAUTIONS....................................................................................................... 42 STORE AdBlue/DEF................................................................................................................ 43 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT.................................................................................... 44 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS......................................................................... 47 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT................................................................................... 54 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT.................................................................................. 56 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT................................................................................ 57 PRACTICAL USE OF KOMTRAX........................................................................................................ 58 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER................................................................................... 59 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER....................................................... 59 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER....................................................... 60 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER....................................................... 61 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...................................................................... 63 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR....................................................................... 67 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR............................................................... 68 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL............................................................. 70 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH............................................................. 71 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE........................................................ 73 HOW TO READ ELECTRICAL WIRE CODE................................................................................................ 74 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................................................... 78 STANDARD TIGHTENING TORQUE TABLE................................................................................................ 81 CONVERSION TABLE................................................................................................................ 88 01 SPECIFICATIONS....................................................................................................................... 93 CONTENTS............................................................................................................................ 94 ABBREVIATION LIST................................................................................................................... 95 SPECIFICATIONS...................................................................................................................... 101 SPECIFICATION DRAWING........................................................................................................... 101 SPECIFICATION DRAWING: PC650LC-11........................................................................................... 101 WORKING RANGE DRAWINGS.......................................................................................................... 103 WORKING RANGE: PC650LC-11................................................................................................... 103 SPECIFICATIONS.................................................................................................................. 104 SPECIFICATIONS: PC650LC-11.................................................................................................. 104 WEIGHT TABLE.................................................................................................................... 107 WEIGHT TABLE: PC650LC-11.................................................................................................... 107 TABLE OF FUEL, COOLANT, AND LUBRICANTS.......................................................................................... 109 10 STRUCTURE AND FUNCTION............................................................................................................... 111 CONTENTS............................................................................................................................ 112 ABBREVIATION LIST................................................................................................................... 115 UREA SCR SYSTEM..................................................................................................................... 121 LAYOUT DRAWING OF UREA SCR SYSTEM............................................................................................... 121 UREA SCR SYSTEM DIAGRAM......................................................................................................... 126 FUNCTION OF UREA SCR SYSTEM..................................................................................................... 127 FUNCTION OF AdBlue/DEF SYSTEM............................................................................................... 127 INDUCEMENT STRATEGY......................................................................................................... 129 COMPONENT PARTS OF UREA SCR SYSTEM.............................................................................................. 136 AdBlue/DEF MIXING TUBE...................................................................................................... 136 SCR ASSEMBLY................................................................................................................ 137 AdBlue/DEF TANK............................................................................................................. 139 AdBlue/DEF PUMP............................................................................................................. 141 AdBlue/DEF INJECTOR......................................................................................................... 142 AdBlue/DEF HOSE............................................................................................................. 143 AdBlue/DEF TANK HEATING VALVE............................................................................................... 144 BOOT-UP SYSTEM...................................................................................................................... 145 LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................................ 145 SYSTEM OPERATING LAMP SYSTEM.................................................................................................... 146 SYSTEM OPERATING LAMP SYSTEM DIAGRAM........................................................................................ 146 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM.................................................................................... 146 BATTERY DISCONNECT SWITCH....................................................................................................... 147 FUNCTION OF BATTERY DISCONNECT SWITCH....................................................................................... 147 ENGINE SYSTEM....................................................................................................................... 148 LAYOUT DRAWING OF ENGINE SYSTEM................................................................................................. 148 FUNCTION OF ENGINE SYSTEM................................................................................................... 149 ENGINE CONTROL SYSTEM........................................................................................................... 150 ENGINE CONTROL SYSTEM DIAGRAM............................................................................................... 150 FUNCTION OF ENGINE CONTROL SYSTEM........................................................................................... 150 AUTO-DECELERATION SYSTEM........................................................................................................ 153 AUTO-DECELERATION SYSTEM DIAGRAM............................................................................................ 153 FUNCTION OF AUTO-DECELERATION SYSTEM........................................................................................ 153 OPERATION OF AUTO-DECELERATION SYSTEM....................................................................................... 154 AUTOMATIC LOW IDLE SYSTEM....................................................................................................... 155 AUTOMATIC LOW IDLE SYSTEM DIAGRAM........................................................................................... 155 FUNCTION OF AUTOMATIC LOW IDLE SYSTEM....................................................................................... 155 OPERATION OF AUTOMATIC LOW IDLE SYSTEM...................................................................................... 156 ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................................. 157 ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM..................................................................................... 157 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................. 159 OVERHEAT PREVENTION SYSTEM...................................................................................................... 160 OVERHEAT PREVENTION SYSTEM DIAGRAM.......................................................................................... 160 FUNCTION OF OVERHEAT PREVENTION SYSTEM...................................................................................... 161 TURBOCHARGER PROTECTION SYSTEM.................................................................................................. 162 TURBOCHARGER PROTECTION SYSTEM DIAGRAM...................................................................................... 162 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM.................................................................................. 163 AUTOMATIC IDLE STOP SYSTEM...................................................................................................... 164 AUTOMATIC IDLE STOP SYSTEM DIAGRAM.......................................................................................... 164 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...................................................................................... 164 COMPONENT PARTS OF ENGINE SYSTEM................................................................................................ 167 PTO......................................................................................................................... 167 VGT......................................................................................................................... 168 EGR SYSTEM.................................................................................................................. 172 EGR VALVE................................................................................................................... 174 EGR COOLER.................................................................................................................. 176 KCCV SYSTEM................................................................................................................. 177 KCCV VENTILATOR............................................................................................................. 179 KDPF........................................................................................................................ 181 COOLING SYSTEM...................................................................................................................... 185 LAYOUT DRAWING OF COOLING SYSTEM................................................................................................ 185 SPECIFICATIONS OF COOLING SYSTEM............................................................................................ 186 FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN....................................................................................... 187 FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN........................................................................... 187 FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN....................................................................... 188 ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN................................................................................... 189 ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN....................................................................... 189 FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN................................................................... 189 FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN.................................................................................... 191 FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN........................................................................ 191 FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN.................................................................... 191 COMPONENT PARTS OF COOLING SYSTEM............................................................................................... 192 COOLING FAN PUMP............................................................................................................ 192 COOLING FAN MOTOR........................................................................................................... 200 CONTROL SYSTEM...................................................................................................................... 207 LAYOUT DRAWING OF CONTROL SYSTEM................................................................................................ 207 MACHINE MONITOR SYSTEM.......................................................................................................... 209 MACHINE MONITOR SYSTEM DIAGRAM.............................................................................................. 209 FUNCTION OF MACHINE MONITOR SYSTEM.......................................................................................... 209 KomVision SYSTEM................................................................................................................ 211 LAYOUT DRAWING OF KOMVISION SYSTEM.......................................................................................... 211 KomVision SYSTEM DIAGRAM.................................................................................................... 213 FUNCTION OF KomVision SYSTEM................................................................................................ 214 KOMTRAX SYSTEM.................................................................................................................. 216 KOMTRAX SYSTEM DIAGRAM...................................................................................................... 216 FUNCTION OF KOMTRAX SYSTEM.................................................................................................. 216 COMPONENT PARTS OF CONTROL SYSTEM............................................................................................... 217 MACHINE MONITOR............................................................................................................. 217 KomVision CONTROLLER........................................................................................................ 232 KomVision CAMERA............................................................................................................ 236 KOMTRAX TERMINAL............................................................................................................ 237 PUMP CONTROLLER............................................................................................................. 239 RESISTOR FOR TVC VALVE...................................................................................................... 244 CAN TERMINATING RESISTOR.................................................................................................... 245 ENGINE CONTROLLER........................................................................................................... 246 FUEL CONTROL DIAL........................................................................................................... 253 FUEL FEED PUMP.............................................................................................................. 255 FUEL FEED PUMP SWITCH....................................................................................................... 256 HYDRAULIC SYSTEM.................................................................................................................... 257 LAYOUT DRAWING OF HYDRAULIC SYSTEM.............................................................................................. 257 OLSS............................................................................................................................ 260 STRUCTURE OF OLSS........................................................................................................... 260 FUNCTION OF OLSS............................................................................................................ 260 PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL................................................................................... 262 ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................................... 273 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM............................................................................. 273 FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................... 275 COMPONENT PARTS OF HYDRAULIC SYSTEM............................................................................................. 278 HYDRAULIC TANK.............................................................................................................. 278 MAIN PUMP................................................................................................................... 280 CONTROL VALVE............................................................................................................... 308 VARIABLE BACK PRESSURE VALVE................................................................................................ 329 WORK EQUIPMENT SYSTEM............................................................................................................... 332 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM......................................................................................... 332 ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................................... 338 ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM................................................................................... 338 FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................... 339 MACHINE PUSH-UP SYSTEM.......................................................................................................... 340 MACHINE PUSH-UP SYSTEM DIAGRAM.............................................................................................. 340 FUNCTION OF MACHINE PUSH-UP SYSTEM.......................................................................................... 341 BOOM SHOCKLESS CONTROL FUNCTION................................................................................................. 342 BOOM SHOCKLESS CONTROL FUNCTION SYSTEM DIAGRAM.............................................................................. 342 OPERATION OF BOOM SHOCKLESS CONTROL FUNCTION................................................................................ 342 PPC LOCK SYSTEM................................................................................................................. 343 PPC LOCK SYSTEM DIAGRAM..................................................................................................... 343 FUNCTION OF PPC LOCK SYSTEM................................................................................................. 343 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................................. 344 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM..................................................................... 344 FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................. 344 OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................ 345 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM........................................................................................ 346 WORK EQUIPMENT AND SWING PPC VALVE.......................................................................................... 346 1ST-LINE ATTACHMENT PPC VALVE............................................................................................... 351 PPC SHUTTLE VALVE........................................................................................................... 353 SOLENOID VALVE.............................................................................................................. 354 PILOT CIRCUIT ACCUMULATOR................................................................................................... 357 SWING SYSTEM........................................................................................................................ 358 LAYOUT DRAWING OF SWING SYSTEM.................................................................................................. 358 SWING CONTROL SYSTEM DIAGRAM.................................................................................................... 361 FUNCTION OF SWING CONTROL SYSTEM............................................................................................ 362 COMPONENT PARTS OF SWING SYSTEM................................................................................................. 365 SWING MOTOR................................................................................................................. 365 SWING MACHINERY............................................................................................................. 377 SWING CIRCLE................................................................................................................ 379 TRAVEL SYSTEM....................................................................................................................... 380 LAYOUT DRAWING OF TRAVEL SYSTEM................................................................................................. 380 TRAVEL CONTROL SYSTEM DIAGRAM................................................................................................... 384 FUNCTION OF TRAVEL CONTROL SYSTEM........................................................................................... 386 COMPONENT PARTS OF TRAVEL SYSTEM................................................................................................ 387 TRAVEL MOTOR................................................................................................................ 387 FINAL DRIVE................................................................................................................. 400 TRAVEL PPC VALVE............................................................................................................ 402 CENTER SWIVEL JOINT......................................................................................................... 406 UNDERCARRIAGE AND FRAME............................................................................................................. 408 LAYOUT DRAWING OF UNDERCARRIAGE................................................................................................. 408 SPECIFICATIONS OF UNDERCARRIAGE............................................................................................. 408 WORK EQUIPMENT...................................................................................................................... 409 STRUCTURE OF WORK EQUIPMENT..................................................................................................... 409 FUNCTION OF WORK EQUIPMENT...................................................................................................... 410 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................................ 411 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................ 411 BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................................ 412 FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................ 412 CAB AND ITS ATTACHMENTS............................................................................................................. 413 ROPS CAB........................................................................................................................ 413 STRUCTURE OF ROPS CAB....................................................................................................... 413 FUNCTION OF ROPS CAB........................................................................................................ 413 CAB MOUNT....................................................................................................................... 414 STRUCTURE OF CAB MOUNT...................................................................................................... 414 FUNCTION OF CAB MOUNT....................................................................................................... 414 CAB TIPPING STOPPER............................................................................................................. 415 STRUCTURE OF CAB TIPPING STOPPER............................................................................................ 415 FUNCTION OF CAB TIPPING STOPPER............................................................................................. 415 20 STANDARD VALUE TABLE................................................................................................................. 417 CONTENTS............................................................................................................................ 418 ABBREVIATION LIST................................................................................................................... 419 STANDARD VALUE TABLE FOR ENGINE..................................................................................................... 425 STANDARD VALUE TABLE FOR ENGINE: PC650LC-11..................................................................................... 425 STANDARD VALUE TABLE FOR MACHINE.................................................................................................... 430 STANDARD VALUE TABLE FOR MACHINE: PC650LC-11.................................................................................... 430 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE......................................................................... 447 30 TESTING AND ADJUSTING................................................................................................................ 451 CONTENTS............................................................................................................................ 452 ABBREVIATION LIST................................................................................................................... 455 RELATED INFORMATION ON TESTING AND ADJUSTING........................................................................................ 461 TOOLS FOR TESTING AND ADJUSTING................................................................................................. 461 SKETCH OF TOOLS FOR TESTING AND ADJUSTING....................................................................................... 470 ENGINE AND COOLING SYSTEM........................................................................................................... 471 TEST ENGINE SPEED............................................................................................................... 471 METHOD FOR TESTING ENGINE SPEED............................................................................................. 471 TEST BOOST PRESSURE............................................................................................................. 474 METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR........................................................................ 474 METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL........................................................................... 475 TEST EXHAUST GAS TEMPERATURE.................................................................................................... 476 METHOD FOR TESTING EXHAUST GAS TEMPERATURE.................................................................................. 476 TEST EXHAUST GAS COLOR.......................................................................................................... 478 METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER................................................................. 478 METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER......................................................................... 479 TEST AND ADJUST VALVE CLEARANCE................................................................................................. 481 METHOD FOR TESTING VALVE CLEARANCE.......................................................................................... 481 METHOD FOR ADJUSTING VALVE CLEARANCE........................................................................................ 482 TEST COMPRESSION PRESSURE....................................................................................................... 484 METHOD FOR TESTING COMPRESSION PRESSURE..................................................................................... 484 TEST BLOWBY PRESSURE............................................................................................................ 487 METHOD FOR TESTING BLOWBY PRESSURE.......................................................................................... 487 TEST ENGINE OIL PRESSURE........................................................................................................ 489 METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR................................................................... 489 METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL...................................................................... 489 TEST EGR VALVE AND VGT OIL PRESSURE............................................................................................. 491 METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE........................................................................... 491 TEST FUEL PRESSURE.............................................................................................................. 493 METHOD FOR TESTING FUEL PRESSURE............................................................................................ 493 TEST FUEL RETURN RATE AND LEAKAGE............................................................................................... 495 METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE............................................................................. 495 BLEED AIR FROM FUEL SYSTEM...................................................................................................... 498 METHOD FOR BLEEDING AIR FROM FUEL SYSTEM.................................................................................... 498 TEST FUEL CIRCUIT FOR LEAKAGE................................................................................................... 500 METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE................................................................................. 500 HANDLE CYLINDER CUT-OUT MODE OPERATION.......................................................................................... 502 HANDLE NO-INJECTION CRANKING OPERATION.......................................................................................... 503 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION......................................................................... 504 METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT......................................................................... 504 CLEAN FUEL DOSER................................................................................................................ 505 METHOD FOR CLEANING FUEL DOSER.............................................................................................. 505 WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER.......................................................................... 507 METHOD FOR WRITING INJECTOR COMPENSATION VALUE.............................................................................. 507 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER.................................................................. 513 METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER................................................. 513 TEST SCR RELATED FUNCTIONS...................................................................................................... 514 TEST AdBlue/DEF PUMP RAISED PRESSURE........................................................................................ 518 TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR.............................................................................. 521 TEST AdBlue/DEF LINE HEATER RELAY 1......................................................................................... 526 TEST AdBlue/DEF LINE HEATER RELAY 2......................................................................................... 530 TEST AdBlue/DEF PUMP HEATER RELAY........................................................................................... 533 TEST AdBlue/DEF TANK HEATER VALVE........................................................................................... 536 TEST DENITRATION EFFICIENCY OF SCR.......................................................................................... 539 CLEAN AdBlue/DEF TANK........................................................................................................... 543 METHOD FOR CLEANING AdBlue/DEF TANK......................................................................................... 543 POWER TRAIN......................................................................................................................... 547 TEST SWING CIRCLE BEARING CLEARANCE............................................................................................. 547 METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE........................................................................... 547 UNDERCARRIAGE AND FRAME............................................................................................................. 548 TEST AND ADJUST TRACK TENSION................................................................................................... 548 METHOD FOR TESTING TRACK TENSION............................................................................................ 548 METHOD FOR ADJUSTING TRACK TENSION.......................................................................................... 548 HYDRAULIC SYSTEM.................................................................................................................... 550 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM................................................................................ 550 METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT.............................................................. 550 METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT............................................................ 559 METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT........................................................... 559 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...................................................... 560 METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS............................................... 563 METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS............................................. 571 TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT................................................................................. 575 METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT.......................................................................... 575 METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT........................................................................ 576 TEST AND ADJUST PISTON PUMP CONTROL OIL PRESSURE................................................................................ 577 METHOD FOR TESTING TVC VALVE OUTLET PRESSURE................................................................................ 577 METHOD FOR TESTING CO AND NC VALVE OUTLET PRESSURE.......................................................................... 578 METHOD FOR TESTING JET SENSOR OUTLET PRESSURE............................................................................... 579 METHOD FOR ADJUSTING TVC VALVE.............................................................................................. 581 METHOD FOR ADJUSTING CO AND NC VALVE........................................................................................ 582 METHOD FOR ADJUSTING JET SENSOR............................................................................................. 583 TEST SERVO PISTON STROKE........................................................................................................ 584 METHOD FOR TESTING SERVO PISTON STROKE...................................................................................... 584 TEST OUTLET PRESSURE OF SOLENOID VALVE.......................................................................................... 586 METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE........................................................................ 586 OPERATING CONDITION OF SOLENOID VALVE....................................................................................... 587 TEST PPC VALVE OUTLET PRESSURE.................................................................................................. 590 METHOD FOR TESTING PPC VALVE OUTLET PRESSURE................................................................................ 590 TEST PPC SHUTTLE VALVE OUTLET PRESSURE.......................................................................................... 592 METHOD FOR TESTING PPC SHUTTLE VALVE OUTLET PRESSURE........................................................................ 592 ADJUST WORK EQUIPMENT AND SWING PPC VALVES...................................................................................... 596 METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES............................................................ 596 TEST AND ADJUST TRAVEL DEVIATION................................................................................................ 597 METHOD FOR TESTING TRAVEL DEVIATION......................................................................................... 597 METHOD FOR ADJUSTING TRAVEL DEVIATION....................................................................................... 597 TEST COOLING FAN SPEED.......................................................................................................... 599 METHOD FOR TESTING COOLING FAN SPEED........................................................................................ 599 TEST OIL PRESSURE IN FAN PUMP CIRCUIT........................................................................................... 600 METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT......................................................................... 600 TEST FAN PUMP EPC ELECTRIC CURRENT.............................................................................................. 601 METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT............................................................................ 601 TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE................................................................................ 602 METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE.............................................................. 602 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT........................................................................ 603 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER................................... 603 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER........................................................ 603 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE........................................................... 604 TEST OIL LEAKAGE................................................................................................................ 605 METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER........................................................................... 605 METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER............................................................................ 606 METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER......................................................................... 606 METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR............................................................................. 607 METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR............................................................................ 607 METHOD FOR TESTING OIL LEAKAGE OF SWIVEL JOINT.............................................................................. 608 BLEED AIR FROM HYDRAULIC CIRCUIT................................................................................................ 610 METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT.............................................................................. 611 CAB AND ITS ATTACHMENTS............................................................................................................. 614 TEST CAB TIPPING STOPPER........................................................................................................ 614 METHOD FOR TESTING CAB TIPPING STOPPER...................................................................................... 614 METHOD FOR ADJUSTING MIRRORS.................................................................................................... 615 PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)....................................................................... 615 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)................................................... 616 PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)...................................................................... 617 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B).................................................. 618 ELECTRICAL SYSTEM................................................................................................................... 620 SET AND OPERATE MACHINE MONITOR................................................................................................. 620 OPERATOR MODE............................................................................................................... 624 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN................................................................. 624 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN.................................................................... 624 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)........................................................................... 625 CHECKING FUNCTION OF SERVICE METER.......................................................................................... 625 METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD................................................................... 625 SERVICE MODE................................................................................................................ 628 METHOD FOR OPERATING SERVICE MODE........................................................................................... 628 METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION...................................................................... 630 METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION...................................................................... 636 ABNORMALITY RECORD MENU..................................................................................................... 648 METHOD FOR CONFIRMING MAINTENANCE RECORD.................................................................................... 652 METHOD FOR OPERATING MAINTENANCE MODE SETTING............................................................................... 653 METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING............................................................................. 657 DEFAULT MENU................................................................................................................ 659 DIAGNOSTIC TESTS MENU....................................................................................................... 665 ADJUSTMENT MENU............................................................................................................. 675 METHOD FOR PERFORMING NO-INJECTION CRANKING................................................................................. 678 KOMTRAX SETTINGS MENU....................................................................................................... 680 METHOD FOR DISPLAYING SERVICE MESSAGE....................................................................................... 682 METHOD FOR STARTING UP KOMTRAX TERMINAL......................................................................................... 684 ADJUST REARVIEW CAMERA ANGLE.................................................................................................... 689 METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE................................................................................. 689 ADJUST KomVision CAMERA ANGLE................................................................................................... 691 METHOD FOR ADJUSTING KomVision CAMERA ANGLE................................................................................. 692 ADJUST KomVision RELATED ITEMS.................................................................................................. 694 SETTING OF KomVision (MAIN SETTING)......................................................................................... 695 SETTING OF KomVision (CAMERA SETTING)....................................................................................... 697 SETTING OF KomVision (CAMERA CALIBRATION)................................................................................... 698 KomVision screen - Check 12 m visibility.................................................................................... 711 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER..................................................................................... 714 HANDLE BATTERY DISCONNECT SWITCH................................................................................................ 715 TEST DIODES..................................................................................................................... 716 METHOD FOR TESTING DIODE USING DIGITAL TESTER............................................................................... 716 METHOD FOR TESTING DIODE USING ANALOG TESTER................................................................................ 716 Pm CLINIC........................................................................................................................... 717 Pm CLINIC SERVICE............................................................................................................... 717 Pm CLINIC CHECK SHEET: PC650LC-11........................................................................................... 721 40 TROUBLESHOOTING...................................................................................................................... 737 CONTENTS............................................................................................................................ 738 ABBREVIATION LIST................................................................................................................... 749 RELATED INFORMATION ON TROUBLESHOOTING.............................................................................................. 755 GENERAL TROUBLESHOOTING POINTS.................................................................................................. 755 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...................................................................................... 756 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................... 768 CHECKS BEFORE TROUBLESHOOTING................................................................................................... 770 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING..................................................................................... 772 WALK-AROUND CHECK........................................................................................................... 772 TESTING IN ACCORDANCE WITH TESTING PROCEDURE.................................................................................... 774 CHECK FUEL LEVEL AND TYPE................................................................................................... 774 CHECK IMPURE INGREDIENT IN FUEL............................................................................................. 775 CHECK FUEL PREFILTER........................................................................................................ 775 WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT.......................................................................... 775 FUEL PREFILTER CARTRIDGE - REPLACE.......................................................................................... 776 CHECK MAIN FILTER........................................................................................................... 777 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN).............................................................................. 778 CHECK COOLANT LEVEL (RESERVOIR TANK)........................................................................................ 780 CHECK CLOGGING OF AIR CLEANER............................................................................................... 780 OUTER ELEMENT - CLEAN....................................................................................................... 780 ELEMENTS - REPLACE.......................................................................................................... 783 CHECK HYDRAULIC OIL LEVEL................................................................................................... 783 CHECK HYDRAULIC OIL STRAINER................................................................................................ 785 CHECK HYDRAULIC FILTER...................................................................................................... 785 CHECK OIL LEVEL IN SWING MACHINERY CASE..................................................................................... 786 CHECK OIL LEVEL IN PTO CASE................................................................................................. 787 CHECK PTO LUBRICATION FILTER STRAINER....................................................................................... 787 CHECK OIL LEVEL IN FINAL DRIVE CASE......................................................................................... 788 BLEED AIR FROM FUEL SYSTEM.................................................................................................. 788 BLEED AIR FROM HYDRAULIC SYSTEM............................................................................................. 789 ELECTRICAL EQUIPMENT - CHECK METHOD......................................................................................... 789 PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM............................................................................ 795 PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR.......................................................................... 795 PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER........................................................................ 795 PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER.......................................................................... 795 PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL......................................................................... 795 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK......................................................... 796 PROCEDURE FOR TESTING AND TROUBLESHOOTING....................................................................................... 800 SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS................................................................................. 803 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................................................. 807 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM............................................. 809 CONNECTOR LIST AND LAYOUT....................................................................................................... 812 CONNECTOR CONTACT IDENTIFICATION................................................................................................ 826 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE......................................................................................... 866 FUSE LOCATION TABLE............................................................................................................. 872 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)..................................................................... 875 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])..................................... 879 FAILURE CODES TABLE............................................................................................................. 881 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)................................................................................... 898 FAILURE CODE [879AKA]........................................................................................................... 898 FAILURE CODE [879AKB]........................................................................................................... 899 FAILURE CODE [879BKA]........................................................................................................... 900 FAILURE CODE [879BKB]........................................................................................................... 902 FAILURE CODE [879CKA]........................................................................................................... 904 FAILURE CODE [879CKB]........................................................................................................... 905 FAILURE CODE [879DKZ]........................................................................................................... 906 FAILURE CODE [879EMC]........................................................................................................... 908 FAILURE CODE [879FMC]........................................................................................................... 909 FAILURE CODE [879GKX]........................................................................................................... 910 FAILURE CODE [989L00]........................................................................................................... 912 FAILURE CODE [989M00]........................................................................................................... 913 FAILURE CODE [989N00]........................................................................................................... 914 FAILURE CODE [A1U0N3]........................................................................................................... 915 FAILURE CODE [A1U0N4]........................................................................................................... 917 FAILURE CODE [A900FR]........................................................................................................... 919 FAILURE CODE [A900N6]........................................................................................................... 920 FAILURE CODE [A900NY]........................................................................................................... 921 FAILURE CODE [AA10NX]........................................................................................................... 922 FAILURE CODE [AB00KE]........................................................................................................... 924 FAILURE CODE [AQ10N3]........................................................................................................... 926 FAILURE CODE [AS00N3]........................................................................................................... 928 FAILURE CODE [AS00R2]........................................................................................................... 930 FAILURE CODE [AS00R3]........................................................................................................... 931 FAILURE CODE [AS00R4]........................................................................................................... 932 FAILURE CODE [AS00R5]........................................................................................................... 933 FAILURE CODE [AS00R6]........................................................................................................... 934 FAILURE CODE [AS00ZK]........................................................................................................... 935 FAILURE CODE [AS10KM]........................................................................................................... 936 FAILURE CODE [AS10NR]........................................................................................................... 937 FAILURE CODE [AS10NT]........................................................................................................... 938 FAILURE CODE [B@BAZG]........................................................................................................... 939 FAILURE CODE [B@BAZK]........................................................................................................... 940 FAILURE CODE [B@BCNS]........................................................................................................... 942 FAILURE CODE [B@BCQA]........................................................................................................... 943 FAILURE CODE [B@BCZK]........................................................................................................... 945 FAILURE CODE [B@HANS]........................................................................................................... 947 FAILURE CODE [CA115]............................................................................................................ 948 FAILURE CODE [CA122]............................................................................................................ 949 FAILURE CODE [CA123]............................................................................................................ 951 FAILURE CODE [CA131]............................................................................................................ 953 FAILURE CODE [CA132]............................................................................................................ 955 FAILURE CODE [CA135]............................................................................................................ 957 FAILURE CODE [CA141]............................................................................................................ 959 FAILURE CODE [CA144]............................................................................................................ 961 FAILURE CODE [CA145]............................................................................................................ 963 FAILURE CODE [CA153]............................................................................................................ 965 FAILURE CODE [CA154]............................................................................................................ 968 FAILURE CODE [CA187]............................................................................................................ 971 FAILURE CODE [CA221]............................................................................................................ 973 FAILURE CODE [CA222]............................................................................................................ 975 FAILURE CODE [CA227]............................................................................................................ 977 FAILURE CODE [CA234]............................................................................................................ 978 FAILURE CODE [CA238]............................................................................................................ 979 FAILURE CODE [CA239]............................................................................................................ 981 FAILURE CODE [CA249]............................................................................................................ 983 FAILURE CODE [CA256]............................................................................................................ 985 FAILURE CODE [CA271]............................................................................................................ 987 FAILURE CODE [CA272]............................................................................................................ 989 FAILURE CODE [CA273]............................................................................................................ 990 FAILURE CODE [CA274]............................................................................................................ 992 FAILURE CODE [CA322]............................................................................................................ 993 FAILURE CODE [CA323]............................................................................................................ 995 FAILURE CODE [CA324]............................................................................................................ 997 FAILURE CODE [CA325]............................................................................................................ 999 FAILURE CODE [CA331]............................................................................................................1001 FAILURE CODE [CA332]............................................................................................................1003 FAILURE CODE [CA343]............................................................................................................1005 FAILURE CODE [CA351]............................................................................................................1006 FAILURE CODE [CA352]............................................................................................................1007 FAILURE CODE [CA356]............................................................................................................1010 FAILURE CODE [CA357]............................................................................................................1012 FAILURE CODE [CA386]............................................................................................................1014 FAILURE CODE [CA441]............................................................................................................1015 FAILURE CODE [CA442]............................................................................................................1017 FAILURE CODE [CA449]............................................................................................................1018 FAILURE CODE [CA451]............................................................................................................1019 FAILURE CODE [CA452]............................................................................................................1021 FAILURE CODE [CA515]............................................................................................................1023 FAILURE CODE [CA516]............................................................................................................1025 FAILURE CODE [CA553]............................................................................................................1027 FAILURE CODE [CA555]............................................................................................................1028 FAILURE CODE [CA556]............................................................................................................1029 FAILURE CODE [CA559]............................................................................................................1030 FAILURE CODE [CA595]............................................................................................................1035 FAILURE CODE [CA687]............................................................................................................1036 FAILURE CODE [CA689]............................................................................................................1038 FAILURE CODE [CA691]............................................................................................................1040 FAILURE CODE [CA692]............................................................................................................1042 FAILURE CODE [CA697]............................................................................................................1044 FAILURE CODE [CA698]............................................................................................................1045 FAILURE CODE [CA731]............................................................................................................1046 FAILURE CODE [CA778]............................................................................................................1047 FAILURE CODE [CA1117]...........................................................................................................1050 FAILURE CODE [CA1664]...........................................................................................................1051 FAILURE CODE [CA1669]...........................................................................................................1055 FAILURE CODE [CA1673]...........................................................................................................1056 FAILURE CODE [CA1677]...........................................................................................................1057 FAILURE CODE [CA1678]...........................................................................................................1058 FAILURE CODE [CA1682]...........................................................................................................1059 FAILURE CODE [CA1683]...........................................................................................................1061 FAILURE CODE [CA1684]...........................................................................................................1063 FAILURE CODE [CA1686]...........................................................................................................1065 FAILURE CODE [CA1691]...........................................................................................................1066 FAILURE CODE [CA1694]...........................................................................................................1069 FAILURE CODE [CA1695]...........................................................................................................1071 FAILURE CODE [CA1696]...........................................................................................................1072 FAILURE CODE [CA1712]...........................................................................................................1074 FAILURE CODE [CA1713]...........................................................................................................1077 FAILURE CODE [CA1714]...........................................................................................................1080 FAILURE CODE [CA1715]...........................................................................................................1081 FAILURE CODE [CA1776]...........................................................................................................1082 FAILURE CODE [CA1777]...........................................................................................................1085 FAILURE CODE [CA1843]...........................................................................................................1088 FAILURE CODE [CA1844]...........................................................................................................1090 FAILURE CODE [CA1879]...........................................................................................................1093 FAILURE CODE [CA1881]...........................................................................................................1096 FAILURE CODE [CA1883]...........................................................................................................1098 FAILURE CODE [CA1885]...........................................................................................................1102 FAILURE CODE [CA1887]...........................................................................................................1104 FAILURE CODE [CA1921]...........................................................................................................1106 FAILURE CODE [CA1922]...........................................................................................................1109 FAILURE CODE [CA1923]...........................................................................................................1115 FAILURE CODE [CA1924]...........................................................................................................1117 FAILURE CODE [CA1925]...........................................................................................................1119 FAILURE CODE [CA1927]...........................................................................................................1121 FAILURE CODE [CA1928]...........................................................................................................1123 FAILURE CODE [CA1942]...........................................................................................................1125 FAILURE CODE [CA1963]...........................................................................................................1126 FAILURE CODE [CA1977]...........................................................................................................1130 FAILURE CODE [CA1993]...........................................................................................................1133 FAILURE CODE [CA2185]...........................................................................................................1136 FAILURE CODE [CA2186]...........................................................................................................1138 FAILURE CODE [CA2249]...........................................................................................................1140 FAILURE CODE [CA2265]...........................................................................................................1141 FAILURE CODE [CA2266]...........................................................................................................1143 FAILURE CODE [CA2271]...........................................................................................................1145 FAILURE CODE [CA2272]...........................................................................................................1147 FAILURE CODE [CA2349]...........................................................................................................1149 FAILURE CODE [CA2353]...........................................................................................................1151 FAILURE CODE [CA2357]...........................................................................................................1153 FAILURE CODE [CA2381]...........................................................................................................1154 FAILURE CODE [CA2382]...........................................................................................................1156 FAILURE CODE [CA2383]...........................................................................................................1158 FAILURE CODE [CA2386]...........................................................................................................1160 FAILURE CODE [CA2387]...........................................................................................................1162 FAILURE CODE [CA2555]...........................................................................................................1163 FAILURE CODE [CA2556]...........................................................................................................1165 FAILURE CODE [CA2637]...........................................................................................................1167 FAILURE CODE [CA2639]...........................................................................................................1169 FAILURE CODE [CA2732]...........................................................................................................1171 FAILURE CODE [CA2733]...........................................................................................................1173 FAILURE CODE [CA2741]...........................................................................................................1175 FAILURE CODE [CA2765]...........................................................................................................1176 FAILURE CODE [CA2771]...........................................................................................................1177 FAILURE CODE [CA2777]...........................................................................................................1183 FAILURE CODE [CA2878]...........................................................................................................1186 FAILURE CODE [CA2881]...........................................................................................................1189 FAILURE CODE [CA2976]...........................................................................................................1192 FAILURE CODE [CA3133]...........................................................................................................1194 FAILURE CODE [CA3134]...........................................................................................................1196 FAILURE CODE [CA3135]...........................................................................................................1198 FAILURE CODE [CA3142]...........................................................................................................1201 FAILURE CODE [CA3143]...........................................................................................................1202 FAILURE CODE [CA3144]...........................................................................................................1203 FAILURE CODE [CA3146]...........................................................................................................1205 FAILURE CODE [CA3147]...........................................................................................................1206 FAILURE CODE [CA3148]...........................................................................................................1207 FAILURE CODE [CA3151]...........................................................................................................1209 FAILURE CODE [CA3165]...........................................................................................................1214 FAILURE CODE [CA3167]...........................................................................................................1216 FAILURE CODE [CA3229]...........................................................................................................1220 FAILURE CODE [CA3231]...........................................................................................................1223 FAILURE CODE [CA3232]...........................................................................................................1226 FAILURE CODE [CA3235]...........................................................................................................1231 FAILURE CODE [CA3239]...........................................................................................................1233 FAILURE CODE [CA3241]...........................................................................................................1236 FAILURE CODE [CA3242]...........................................................................................................1239 FAILURE CODE [CA3251]...........................................................................................................1242 FAILURE CODE [CA3253]...........................................................................................................1246 FAILURE CODE [CA3254]...........................................................................................................1252 FAILURE CODE [CA3255]...........................................................................................................1256 FAILURE CODE [CA3256]...........................................................................................................1259 FAILURE CODE [CA3311]...........................................................................................................1262 FAILURE CODE [CA3312]...........................................................................................................1265 FAILURE CODE [CA3313]...........................................................................................................1268 FAILURE CODE [CA3314]...........................................................................................................1269 FAILURE CODE [CA3315]...........................................................................................................1270 FAILURE CODE [CA3316]...........................................................................................................1273 FAILURE CODE [CA3317]...........................................................................................................1274 FAILURE CODE [CA3318]...........................................................................................................1275 FAILURE CODE [CA3319]...........................................................................................................1278 FAILURE CODE [CA3321]...........................................................................................................1279 FAILURE CODE [CA3322]...........................................................................................................1280 FAILURE CODE [CA3419]...........................................................................................................1283 FAILURE CODE [CA3421]...........................................................................................................1285 FAILURE CODE [CA3497]...........................................................................................................1287 FAILURE CODE [CA3498]...........................................................................................................1288 FAILURE CODE [CA3543]...........................................................................................................1289 FAILURE CODE [CA3545]...........................................................................................................1294 FAILURE CODE [CA3547]...........................................................................................................1296 FAILURE CODE [CA3558]...........................................................................................................1297 FAILURE CODE [CA3559]...........................................................................................................1299 FAILURE CODE [CA3562]...........................................................................................................1301 FAILURE CODE [CA3563]...........................................................................................................1303 FAILURE CODE [CA3567]...........................................................................................................1306 FAILURE CODE [CA3568]...........................................................................................................1309 FAILURE CODE [CA3571]...........................................................................................................1313 FAILURE CODE [CA3572]...........................................................................................................1315 FAILURE CODE [CA3574]...........................................................................................................1317 FAILURE CODE [CA3575]...........................................................................................................1320 FAILURE CODE [CA3577]...........................................................................................................1322 FAILURE CODE [CA3578]...........................................................................................................1324 FAILURE CODE [CA3582]...........................................................................................................1326 FAILURE CODE [CA3583]...........................................................................................................1331 FAILURE CODE [CA3596]...........................................................................................................1333 FAILURE CODE [CA3649]...........................................................................................................1337 FAILURE CODE [CA3681]...........................................................................................................1340 FAILURE CODE [CA3682]...........................................................................................................1345 FAILURE CODE [CA3713]...........................................................................................................1351 FAILURE CODE [CA3717]...........................................................................................................1354 FAILURE CODE [CA3718]...........................................................................................................1355 FAILURE CODE [CA3725]...........................................................................................................1356 FAILURE CODE [CA3748]...........................................................................................................1359 FAILURE CODE [CA3751]...........................................................................................................1361 FAILURE CODE [CA3755]...........................................................................................................1363 FAILURE CODE [CA3866]...........................................................................................................1365 FAILURE CODE [CA3867]...........................................................................................................1369 FAILURE CODE [CA3868]...........................................................................................................1372 FAILURE CODE [CA3899]...........................................................................................................1376 FAILURE CODE [CA3911]...........................................................................................................1379 FAILURE CODE [CA3912]...........................................................................................................1383 FAILURE CODE [CA3932]...........................................................................................................1385 FAILURE CODE [CA3933]...........................................................................................................1387 FAILURE CODE [CA3934]...........................................................................................................1389 FAILURE CODE [CA3935]...........................................................................................................1392 FAILURE CODE [CA3936]...........................................................................................................1394 FAILURE CODE [CA4151]...........................................................................................................1396 FAILURE CODE [CA4152]...........................................................................................................1400 FAILURE CODE [CA4155]...........................................................................................................1404 FAILURE CODE [CA4156]...........................................................................................................1406 FAILURE CODE [CA4157]...........................................................................................................1409 FAILURE CODE [CA4158]...........................................................................................................1411 FAILURE CODE [CA4159]...........................................................................................................1413 FAILURE CODE [CA4161]...........................................................................................................1415 FAILURE CODE [CA4162]...........................................................................................................1418 FAILURE CODE [CA4163]...........................................................................................................1421 FAILURE CODE [CA4164]...........................................................................................................1423 FAILURE CODE [CA4165]...........................................................................................................1426 FAILURE CODE [CA4166]...........................................................................................................1429 FAILURE CODE [CA4168]...........................................................................................................1432 FAILURE CODE [CA4169]...........................................................................................................1437 FAILURE CODE [CA4171]...........................................................................................................1442 FAILURE CODE [CA4249]...........................................................................................................1447 FAILURE CODE [CA4251]...........................................................................................................1451 FAILURE CODE [CA4259]...........................................................................................................1455 FAILURE CODE [CA4261]...........................................................................................................1458 FAILURE CODE [CA4277]...........................................................................................................1461 FAILURE CODE [CA4281]...........................................................................................................1465 FAILURE CODE [CA4459]...........................................................................................................1468 FAILURE CODE [CA4461]...........................................................................................................1471 FAILURE CODE [CA4658]...........................................................................................................1474 FAILURE CODE [CA4731]...........................................................................................................1478 FAILURE CODE [CA4732]...........................................................................................................1479 FAILURE CODE [CA4739]...........................................................................................................1480 FAILURE CODE [CA4768]...........................................................................................................1481 FAILURE CODE [CA4769]...........................................................................................................1483 FAILURE CODE [CA4842]...........................................................................................................1486 FAILURE CODE [CA4952]...........................................................................................................1490 FAILURE CODE [CA5115]...........................................................................................................1492 FAILURE CODE [CA5179]...........................................................................................................1495 FAILURE CODE [CA5181]...........................................................................................................1497 FAILURE CODE [CA5383]...........................................................................................................1499 FAILURE CODE [D110KB]...........................................................................................................1501 FAILURE CODE [D163KB]...........................................................................................................1503 FAILURE CODE [D195KA]...........................................................................................................1505 FAILURE CODE [D195KB]...........................................................................................................1507 FAILURE CODE [D19JKZ]...........................................................................................................1509 FAILURE CODE [D811MC]...........................................................................................................1511 FAILURE CODE [D862KA]...........................................................................................................1512 FAILURE CODE [D8ALKA]...........................................................................................................1513 FAILURE CODE [D8ALKB]...........................................................................................................1515 FAILURE CODE [D8AQKR]...........................................................................................................1517 FAILURE CODE [DA20MC]...........................................................................................................1521 FAILURE CODE [DA22KK]...........................................................................................................1522 FAILURE CODE [DA25KP]...........................................................................................................1524 FAILURE CODE [DA26KP]...........................................................................................................1526 FAILURE CODE [DA29KQ]...........................................................................................................1529 FAILURE CODE [DA2LKA]...........................................................................................................1531 FAILURE CODE [DA2LKB]...........................................................................................................1533 FAILURE CODE [DA2QKR]...........................................................................................................1535 FAILURE CODE [DA2RKR]...........................................................................................................1540 FAILURE CODE [DAF0KM]...........................................................................................................1545 FAILURE CODE [DAF0MB]...........................................................................................................1546 FAILURE CODE [DAF0MC]...........................................................................................................1547 FAILURE CODE [DAF8KB]...........................................................................................................1548 FAILURE CODE [DAF9KQ]...........................................................................................................1549 FAILURE CODE [DAFGMC]...........................................................................................................1550 FAILURE CODE [DAFLKA]...........................................................................................................1551 FAILURE CODE [DAFLKB]...........................................................................................................1553 FAILURE CODE [DAFQKR]...........................................................................................................1555 FAILURE CODE [DAZ9KQ]...........................................................................................................1559 FAILURE CODE [DAZQKR]...........................................................................................................1560 FAILURE CODE [DB2QKR]...........................................................................................................1564 FAILURE CODE [DB2RKR]...........................................................................................................1569 FAILURE CODE [DBP0KM]...........................................................................................................1574 FAILURE CODE [DBP0KT]...........................................................................................................1575 FAILURE CODE [DBPQKR]...........................................................................................................1576 FAILURE CODE [DDNRKA]...........................................................................................................1581 FAILURE CODE [DDNRKY]...........................................................................................................1583 FAILURE CODE [DDNS00]...........................................................................................................1585 FAILURE CODE [DGE5KB]...........................................................................................................1587 FAILURE CODE [DGH2KA]...........................................................................................................1588 FAILURE CODE [DGH2KB]...........................................................................................................1590 FAILURE CODE [DHA4KA]...........................................................................................................1592 FAILURE CODE [DHAAMA]...........................................................................................................1594 FAILURE CODE [DHACMA]...........................................................................................................1596 FAILURE CODE [DHPAMA]...........................................................................................................1598 FAILURE CODE [DHPBMA]...........................................................................................................1600 FAILURE CODE [DHS3MA]...........................................................................................................1602 FAILURE CODE [DHS4MA]...........................................................................................................1605 FAILURE CODE [DHS8MA]...........................................................................................................1608 FAILURE CODE [DHS9MA]...........................................................................................................1611 FAILURE CODE [DHSAMA]...........................................................................................................1614 FAILURE CODE [DHSBMA]...........................................................................................................1617 FAILURE CODE [DHSCMA]...........................................................................................................1620 FAILURE CODE [DHSDMA]...........................................................................................................1623 FAILURE CODE [DHSFMA]...........................................................................................................1626 FAILURE CODE [DHSGMA]...........................................................................................................1629 FAILURE CODE [DHSHMA]...........................................................................................................1632 FAILURE CODE [DHSJMA]...........................................................................................................1635 FAILURE CODE [DHSVMA]...........................................................................................................1638 FAILURE CODE [DKULKA]...........................................................................................................1640 FAILURE CODE [DKULKB]...........................................................................................................1642 FAILURE CODE [DKULKY]...........................................................................................................1644 FAILURE CODE [DLM3KA]...........................................................................................................1646 FAILURE CODE [DLM3KB]...........................................................................................................1648 FAILURE CODE [DLM3MB]...........................................................................................................1650 FAILURE CODE [DR10KA]...........................................................................................................1651 FAILURE CODE [DR21KX]...........................................................................................................1654 FAILURE CODE [DR31KX]...........................................................................................................1656 FAILURE CODE [DUMBKA]...........................................................................................................1658 FAILURE CODE [DUMBKB]...........................................................................................................1660 FAILURE CODE [DV20KB]...........................................................................................................1662 FAILURE CODE [DW43KA]...........................................................................................................1663 FAILURE CODE [DW43KB]...........................................................................................................1665 FAILURE CODE [DW43KY]...........................................................................................................1667 FAILURE CODE [DW45KA]...........................................................................................................1668 FAILURE CODE [DW45KB]...........................................................................................................1671 FAILURE CODE [DW45KY]...........................................................................................................1674 FAILURE CODE [DW48KA]...........................................................................................................1676 FAILURE CODE [DW48KB]...........................................................................................................1678 FAILURE CODE [DW48KY]...........................................................................................................1680 FAILURE CODE [DW4CKY]...........................................................................................................1681 FAILURE CODE [DW4XKA]...........................................................................................................1683 FAILURE CODE [DW4XKB]...........................................................................................................1685 FAILURE CODE [DW4XKY]...........................................................................................................1687 FAILURE CODE [DW7BKA]...........................................................................................................1688 FAILURE CODE [DW7BKB]...........................................................................................................1690 FAILURE CODE [DW7BKY]...........................................................................................................1692 FAILURE CODE [DWK0KA]...........................................................................................................1693 FAILURE CODE [DWK0KB]...........................................................................................................1695 FAILURE CODE [DWK0KY]...........................................................................................................1697 FAILURE CODE [DWK2KA]...........................................................................................................1698 FAILURE CODE [DWK2KB]...........................................................................................................1700 FAILURE CODE [DWK2KY]...........................................................................................................1702 FAILURE CODE [DWK8KA]...........................................................................................................1703 FAILURE CODE [DWK8KB]...........................................................................................................1705 FAILURE CODE [DWK8KY]...........................................................................................................1707 FAILURE CODE [DX16KA]...........................................................................................................1708 FAILURE CODE [DX16KB]...........................................................................................................1710 FAILURE CODE [DXA2KA]...........................................................................................................1711 FAILURE CODE [DXA2KB]...........................................................................................................1714 FAILURE CODE [DXA3KA]...........................................................................................................1716 FAILURE CODE [DXA3KB]...........................................................................................................1719 FAILURE CODE [DY20KA]...........................................................................................................1721 FAILURE CODE [DY20MA]...........................................................................................................1723 FAILURE CODE [DY2CKB]...........................................................................................................1725 FAILURE CODE [DY2DKB]...........................................................................................................1727 FAILURE CODE [DY2EKB]...........................................................................................................1729 FAILURE CODE [DY2FMA]...........................................................................................................1731 FAILURE CODE [DY2GKM]...........................................................................................................1733 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).......................................................................................1735 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...............................................................................1735 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK......................................................................................1741 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...................................................................................1744 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...........................................................1746 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING.............................................1748 E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW..........1751 E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW....1752 E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...............................................1753 E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING................................................1754 E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...................................................1755 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............................................................1756 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................................1757 E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................1758 E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.......................................................1759 E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.................................................1760 E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...................................................................1761 E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL.......................................................................1763 E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.............................................1764 E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE........................................1765 E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM..............................................1766 E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE.............................................1768 E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED.....................................................................1769 E-23 FUNCTION SWITCH DOES NOT OPERATE...........................................................................................1770 E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)...................................................................1771 E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF....................1772 E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER....................................................................1773 E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED.......................................1774 E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED..........................................1775 E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE.................................................1776 E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE................................................1777 E-31 ALARM BUZZER CANNOT BE CANCELED............................................................................................1778 E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...................................................1779 E-33 SERVICE MODE CANNOT BE SELECTED............................................................................................1780 E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE............................................................1781 E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK.............................................................1784 E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING.............................................1786 E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE.............................1789 E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR.......................1791 E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED.......................................................................1793 E-40 ALARM DOES NOT SOUND DURING TRAVEL.........................................................................................1794 E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED......................................................................1796 E-42 HORN DOES NOT SOUND........................................................................................................1797 E-43 HORN DOES NOT STOP SOUNDING................................................................................................1800 E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF...................................................1802 E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...........................................................1803 E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE......................................................1805 E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................1806 E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................1807 E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................................1808 E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................1809 E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................................1810 E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................................1811 E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.........................................................1812 E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................1813 E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................................1814 E-56 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...................................................................................1816 E-57 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED................................................................................1817 E-58 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................................................1819 E-59 STEP LIGHT DOES NOT LIGHT UP...............................................................................................1820 E-60 STEP LIGHT DOES NOT GO OUT.................................................................................................1822 E-61 BOOM SHOCKLESS FUNCTION CANNOT BE CANCELED.................................................................................1824 E-62 BOOM SHOCKLESS FUNCTION DOES NOT WORK......................................................................................1826 E-63 ELECTRIC GREASE GUN DOES NOT WORK..........................................................................................1827 E-64 ELECTRIC GREASE GUN DOES NOT STOP..........................................................................................1829 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).......................................................................1830 H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK............................................................................1830 H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER...................................................................1831 H-3 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...........................................................................1833 H-4 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS..................................................................................1834 H-5 TRAVEL SPEED OR POWER IS LOW................................................................................................1835 H-6 AUTO-DECELERATION FUNCTION CANNOT BE CANCELED...............................................................................1836 H-7 SPEED OR POWER OF BOOM IS LOW...............................................................................................1837 H-8 ARM SPEED OR POWER IS LOW...................................................................................................1839 H-9 BUCKET SPEED OR POWER IS LOW................................................................................................1840 H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION...........................................................................1841 H-11 HYDRAULIC DRIFT OF BOOM IS LARGE...........................................................................................1842 H-12 HYDRAULIC DRIFT OF ARM IS LARGE............................................................................................1843 H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE.........................................................................................1844 H-14 TIME LAG OF WORK EQUIPMENT IS LARGE........................................................................................1845 H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE.......................................................................1846 H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................................................1847 H-17 MACHINE DOES NOT TRAVEL STRAIGHT...........................................................................................1848 H-18 SPEED OF BOOM AND BUCKET IS SLOW AT COMBINED OPERATION OF ARM, BOOM AND BUCKET.............................................1849 H-19 SPEED OF BOOM, ARM, SWING AND TRAVEL IS SLOW AT COMBINED OPERATION OF BUCKET, BOOM AND ARM.................................1850 H-20 SWING SPEED IS SLOW AT COMBINED OPERATION OF ARM AND SWING.................................................................1851 H-21 TRAVEL DEVIATION IS LARGE AT START OF TRAVELING............................................................................1852 H-22 TRAVEL DEVIATION IS LARGE AT COMBINED OPERATION............................................................................1854 H-23 ONE OF TRACKS DOES NOT RUN.................................................................................................1855 H-24 TRAVEL SPEED DOES NOT CHANGE...............................................................................................1857 H-25 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT..................................................................1858 H-26 SWINGS ONLY IN ONE DIRECTION...............................................................................................1859 H-27 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)...............................................1860 H-28 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION........................................1861 H-29 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)..........................................1862 H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)......................1863 H-31 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING.........................................................................1864 H-32 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING...........................................................1865 H-33 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED).....................................................1866 H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)....................................................1867 H-35 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY).....................................................................1868 H-36 UNUSUAL NOISE IS HEARD FROM AROUND FAN.....................................................................................1869 TROUBLESHOOTING OF ENGINE (S-MODE)..................................................................................................1870 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE).........................................................................1870 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION......................................................1871 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT..................................................................................1872 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)..............................1873 S-4 ENGINE STARTABILITY IS POOR.................................................................................................1874 S-5 ENGINE DOES NOT PICK UP SMOOTHLY............................................................................................1876 S-6 ENGINE STOPS DURING OPERATION...............................................................................................1878 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE............................................................................................1880 S-8 ENGINE LACKS POWER..........................................................................................................1881 S-9 KDPF GETS CLOGGED IN A SHORT TIME...........................................................................................1883 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE........................................................................................1885 S-11 OIL BECOMES CONTAMINATED QUICKLY...........................................................................................1886 S-12 FUEL CONSUMPTION IS EXCESSIVE..............................................................................................1887 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)......................................................1888 S-14 OIL PRESSURE DROPS.........................................................................................................1889 S-15 FUEL MIXES INTO ENGINE OIL.................................................................................................1891 S-16 WATER MIXES INTO ENGINE OIL (MILKY)........................................................................................1892 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...........................................................................1893 S-18 UNUSUAL NOISE IS HEARD.....................................................................................................1894 S-19 VIBRATION IS EXCESSIVE.....................................................................................................1895 S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.......................................................................................1896 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY.................................................................................1897 S-22 ACTIVE REGENERATION TAKES TIME.............................................................................................1899 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION........................................................................1901 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE........................................................................................1902 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)...................................................................................1904 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)..................................................................1905 50 DISASSEMBLY AND ASSEMBLY.............................................................................................................1907 CONTENTS............................................................................................................................1908 ABBREVIATION LIST...................................................................................................................1913 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY.....................................................................................1919 HOW TO READ THIS MANUAL.........................................................................................................1919 COATING MATERIALS LIST..........................................................................................................1921 SPECIAL TOOLS LIST..............................................................................................................1925 SKETCHES OF SPECIAL TOOLS.......................................................................................................1942 ENGINE AND COOLING SYSTEM...........................................................................................................1949 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY.........................................................................................1949 METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY....................................................................................1949 METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY..................................................................................1951 REMOVE AND INSTALL INJECTOR ASSEMBLY............................................................................................1956 METHOD FOR REMOVING INJECTOR ASSEMBLY.......................................................................................1956 METHOD FOR INSTALLING INJECTOR ASSEMBLY.....................................................................................1961 REMOVE AND INSTALL FUEL DOSER ASSEMBLY..........................................................................................1970 METHOD FOR REMOVING FUEL DOSER ASSEMBLY.....................................................................................1970 METHOD FOR INSTALLING FUEL DOSER ASSEMBLY...................................................................................1971 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY.......................................................................................1973 METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY..................................................................................1974 METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY................................................................................1984 REMOVE AND INSTALL EGR VALVE ASSEMBLY...........................................................................................2001 METHOD FOR REMOVING EGR VALVE ASSEMBLY......................................................................................2001 METHOD FOR INSTALLING EGR VALVE ASSEMBLY....................................................................................2003 REMOVE AND INSTALL EGR COOLER ASSEMBLY..........................................................................................2005 METHOD FOR REMOVING EGR COOLER ASSEMBLY.....................................................................................2005 METHOD FOR INSTALLING EGR COOLER ASSEMBLY...................................................................................2008 REMOVE AND INSTALL STARTER ASSEMBLY.............................................................................................2012 METHOD FOR REMOVING STARTER ASSEMBLY........................................................................................2012 METHOD FOR INSTALLING STARTER ASSEMBLY......................................................................................2012 REMOVE AND INSTALL ALTERNATOR BELT..............................................................................................2014 METHOD FOR REMOVING ALTERNATOR BELT.........................................................................................2014 METHOD FOR INSTALLING ALTERNATOR BELT.......................................................................................2015 REMOVE AND INSTALL RADIATOR ASSEMBLY............................................................................................2017 METHOD FOR REMOVING RADIATOR ASSEMBLY.......................................................................................2017 METHOD FOR INSTALLING RADIATOR ASSEMBLY.....................................................................................2020 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY................................................................................2024 METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY...........................................................................2024 METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY.........................................................................2027 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY.........................................................................................2031 METHOD FOR REMOVING AFTERCOOLER ASSEMBLY....................................................................................2031 METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY..................................................................................2033 REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY...................................................................................2036 METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY..............................................................................2036 METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY............................................................................2045 REMOVE AND INSTALL ENGINE PTO AND HYDRAULIC ASSEMBLY............................................................................2054 METHOD FOR REMOVING ENGINE PTO AND HYDRAULIC ASSEMBLY.......................................................................2054 METHOD FOR INSTALLING ENGINE PTO AND HYDRAULIC ASSEMBLY.....................................................................2065 REMOVE AND INSTALL ENGINE FRONT OIL SEAL........................................................................................2076 METHOD FOR REMOVING ENGINE FRONT OIL SEAL...................................................................................2076 METHOD FOR INSTALLING ENGINE FRONT OIL SEAL.................................................................................2077 REMOVE AND INSTALL ENGINE REAR OIL SEAL.........................................................................................2080 METHOD FOR REMOVING ENGINE REAR OIL SEAL....................................................................................2080 METHOD FOR INSTALLING ENGINE REAR OIL SEAL..................................................................................2082 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY.........................................................................................2089 METHOD FOR REMOVING ENGINE HOOD ASSEMBLY....................................................................................2089 METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY..................................................................................2093 REMOVE AND INSTALL FUEL TANK ASSEMBLY...........................................................................................2099 METHOD FOR REMOVING FUEL TANK ASSEMBLY......................................................................................2099 METHOD FOR INSTALLING FUEL TANK ASSEMBLY....................................................................................2102 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY.....................................................................................2106 METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY................................................................................2107 METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY..............................................................................2113 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.......................................................................2118 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..................................................................2118 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY................................................................2118 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR.......................................................................................2120 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR..................................................................................2120 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR................................................................................2120 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER.....................................................................................2122 METHOD FOR REMOVING AdBlue/DEF TANK STRAINER................................................................................2122 METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER..............................................................................2122 REMOVE AND INSTALL KDPF ASSEMBLY................................................................................................2123 METHOD FOR REMOVING KDPF ASSEMBLY...........................................................................................2123 METHOD FOR INSTALLING KDPF ASSEMBLY.........................................................................................2127 DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY.......................................................................................2136 METHOD FOR DISASSEMBLING KDPF ASSEMBLY......................................................................................2137 METHOD FOR ASSEMBLING KDPF ASSEMBLY.........................................................................................2141 REMOVE AND INSTALL SCR ASSEMBLY.................................................................................................2146 METHOD FOR REMOVING SCR ASSEMBLY............................................................................................2146 METHOD FOR INSTALLING SCR ASSEMBLY..........................................................................................2148 REMOVE AND INSTALL KDPF, SCR ASSEMBLY...........................................................................................2152 METHOD FOR REMOVING KDPF, SCR ASSEMBLY......................................................................................2153 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY....................................................................................2159 REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY........................................................................................2171 METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY...................................................................................2171 METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY.................................................................................2173 REMOVE AND INSTALL KCCV ASSEMBLY................................................................................................2181 METHOD FOR REMOVING KCCV ASSEMBLY...........................................................................................2181 METHOD FOR INSTALLING KCCV ASSEMBLY.........................................................................................2182 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE.......................................................................................2184 METHOD FOR REMOVING AdBlue/DEF MIXING TUBE..................................................................................2184 METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE................................................................................2189 REMOVE AND INSTALL AdBlue/DEF INJECTOR..........................................................................................2196 METHOD FOR REMOVING AdBlue/DEF INJECTOR.....................................................................................2196 METHOD FOR INSTALLING AdBlue/DEF INJECTOR...................................................................................2199 REMOVE AND INSTALL AdBlue/DEF PUMP..............................................................................................2203 METHOD FOR REMOVING AdBlue/DEF PUMP.........................................................................................2203 METHOD FOR INSTALLING AdBlue/DEF PUMP.......................................................................................2206 REMOVE AND INSTALL AdBlue/DEF HOSE..............................................................................................2209 METHOD FOR REMOVING AdBlue/DEF HOSE.........................................................................................2210 METHOD FOR INSTALLING AdBlue/DEF HOSE.......................................................................................2218 REMOVE AND INSTALL AIR CLEANER ASSEMBLY.........................................................................................2224 METHOD FOR REMOVING AIR CLEANER ASSEMBLY....................................................................................2224 METHOD FOR INSTALLING AIR CLEANER ASSEMBLY..................................................................................2225 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................2226 METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY.....................................................................2226 METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...................................................................2227 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...........................................................................2228 METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY......................................................................2228 METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY....................................................................2229 POWER TRAIN.........................................................................................................................2230 DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY...........................................................................................2230 METHOD FOR DISASSEMBLING PTO ASSEMBLY.......................................................................................2230 METHOD FOR ASSEMBLING PTO ASSEMBLY..........................................................................................2231 REMOVE AND INSTALL PTO ASSEMBLY.................................................................................................2234 METHOD FOR REMOVING PTO ASSEMBLY............................................................................................2234 METHOD FOR INSTALLING PTO ASSEMBLY..........................................................................................2235 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY........................................................................2238 METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...................................................................2238 METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.................................................................2239 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...................................................................................2240 METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY...............................................................................2241 METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY..................................................................................2246 REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................................................................2255 METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY................................................................2255 METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY..............................................................2256 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY...............................................................................2258 METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY...........................................................................2258 METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY..............................................................................2262 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY........................................................................................2267 METHOD FOR REMOVING SWING CIRCLE ASSEMBLY...................................................................................2267 METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY.................................................................................2268 UNDERCARRIAGE AND FRAME.............................................................................................................2269 DISASSEMBLE AND ASSEMBLE RECOIL SPRING..........................................................................................2269 METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING.......................................................................2269 METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY................................................................................2270 REMOVE AND INSTALL TRACK ROLLER ASSEMBLY........................................................................................2272 METHOD FOR REMOVING TRACK ROLLER ASSEMBLY...................................................................................2272 METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY.................................................................................2273 REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY......................................................................................2274 METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY.................................................................................2274 METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY...............................................................................2274 DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD.......................................................................2276 METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD...................................................................2278 METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD......................................................................2279 SEPARATION AND CONNECTION OF TRACK ASSEMBLY.....................................................................................2282 METHOD FOR SEPARATING TRACK ASSEMBLY........................................................................................2282 METHOD FOR INSTALLING TRACK ASSEMBLY........................................................................................2283 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY.............................................................................2285 METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY........................................................................2285 METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY......................................................................2286 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY.........................................................................................2287 METHOD FOR DISASSEMBLING IDLER ASSEMBLY.....................................................................................2287 METHOD FOR ASSEMBLING IDLER ASSEMBLY........................................................................................2288 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY..............................................................................2291 METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY.............................................................................2291 METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY................................................................................2292 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY..................................................................................2294 METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY..............................................................................2294 METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY.................................................................................2295 DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY.................................................................................2298 METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY............................................................................2298 METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY...............................................................................2299 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY.....................................................................................2301 METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY................................................................................2301 METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY..............................................................................2302 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY.......................................................................................2304 METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY..................................................................................2304 METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY................................................................................2304 HYDRAULIC SYSTEM....................................................................................................................2306 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY.................................................................................2306 METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY............................................................................2306 METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY..........................................................................2306 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY...........................................................................2308 METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY.......................................................................2309 METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY..........................................................................2310 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY......................................................................................2311 METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY.................................................................................2311 METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...............................................................................2313 REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY......................................................................................2316 METHOD FOR REMOVING HYDRAULIC PUMP ASSEMBLY.................................................................................2316 METHOD FOR INSTALLING HYDRAULIC PUMP ASSEMBLY...............................................................................2318 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY.......................................................................................2324 METHOD FOR REMOVING CONTROL VALVE ASSEMBLY..................................................................................2324 METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY................................................................................2327 REMOVE AND INSTALL SWING MOTOR ASSEMBLY.........................................................................................2331 METHOD FOR REMOVING SWING MOTOR ASSEMBLY....................................................................................2331 METHOD FOR INSTALLING SWING MOTOR ASSEMBLY..................................................................................2332 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY......................................................................2333 METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY..................................................................2333 METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................................2334 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY..............................................................................2336 METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY..........................................................................2336 METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY.............................................................................2337 DISASSEMBLE AND ASSEMBLE GREASE GUN ASSEMBLY....................................................................................2339 METHOD FOR DISASSEMBLING GREASE GUN ASSEMBLY................................................................................2339 METHOD FOR ASSEMBLING GREASE GUN ASSEMBLY...................................................................................2339 WORK EQUIPMENT......................................................................................................................2340 REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY.....................................................................................2340 METHOD FOR REMOVING BUCKET CYLINDER ASSEMBLY................................................................................2340 METHOD FOR INSTALLING BUCKET CYLINDER ASSEMBLY..............................................................................2341 REMOVE AND INSTALL ARM CYLINDER ASSEMBLY........................................................................................2343 METHOD FOR REMOVING ARM CYLINDER ASSEMBLY...................................................................................2343 METHOD FOR INSTALLING ARM CYLINDER ASSEMBLY.................................................................................2344 REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY.......................................................................................2346 METHOD FOR REMOVING BOOM CYLINDER ASSEMBLY..................................................................................2346 METHOD FOR INSTALLING BOOM CYLINDER ASSEMBLY................................................................................2347 REMOVE AND INSTALL BUCKET ASSEMBLY..............................................................................................2349 METHOD FOR REMOVING BUCKET ASSEMBLY.........................................................................................2349 METHOD FOR INSTALLING BUCKET ASSEMBLY.......................................................................................2350 REMOVE AND INSTALL ARM ASSEMBLY.................................................................................................2351 METHOD FOR REMOVING ARM ASSEMBLY............................................................................................2351 METHOD FOR INSTALLING ARM ASSEMBLY..........................................................................................2353 REMOVE AND INSTALL BOOM ASSEMBLY................................................................................................2355 METHOD FOR REMOVING BOOM ASSEMBLY...........................................................................................2355 METHOD FOR INSTALLING BOOM ASSEMBLY.........................................................................................2356 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY......................................................................................2358 METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY.................................................................................2358 METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...............................................................................2360 ................................................................................................................................2361 METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY...........................................................................2361 METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY..............................................................................2362 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY.......................................................................2363 METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...................................................................2364 METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY......................................................................2366 CAB AND ITS ATTACHMENTS.............................................................................................................2371 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY......................................................................................2371 METHOD FOR REMOVING OPERATOR CAB ASSEMBLY...................................................................................2371 METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY.................................................................................2378 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...........................................................................2385 METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)......................................................................2387 METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)....................................................................2387 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY........................................................................................2397 METHOD FOR REMOVING FRONT WINDOW ASSEMBLY...................................................................................2397 METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY.................................................................................2400 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.........................................................................................2406 METHOD FOR REMOVING FLOOR FRAME ASSEMBLY....................................................................................2406 METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY..................................................................................2409 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY................................................................................2414 METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...........................................................................2414 METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY.........................................................................2418 REMOVE AND INSTALL OPERATOR'S SEAT..............................................................................................2424 METHOD FOR REMOVING OPERATOR'S SEAT.........................................................................................2424 METHOD FOR INSTALLING OPERATOR'S SEAT.......................................................................................2426 REMOVE AND INSTALL SEAT BELT....................................................................................................2429 METHOD FOR REMOVING SEAT BELT...............................................................................................2429 METHOD FOR INSTALLING SEAT BELT.............................................................................................2429 REMOVE AND INSTALL FRONT WIPER ASSEMBLY.........................................................................................2431 METHOD FOR REMOVING FRONT WIPER ASSEMBLY....................................................................................2431 METHOD FOR INSTALLING FRONT WIPER ASSEMBLY..................................................................................2436 ELECTRICAL SYSTEM...................................................................................................................2445 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...................................................................................2445 METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY..............................................................................2445 METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY............................................................................2446 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.....................................................................................2449 METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY................................................................................2449 METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY..............................................................................2451 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY.....................................................................................2454 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY................................................................................2454 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY..............................................................................2456 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR.........................................................................2460 METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR....................................................................2460 METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR..................................................................2461 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...............................................................................2462 METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR..........................................................................2462 METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR........................................................................2463 REMOVE AND INSTALL SCR TEMPERATURE SENSOR.......................................................................................2465 METHOD FOR REMOVING SCR TEMPERATURE SENSOR..................................................................................2465 METHOD FOR INSTALLING SCR TEMPERATURE SENSOR................................................................................2467 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY....................................................................................2469 METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY...............................................................................2469 METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY.............................................................................2470 60 MAINTENANCE STANDARD.................................................................................................................2473 CONTENTS............................................................................................................................2474 ABBREVIATION LIST...................................................................................................................2475 ENGINE AND COOLING SYSTEM...........................................................................................................2481 MAINTENANCE STANDARD OF ENGINE MOUNT............................................................................................2481 MAINTENANCE STANDARD FOR PTO....................................................................................................2483 MAINTENANCE STANDARD OF COOLING SYSTEM..........................................................................................2484 MAINTENANCE STANDARD OF COOLING FAN PUMP........................................................................................2485 MAINTENANCE STANDARD OF SERVO VALVE.........................................................................................2486 MAINTENANCE STANDARD OF COOLING FAN MOTOR.......................................................................................2487 POWER TRAIN.........................................................................................................................2488 MAINTENANCE STANDARD OF SWING CIRCLE............................................................................................2488 MAINTENANCE STANDARD OF SWING MACHINERY.........................................................................................2489 MAINTENANCE STANDARD OF FINAL DRIVE.............................................................................................2491 MAINTENANCE STANDARD OF SPROCKET................................................................................................2493 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING...............................................................2494 UNDERCARRIAGE AND FRAME.............................................................................................................2496 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION...........................................................................2496 MAINTENANCE STANDARD OF IDLER...................................................................................................2498 MAINTENANCE STANDARD OF TRACK ROLLER............................................................................................2500 MAINTENANCE STANDARD OF CARRIER ROLLER..........................................................................................2501 MAINTENANCE STANDARD OF TRACK SHOE..............................................................................................2502 MAINTENANCE STANDARD OF DOUBLE SHOE.............................................................................................2505 MAINTENANCE STANDARD OF TRIPLE SHOE.............................................................................................2506 HYDRAULIC SYSTEM....................................................................................................................2507 MAINTENANCE STANDARD OF MAIN PUMP...............................................................................................2507 MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE...............................................................................2509 MAINTENANCE STANDARD OF MAIN PUMP TVC VALVE.................................................................................2511 MAINTENANCE STANDARD OF MAIN PUMP CO AND NC VALVE...........................................................................2512 MAINTENANCE STANDARD OF SWING MOTOR.............................................................................................2513 MAINTENANCE STANDARD OF TRAVEL MOTOR............................................................................................2514 MAINTENANCE STANDARD OF CONTROL VALVE...........................................................................................2516 MAINTENANCE STANDARD OF TRAVEL SHUTTLE VALVE OF CONTROL VALVE...............................................................2523 MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE VALVE............................................................................2524 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE......................................................................2525 MAINTENANCE STANDARD OF TRAVEL PPC VALVE........................................................................................2528 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE...........................................................................2531 MAINTENANCE STANDARD OF SOLENOID VALVE..........................................................................................2533 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT.....................................................................................2534 WORK EQUIPMENT......................................................................................................................2535 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE..................................................................................2535 DIMENSION OF ARM............................................................................................................2540 DIMENSIONS OF BUCKET........................................................................................................2542 MAINTENANCE STANDARD OF BOOM CYLINDER...........................................................................................2544 MAINTENANCE STANDARD OF ARM CYLINDER............................................................................................2545 MAINTENANCE STANDARD OF BUCKET CYLINDER.........................................................................................2546 80 APPENDIX.............................................................................................................................2547 CONTENTS............................................................................................................................2548 ABBREVIATION LIST...................................................................................................................2550 AIR CONDITIONER SYSTEM..............................................................................................................2556 PRECAUTIONS FOR REFRIGERANT.....................................................................................................2556 AIR CONDITIONER COMPONENT.......................................................................................................2557 SPECIFICATIONS OF AIR CONDITIONER...............................................................................................2559 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...............................................................................2560 OUTLINE OF REFRIGERATION CYCLE..................................................................................................2561 COMPONENT PARTS OF AIR CONDITIONER SYSTEM...........................................................................................2563 AIR CONDITIONER UNIT............................................................................................................2563 CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...............................................................................2563 FUNCTION OF AIR CONDITIONER UNIT............................................................................................2565 COMPONENT PARTS OF AIR CONDITIONER UNIT.........................................................................................2567 FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT....................................................................2568 FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...................................................................2568 FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT.................................................2568 FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...................................................................2568 STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT..............................................................2569 FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...............................................................2569 OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...................................................................2569 FUNCTION OF DUAL PRESSURE SWITCH............................................................................................2570 AIR CONDITIONER CONTROLLER......................................................................................................2571 STRUCTURE OF AIR CONDITIONER CONTROLLER.....................................................................................2571 COMPRESSOR......................................................................................................................2572 STRUCTURE OF COMPRESSOR.....................................................................................................2572 SPECIFICATIONS OF COMPRESSOR................................................................................................2572 FUNCTION OF COMPRESSOR......................................................................................................2572 CONDENSER.......................................................................................................................2573 STRUCTURE OF CONDENSER......................................................................................................2573 SPECIFICATIONS OF CONDENSER.................................................................................................2573 FUNCTION OF CONDENSER.......................................................................................................2573 RECEIVER DRIER..................................................................................................................2574 STRUCTURE OF RECEIVER DRIER.................................................................................................2574 SPECIFICATIONS OF RECEIVER DRIER............................................................................................2574 FUNCTION OF RECEIVER DRIER..................................................................................................2574 SENSORS FOR AIR CONDITIONER SYSTEM..............................................................................................2575 STRUCTURE OF SUNLIGHT SENSOR................................................................................................2575 FUNCTION OF SUNLIGHT SENSOR.................................................................................................2575 STRUCTURE OF AMBIENT TEMPERATURE SENSOR.....................................................................................2575 FUNCTION OF AMBIENT TEMPERATURE SENSOR......................................................................................2575 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER.........................................................2577 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...............................................................2579 AIR CONDITIONER SYSTEM DIAGRAM......................................................................................................2581 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER..........................................................................2582 FUNCTION OF AIR CONDITIONER CONTROLLER......................................................................................2583 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS.......................................................2584 TESTING AIR LEAKAGE (DUCT)..........................................................................................................2588 METHOD FOR TESTING AIR LEAKAGE (DUCT)...........................................................................................2588 TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...............................................................................2590 HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR..................................2591 TEST VENT (MODE) CHANGEOVER.........................................................................................................2592 METHOD FOR TESTING VENT (MODE) CHANGEOVER.......................................................................................2592 TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................................2594 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER..................................................................................2594 TEST SUNLIGHT SENSOR................................................................................................................2595 METHOD FOR TESTING SUNLIGHT SENSOR..............................................................................................2595 TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.........................................................................................2596 METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT.......................................................................2596 TEST RELAYS.........................................................................................................................2597 METHOD FOR TESTING RELAYS.......................................................................................................2597 AIR CONDITIONER TROUBLESHOOTING CHART 1.............................................................................................2598 AIR CONDITIONER TROUBLESHOOTING CHART 2.............................................................................................2599 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE......................................................................................2602 FAILURE CODE [879AKA]...............................................................................................................2604 FAILURE CODE [879AKB]...............................................................................................................2605 FAILURE CODE [879BKA]...............................................................................................................2606 FAILURE CODE [879BKB]...............................................................................................................2608 FAILURE CODE [879CKA]...............................................................................................................2610 FAILURE CODE [879CKB]...............................................................................................................2611 FAILURE CODE [879DKZ]...............................................................................................................2612 FAILURE CODE [879EMC]...............................................................................................................2614 FAILURE CODE [879FMC]...............................................................................................................2615 FAILURE CODE [879GKX]...............................................................................................................2616 A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)......................................................2618 A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED).......................................................2620 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)..............................................2623 A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER.................................................................................2625 TROUBLESHOOTING USING GAUGE PRESSURE................................................................................................2627 CONNECTION OF SERVICE TOOL..........................................................................................................2630 METHOD FOR CONNECTING SERVICE TOOL..............................................................................................2630 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS.............................................2632 HANDLE COMPRESSOR OIL...............................................................................................................2634 90 CIRCUIT DIAGRAMS.....................................................................................................................2637 CONTENTS............................................................................................................................2638 ABBREVIATION LIST...................................................................................................................2639 HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................2645 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.......................................................................................2645 HYDRAULIC CIRCUIT DIAGRAM.......................................................................................................2649 ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................2651 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM......................................................................................2651 ELECTRICAL CIRCUIT DIAGRAM (1/10)...............................................................................................2655 ELECTRICAL CIRCUIT DIAGRAM (2/10)...............................................................................................2657 ELECTRICAL CIRCUIT DIAGRAM (3/10)...............................................................................................2659 ELECTRICAL CIRCUIT DIAGRAM (4/10)...............................................................................................2661 ELECTRICAL CIRCUIT DIAGRAM (5/10)...............................................................................................2663 ELECTRICAL CIRCUIT DIAGRAM (6/10)...............................................................................................2665 ELECTRICAL CIRCUIT DIAGRAM (7/10)...............................................................................................2667 ELECTRICAL CIRCUIT DIAGRAM (8/10)...............................................................................................2669 ELECTRICAL CIRCUIT DIAGRAM (9/10)...............................................................................................2671 ELECTRICAL CIRCUIT DIAGRAM (10/10)..............................................................................................2673 INDEX....................................................................................................................................2675
DESCRIPTION:
KOMATSU PC650LC-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06603-07 – PDF DOWNLOAD
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
S.S 27/12/24
