Komatsu PC650LC-11 Hydraulic Excavator Shop Manual SEN06603-11 – PDF DOWNLOAD

Description

Komatsu PC650LC-11 Hydraulic Excavator Shop Manual SEN06603-11 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC650LC-11 Hydraulic Excavator Shop Manual SEN06603-11 – PDF DOWNLOAD

SERIAL NUMBERS 80001 and up

FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE SHOP MANUAL:

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

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TABLE OF CONTENTS:

Komatsu PC650LC-11 Hydraulic Excavator Shop Manual SEN06603-11 – PDF DOWNLOAD

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 21
FOREWORD, SAFETY, BASIC INFORMATION 24
HOW TO READ THE SHOP MANUAL 24
SAFETY NOTICE FOR OPERATION 26
PRECAUTIONS TO PREVENT FIRE 34
ACTIONS IF FIRE OCCURS 36
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 37
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 38
PRECAUTIONS FOR DEF 39
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 39
PRECAUTIONS FOR ADDING 39
PRECAUTIONS FOR STORING 39
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 39
THE OTHER PRECAUTIONS 39
STORE AdBlue/DEF 40
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 41
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 44
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 51
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 53
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 54
PRACTICAL USE OF KOMTRAX 55
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 57
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 58
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 60
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 64
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 65
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 70
HOW TO READ ELECTRICAL WIRE CODE 71
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 75
STANDARD TIGHTENING TORQUE TABLE 78
CONVERSION TABLE 85
01 SPECIFICATIONS 91
CONTENTS 92
SPECIFICATIONS 93
SPECIFICATION DRAWING 93
SPECIFICATION DRAWING: PC650LC-11 93
WORKING RANGE DRAWINGS 95
WORKING RANGE: PC650LC-11 95
SPECIFICATIONS 96
SPECIFICATIONS: PC650LC-11 96
WEIGHT TABLE 99
WEIGHT TABLE: PC650LC-11 99
TABLE OF FUEL, COOLANT, AND LUBRICANTS 101
10 STRUCTURE AND FUNCTION 103
CONTENTS 104
UREA SCR SYSTEM 107
LAYOUT DRAWING OF UREA SCR SYSTEM 107
UREA SCR SYSTEM DIAGRAM 112
FUNCTION OF UREA SCR SYSTEM 113
FUNCTION OF AdBlue/DEF SYSTEM 113
INDUCEMENT STRATEGY 115
COMPONENT PARTS OF UREA SCR SYSTEM 122
AdBlue/DEF MIXING TUBE 122
SCR ASSEMBLY 123
AdBlue/DEF TANK 125
AdBlue/DEF PUMP 127
AdBlue/DEF INJECTOR 128
AdBlue/DEF HOSE 129
AdBlue/DEF TANK HEATING VALVE 130
BOOT-UP SYSTEM 131
LAYOUT DRAWING OF BOOT-UP SYSTEM 131
SYSTEM OPERATING LAMP SYSTEM 132
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 132
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 132
BATTERY DISCONNECT SWITCH 134
FUNCTION OF BATTERY DISCONNECT SWITCH 134
ENGINE SYSTEM 135
LAYOUT DRAWING OF ENGINE SYSTEM 135
FUNCTION OF ENGINE SYSTEM 136
ENGINE CONTROL SYSTEM 137
ENGINE CONTROL SYSTEM DIAGRAM 137
FUNCTION OF ENGINE CONTROL SYSTEM 137
AUTO-DECELERATION SYSTEM 140
AUTO-DECELERATION SYSTEM DIAGRAM 140
FUNCTION OF AUTO-DECELERATION SYSTEM 140
OPERATION OF AUTO-DECELERATION SYSTEM 141
AUTOMATIC LOW IDLE SYSTEM 142
AUTOMATIC LOW IDLE SYSTEM DIAGRAM 142
FUNCTION OF AUTOMATIC LOW IDLE SYSTEM 142
OPERATION OF AUTOMATIC LOW IDLE SYSTEM 143
ENGINE AUTOMATIC WARM-UP SYSTEM 144
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 144
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 146
OVERHEAT PREVENTION SYSTEM 147
OVERHEAT PREVENTION SYSTEM DIAGRAM 147
FUNCTION OF OVERHEAT PREVENTION SYSTEM 148
TURBOCHARGER PROTECTION SYSTEM 149
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 149
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 150
AUTOMATIC IDLE STOP SYSTEM 151
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 151
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 151
COMPONENT PARTS OF ENGINE SYSTEM 154
PTO 154
VGT 155
EGR SYSTEM 159
EGR VALVE 162
EGR COOLER 164
KCCV SYSTEM 165
KCCV VENTILATOR 167
KDPF 169
COOLING SYSTEM 173
LAYOUT DRAWING OF COOLING SYSTEM 173
SPECIFICATIONS OF COOLING SYSTEM 174
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 175
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 175
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 176
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 177
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 177
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 177
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 179
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN 179
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 179
COMPONENT PARTS OF COOLING SYSTEM 180
COOLING FAN PUMP 180
COOLING FAN MOTOR 188
CONTROL SYSTEM 195
LAYOUT DRAWING OF CONTROL SYSTEM 195
MACHINE MONITOR SYSTEM 197
MACHINE MONITOR SYSTEM DIAGRAM 197
FUNCTION OF MACHINE MONITOR SYSTEM 198
KomVision SYSTEM 199
LAYOUT DRAWING OF KOMVISION SYSTEM 199
KomVision SYSTEM DIAGRAM 201
FUNCTION OF KomVision SYSTEM 202
KOMTRAX SYSTEM 204
KOMTRAX SYSTEM DIAGRAM 204
FUNCTION OF KOMTRAX SYSTEM 204
COMPONENT PARTS OF CONTROL SYSTEM 205
MACHINE MONITOR 205
KomVision CONTROLLER 220
KomVision CAMERA 224
KOMTRAX TERMINAL 225
PUMP CONTROLLER 227
RESISTOR FOR TVC VALVE 232
CAN TERMINATING RESISTOR 233
ENGINE CONTROLLER 234
FUEL CONTROL DIAL 241
FUEL FEED PUMP 243
FUEL FEED PUMP SWITCH 244
HYDRAULIC SYSTEM 245
LAYOUT DRAWING OF HYDRAULIC SYSTEM 245
OLSS 248
STRUCTURE OF OLSS 248
FUNCTION OF OLSS 248
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 250
ENGINE AND PUMP COMBINED CONTROL SYSTEM 261
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 261
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 263
COMPONENT PARTS OF HYDRAULIC SYSTEM 266
HYDRAULIC TANK 266
MAIN PUMP 268
CONTROL VALVE 296
VARIABLE BACK PRESSURE VALVE 317
WORK EQUIPMENT SYSTEM 320
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 320
ONE-TOUCH POWER MAXIMIZING SYSTEM 326
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 326
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 327
MACHINE PUSH-UP SYSTEM 328
MACHINE PUSH-UP SYSTEM DIAGRAM 328
FUNCTION OF MACHINE PUSH-UP SYSTEM 329
BOOM SHOCKLESS CONTROL FUNCTION 330
BOOM SHOCKLESS CONTROL FUNCTION SYSTEM DIAGRAM 330
OPERATION OF BOOM SHOCKLESS CONTROL FUNCTION 330
PPC LOCK SYSTEM 331
PPC LOCK SYSTEM DIAGRAM 331
FUNCTION OF PPC LOCK SYSTEM 331
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 332
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 332
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 332
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 333
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 334
WORK EQUIPMENT AND SWING PPC VALVE 334
1ST-LINE ATTACHMENT PPC VALVE 339
PPC SHUTTLE VALVE 341
SOLENOID VALVE 342
PILOT CIRCUIT ACCUMULATOR 345
SWING SYSTEM 346
LAYOUT DRAWING OF SWING SYSTEM 346
SWING CONTROL SYSTEM DIAGRAM 349
FUNCTION OF SWING CONTROL SYSTEM 350
COMPONENT PARTS OF SWING SYSTEM 353
SWING MOTOR 353
SWING MACHINERY 365
SWING CIRCLE 367
TRAVEL SYSTEM 368
LAYOUT DRAWING OF TRAVEL SYSTEM 368
TRAVEL CONTROL SYSTEM DIAGRAM 372
FUNCTION OF TRAVEL CONTROL SYSTEM 374
COMPONENT PARTS OF TRAVEL SYSTEM 375
TRAVEL MOTOR 375
FINAL DRIVE 388
TRAVEL PPC VALVE 390
CENTER SWIVEL JOINT 394
UNDERCARRIAGE AND FRAME 396
LAYOUT DRAWING OF UNDERCARRIAGE 396
SPECIFICATIONS OF UNDERCARRIAGE 396
WORK EQUIPMENT 397
STRUCTURE OF WORK EQUIPMENT 397
FUNCTION OF WORK EQUIPMENT 398
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 399
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 399
BUCKET CLEARANCE ADJUSTMENT SHIM 400
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 400
CAB AND ITS ATTACHMENTS 401
CAB 401
STRUCTURE OF CAB 401
CAB MOUNT 402
STRUCTURE OF CAB MOUNT 402
FUNCTION OF CAB MOUNT 402
CAB TIPPING STOPPER 403
STRUCTURE OF CAB TIPPING STOPPER 403
FUNCTION OF CAB TIPPING STOPPER 403
20 STANDARD VALUE TABLE 405
CONTENTS 406
STANDARD VALUE TABLE FOR ENGINE 407
STANDARD VALUE TABLE FOR ENGINE: PC650LC-11 407
STANDARD VALUE TABLE FOR MACHINE 412
STANDARD VALUE TABLE FOR MACHINE: PC650LC-11 412
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 429
30 TESTING AND ADJUSTING 433
CONTENTS 434
RELATED INFORMATION ON TESTING AND ADJUSTING 437
TOOLS FOR TESTING AND ADJUSTING 437
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 446
ENGINE AND COOLING SYSTEM 448
TEST ENGINE SPEED 448
METHOD FOR TESTING ENGINE SPEED 448
TEST BOOST PRESSURE 451
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 451
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL 452
TEST EXHAUST GAS TEMPERATURE 453
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 453
TEST EXHAUST GAS COLOR 455
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 455
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 456
TEST AND ADJUST VALVE CLEARANCE 458
METHOD FOR TESTING VALVE CLEARANCE 458
METHOD FOR ADJUSTING VALVE CLEARANCE 459
TEST COMPRESSION PRESSURE 461
METHOD FOR TESTING COMPRESSION PRESSURE 461
TEST BLOWBY PRESSURE 464
METHOD FOR TESTING BLOWBY PRESSURE 464
TEST ENGINE OIL PRESSURE 466
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 466
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 466
TEST EGR VALVE AND VGT OIL PRESSURE 468
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 468
TEST FUEL PRESSURE 470
METHOD FOR TESTING FUEL PRESSURE 470
TEST FUEL RETURN RATE AND LEAKAGE 472
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 472
BLEED AIR FROM FUEL SYSTEM 475
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 475
TEST FUEL CIRCUIT FOR LEAKAGE 477
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 477
HANDLE CYLINDER CUT-OUT MODE OPERATION 479
HANDLE NO-INJECTION CRANKING OPERATION 480
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 481
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 481
CLEAN FUEL DOSER 482
METHOD FOR CLEANING FUEL DOSER 482
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 484
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 484
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 490
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 490
TEST SCR RELATED FUNCTIONS 491
TEST AdBlue/DEF PUMP RAISED PRESSURE 495
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 498
TEST AdBlue/DEF LINE HEATER RELAY 1 503
TEST AdBlue/DEF LINE HEATER RELAY 2 507
TEST AdBlue/DEF PUMP HEATER RELAY 510
TEST AdBlue/DEF TANK HEATER VALVE 513
TEST DENITRATION EFFICIENCY OF SCR 516
CLEAN AdBlue/DEF TANK 520
METHOD FOR CLEANING AdBlue/DEF TANK 520
CLEAN AdBlue/DEF PUMP 524
CLEAN AdBlue/DEF PUMP 524
POWER TRAIN 530
TEST SWING CIRCLE BEARING CLEARANCE 530
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 530
UNDERCARRIAGE AND FRAME 531
TEST AND ADJUST TRACK TENSION 531
METHOD FOR TESTING TRACK TENSION 531
METHOD FOR ADJUSTING TRACK TENSION 531
HYDRAULIC SYSTEM 533
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 533
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 533
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 542
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 542
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 543
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 546
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 554
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 558
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 558
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 559
TEST AND ADJUST PISTON PUMP CONTROL OIL PRESSURE 560
METHOD FOR TESTING TVC VALVE OUTLET PRESSURE 560
METHOD FOR TESTING CO AND NC VALVE OUTLET PRESSURE 561
METHOD FOR TESTING JET SENSOR OUTLET PRESSURE 562
METHOD FOR ADJUSTING TVC VALVE 564
METHOD FOR ADJUSTING CO AND NC VALVE 565
METHOD FOR ADJUSTING JET SENSOR 566
TEST SERVO PISTON STROKE 567
METHOD FOR TESTING SERVO PISTON STROKE 567
TEST OUTLET PRESSURE OF SOLENOID VALVE 569
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 569
OPERATING CONDITION OF SOLENOID VALVE 570
TEST PPC VALVE OUTLET PRESSURE 573
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 573
TEST PPC SHUTTLE VALVE OUTLET PRESSURE 575
METHOD FOR TESTING PPC SHUTTLE VALVE OUTLET PRESSURE 575
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 579
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 579
TEST AND ADJUST TRAVEL DEVIATION 580
METHOD FOR TESTING TRAVEL DEVIATION 580
METHOD FOR ADJUSTING TRAVEL DEVIATION 580
TEST COOLING FAN SPEED 582
METHOD FOR TESTING COOLING FAN SPEED 582
TEST OIL PRESSURE IN FAN PUMP CIRCUIT 583
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT 583
TEST FAN PUMP EPC ELECTRIC CURRENT 584
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 584
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 585
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 585
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 586
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 586
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 586
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 587
TEST OIL LEAKAGE 588
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 588
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 589
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 589
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 590
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 590
METHOD FOR TESTING OIL LEAKAGE OF SWIVEL JOINT 591
BLEED AIR FROM HYDRAULIC CIRCUIT 593
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 594
CAB AND ITS ATTACHMENTS 597
TEST CAB TIPPING STOPPER 597
METHOD FOR TESTING CAB TIPPING STOPPER 597
METHOD FOR ADJUSTING MIRRORS 598
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 598
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 599
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 600
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 601
ELECTRICAL SYSTEM 603
SET AND OPERATE MACHINE MONITOR 603
OPERATOR MODE 607
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 607
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 607
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 608
CHECKING FUNCTION OF SERVICE METER 608
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 608
SERVICE MODE 611
METHOD FOR OPERATING SERVICE MODE 611
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 613
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 619
ABNORMALITY RECORD MENU 631
METHOD FOR CONFIRMING MAINTENANCE RECORD 635
METHOD FOR OPERATING MAINTENANCE MODE SETTING 636
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 640
DEFAULT MENU 642
DIAGNOSTIC TESTS MENU 648
ADJUSTMENT MENU 658
METHOD FOR PERFORMING NO-INJECTION CRANKING 661
KOMTRAX SETTINGS MENU 663
METHOD FOR DISPLAYING SERVICE MESSAGE 665
METHOD FOR STARTING UP KOMTRAX TERMINAL 667
ADJUST REARVIEW CAMERA ANGLE 672
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 672
ADJUST KomVision CAMERA ANGLE 674
METHOD FOR ADJUSTING KomVision CAMERA ANGLE 675
ADJUST KomVision RELATED ITEMS 677
SETTING OF KomVision (MAIN SETTING) 678
SETTING OF KomVision (CAMERA SETTING) 680
SETTING OF KomVision (CAMERA CALIBRATION) 681
KomVision screen – Check 12 m visibility 694
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 697
HANDLE BATTERY DISCONNECT SWITCH 698
TEST DIODES 699
METHOD FOR TESTING DIODE USING DIGITAL TESTER 699
METHOD FOR TESTING DIODE USING ANALOG TESTER 699
Pm CLINIC 700
Pm CLINIC SERVICE 700
Pm CLINIC CHECK SHEET: PC650LC-11 704
40 TROUBLESHOOTING 721
CONTENTS 722
RELATED INFORMATION ON TROUBLESHOOTING 733
GENERAL TROUBLESHOOTING POINTS 733
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 734
SEQUENCE OF EVENTS IN TROUBLESHOOTING 749
CHECKS BEFORE TROUBLESHOOTING 751
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 753
WALK-AROUND CHECK 753
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 755
CHECK FUEL LEVEL AND TYPE 755
CHECK IMPURE INGREDIENT IN FUEL 756
CHECK FUEL PREFILTER 756
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 756
FUEL PREFILTER CARTRIDGE – REPLACE 757
CHECK MAIN FILTER 758
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 759
CHECK COOLANT LEVEL (RESERVOIR TANK) 761
CHECK CLOGGING OF AIR CLEANER 761
OUTER ELEMENT – CLEAN 761
ELEMENTS – REPLACE 764
CHECK HYDRAULIC OIL LEVEL 764
CHECK HYDRAULIC OIL STRAINER 766
CHECK HYDRAULIC FILTER 766
CHECK OIL LEVEL IN SWING MACHINERY CASE 767
CHECK OIL LEVEL IN PTO CASE 768
CHECK PTO LUBRICATION FILTER STRAINER 768
CHECK OIL LEVEL IN FINAL DRIVE CASE 769
BLEED AIR FROM FUEL SYSTEM 770
BLEED AIR FROM HYDRAULIC SYSTEM 770
ELECTRICAL EQUIPMENT – CHECK METHOD 770
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 776
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 776
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 776
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 776
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL 777
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 777
PROCEDURE FOR TESTING AND TROUBLESHOOTING 781
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 784
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 788
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 790
CONNECTOR LIST AND LAYOUT 793
CONNECTOR CONTACT IDENTIFICATION 807
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 847
FUSE LOCATION TABLE 853
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 856
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 860
FAILURE CODES TABLE 862
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 879
FAILURE CODE [879AKA] 879
FAILURE CODE [879AKB] 880
FAILURE CODE [879BKA] 881
FAILURE CODE [879BKB] 883
FAILURE CODE [879CKA] 885
FAILURE CODE [879CKB] 886
FAILURE CODE [879DKZ] 887
FAILURE CODE [879EMC] 889
FAILURE CODE [879FMC] 890
FAILURE CODE [879GKX] 891
FAILURE CODE [989L00] 893
FAILURE CODE [989M00] 894
FAILURE CODE [989N00] 895
FAILURE CODE [A1U0N3] 896
FAILURE CODE [A1U0N4] 898
FAILURE CODE [A900FR] 900
FAILURE CODE [A900N6] 901
FAILURE CODE [A900NY] 902
FAILURE CODE [AA10NX] 903
FAILURE CODE [AB00KE] 905
FAILURE CODE [AQ10N3] 907
FAILURE CODE [AS00N3] 909
FAILURE CODE [AS00R2] 911
FAILURE CODE [AS00R3] 912
FAILURE CODE [AS00R4] 913
FAILURE CODE [AS00R5] 914
FAILURE CODE [AS00R6] 915
FAILURE CODE [AS00ZK] 916
FAILURE CODE [AS10KM] 917
FAILURE CODE [AS10NR] 918
FAILURE CODE [AS10NT] 919
FAILURE CODE [B@BAZG] 920
FAILURE CODE [B@BAZK] 921
FAILURE CODE [B@BCNS] 923
FAILURE CODE [B@BCQA] 924
FAILURE CODE [B@BCZK] 926
FAILURE CODE [B@HANS] 928
FAILURE CODE [CA115] 929
FAILURE CODE [CA122] 930
FAILURE CODE [CA123] 932
FAILURE CODE [CA131] 934
FAILURE CODE [CA132] 936
FAILURE CODE [CA135] 938
FAILURE CODE [CA141] 940
FAILURE CODE [CA144] 942
FAILURE CODE [CA145] 944
FAILURE CODE [CA153] 946
FAILURE CODE [CA154] 949
FAILURE CODE [CA187] 952
FAILURE CODE [CA221] 954
FAILURE CODE [CA222] 956
FAILURE CODE [CA227] 958
FAILURE CODE [CA234] 959
FAILURE CODE [CA238] 960
FAILURE CODE [CA239] 962
FAILURE CODE [CA249] 964
FAILURE CODE [CA256] 966
FAILURE CODE [CA271] 968
FAILURE CODE [CA272] 970
FAILURE CODE [CA273] 971
FAILURE CODE [CA274] 973
FAILURE CODE [CA322] 974
FAILURE CODE [CA323] 976
FAILURE CODE [CA324] 978
FAILURE CODE [CA325] 980
FAILURE CODE [CA331] 982
FAILURE CODE [CA332] 984
FAILURE CODE [CA343] 986
FAILURE CODE [CA351] 987
FAILURE CODE [CA352] 988
FAILURE CODE [CA356] 991
FAILURE CODE [CA357] 993
FAILURE CODE [CA386] 995
FAILURE CODE [CA441] 996
FAILURE CODE [CA442] 998
FAILURE CODE [CA449] 999
FAILURE CODE [CA451] 1000
FAILURE CODE [CA452] 1002
FAILURE CODE [CA515] 1004
FAILURE CODE [CA516] 1006
FAILURE CODE [CA553] 1008
FAILURE CODE [CA555] 1009
FAILURE CODE [CA556] 1010
FAILURE CODE [CA559] 1011
FAILURE CODE [CA595] 1016
FAILURE CODE [CA687] 1017
FAILURE CODE [CA689] 1019
FAILURE CODE [CA691] 1021
FAILURE CODE [CA692] 1023
FAILURE CODE [CA697] 1025
FAILURE CODE [CA698] 1026
FAILURE CODE [CA731] 1027
FAILURE CODE [CA778] 1028
FAILURE CODE [CA1117] 1031
FAILURE CODE [CA1664] 1032
FAILURE CODE [CA1669] 1036
FAILURE CODE [CA1673] 1037
FAILURE CODE [CA1677] 1038
FAILURE CODE [CA1678] 1039
FAILURE CODE [CA1682] 1040
FAILURE CODE [CA1683] 1042
FAILURE CODE [CA1684] 1044
FAILURE CODE [CA1686] 1046
FAILURE CODE [CA1691] 1047
FAILURE CODE [CA1694] 1050
FAILURE CODE [CA1695] 1052
FAILURE CODE [CA1696] 1053
FAILURE CODE [CA1712] 1055
FAILURE CODE [CA1713] 1058
FAILURE CODE [CA1714] 1061
FAILURE CODE [CA1715] 1062
FAILURE CODE [CA1776] 1063
FAILURE CODE [CA1777] 1066
FAILURE CODE [CA1843] 1069
FAILURE CODE [CA1844] 1071
FAILURE CODE [CA1879] 1074
FAILURE CODE [CA1881] 1077
FAILURE CODE [CA1883] 1079
FAILURE CODE [CA1885] 1083
FAILURE CODE [CA1887] 1085
FAILURE CODE [CA1921] 1087
FAILURE CODE [CA1922] 1090
FAILURE CODE [CA1923] 1095
FAILURE CODE [CA1924] 1097
FAILURE CODE [CA1925] 1099
FAILURE CODE [CA1927] 1101
FAILURE CODE [CA1928] 1103
FAILURE CODE [CA1942] 1105
FAILURE CODE [CA1963] 1106
FAILURE CODE [CA1977] 1110
FAILURE CODE [CA1993] 1113
FAILURE CODE [CA2185] 1116
FAILURE CODE [CA2186] 1118
FAILURE CODE [CA2249] 1120
FAILURE CODE [CA2265] 1121
FAILURE CODE [CA2266] 1123
FAILURE CODE [CA2271] 1125
FAILURE CODE [CA2272] 1127
FAILURE CODE [CA2349] 1129
FAILURE CODE [CA2353] 1131
FAILURE CODE [CA2357] 1133
FAILURE CODE [CA2381] 1134
FAILURE CODE [CA2382] 1136
FAILURE CODE [CA2383] 1138
FAILURE CODE [CA2386] 1140
FAILURE CODE [CA2387] 1142
FAILURE CODE [CA2555] 1143
FAILURE CODE [CA2556] 1145
FAILURE CODE [CA2637] 1147
FAILURE CODE [CA2639] 1149
FAILURE CODE [CA2732] 1151
FAILURE CODE [CA2733] 1153
FAILURE CODE [CA2741] 1155
FAILURE CODE [CA2765] 1156
FAILURE CODE [CA2771] 1157
FAILURE CODE [CA2777] 1163
FAILURE CODE [CA2878] 1166
FAILURE CODE [CA2881] 1169
FAILURE CODE [CA2976] 1172
FAILURE CODE [CA3133] 1174
FAILURE CODE [CA3134] 1176
FAILURE CODE [CA3135] 1178
FAILURE CODE [CA3142] 1181
FAILURE CODE [CA3143] 1182
FAILURE CODE [CA3144] 1183
FAILURE CODE [CA3146] 1185
FAILURE CODE [CA3147] 1186
FAILURE CODE [CA3148] 1187
FAILURE CODE [CA3151] 1189
FAILURE CODE [CA3165] 1194
FAILURE CODE [CA3167] 1197
FAILURE CODE [CA3229] 1201
FAILURE CODE [CA3231] 1204
FAILURE CODE [CA3232] 1207
FAILURE CODE [CA3235] 1212
FAILURE CODE [CA3239] 1214
FAILURE CODE [CA3241] 1217
FAILURE CODE [CA3242] 1220
FAILURE CODE [CA3251] 1223
FAILURE CODE [CA3253] 1227
FAILURE CODE [CA3254] 1233
FAILURE CODE [CA3255] 1237
FAILURE CODE [CA3256] 1240
FAILURE CODE [CA3311] 1243
FAILURE CODE [CA3312] 1246
FAILURE CODE [CA3313] 1249
FAILURE CODE [CA3314] 1250
FAILURE CODE [CA3315] 1251
FAILURE CODE [CA3316] 1254
FAILURE CODE [CA3317] 1255
FAILURE CODE [CA3318] 1256
FAILURE CODE [CA3319] 1259
FAILURE CODE [CA3321] 1260
FAILURE CODE [CA3322] 1261
FAILURE CODE [CA3419] 1264
FAILURE CODE [CA3421] 1266
FAILURE CODE [CA3497] 1268
FAILURE CODE [CA3498] 1269
FAILURE CODE [CA3543] 1270
FAILURE CODE [CA3545] 1275
FAILURE CODE [CA3547] 1277
FAILURE CODE [CA3558] 1278
FAILURE CODE [CA3559] 1280
FAILURE CODE [CA3562] 1282
FAILURE CODE [CA3563] 1284
FAILURE CODE [CA3567] 1287
FAILURE CODE [CA3568] 1290
FAILURE CODE [CA3571] 1294
FAILURE CODE [CA3572] 1296
FAILURE CODE [CA3574] 1298
FAILURE CODE [CA3575] 1301
FAILURE CODE [CA3577] 1303
FAILURE CODE [CA3578] 1305
FAILURE CODE [CA3582] 1307
FAILURE CODE [CA3583] 1312
FAILURE CODE [CA3596] 1314
FAILURE CODE [CA3649] 1318
FAILURE CODE [CA3681] 1321
FAILURE CODE [CA3682] 1326
FAILURE CODE [CA3713] 1332
FAILURE CODE [CA3717] 1335
FAILURE CODE [CA3718] 1336
FAILURE CODE [CA3725] 1337
FAILURE CODE [CA3748] 1340
FAILURE CODE [CA3751] 1342
FAILURE CODE [CA3755] 1344
FAILURE CODE [CA3866] 1346
FAILURE CODE [CA3867] 1350
FAILURE CODE [CA3868] 1353
FAILURE CODE [CA3899] 1357
FAILURE CODE [CA3911] 1360
FAILURE CODE [CA3912] 1364
FAILURE CODE [CA3932] 1366
FAILURE CODE [CA3933] 1368
FAILURE CODE [CA3934] 1370
FAILURE CODE [CA3935] 1373
FAILURE CODE [CA3936] 1375
FAILURE CODE [CA4151] 1377
FAILURE CODE [CA4152] 1381
FAILURE CODE [CA4155] 1385
FAILURE CODE [CA4156] 1387
FAILURE CODE [CA4157] 1390
FAILURE CODE [CA4158] 1392
FAILURE CODE [CA4159] 1394
FAILURE CODE [CA4161] 1396
FAILURE CODE [CA4162] 1399
FAILURE CODE [CA4163] 1402
FAILURE CODE [CA4164] 1404
FAILURE CODE [CA4165] 1407
FAILURE CODE [CA4166] 1410
FAILURE CODE [CA4168] 1413
FAILURE CODE [CA4169] 1418
FAILURE CODE [CA4171] 1423
FAILURE CODE [CA4249] 1428
FAILURE CODE [CA4251] 1432
FAILURE CODE [CA4259] 1436
FAILURE CODE [CA4261] 1439
FAILURE CODE [CA4277] 1442
FAILURE CODE [CA4281] 1446
FAILURE CODE [CA4459] 1449
FAILURE CODE [CA4461] 1452
FAILURE CODE [CA4658] 1455
FAILURE CODE [CA4731] 1459
FAILURE CODE [CA4732] 1460
FAILURE CODE [CA4739] 1461
FAILURE CODE [CA4768] 1462
FAILURE CODE [CA4769] 1464
FAILURE CODE [CA4842] 1467
FAILURE CODE [CA4952] 1471
FAILURE CODE [CA5115] 1473
FAILURE CODE [CA5179] 1476
FAILURE CODE [CA5181] 1478
FAILURE CODE [CA5383] 1480
FAILURE CODE [D110KB] 1482
FAILURE CODE [D163KB] 1484
FAILURE CODE [D195KA] 1486
FAILURE CODE [D195KB] 1488
FAILURE CODE [D19JKZ] 1490
FAILURE CODE [D811MC] 1492
FAILURE CODE [D862KA] 1493
FAILURE CODE [D8ALKA] 1494
FAILURE CODE [D8ALKB] 1496
FAILURE CODE [D8AQKR] 1498
FAILURE CODE [DA20MC] 1502
FAILURE CODE [DA22KK] 1503
FAILURE CODE [DA25KP] 1505
FAILURE CODE [DA26KP] 1507
FAILURE CODE [DA29KQ] 1510
FAILURE CODE [DA2LKA] 1512
FAILURE CODE [DA2LKB] 1514
FAILURE CODE [DA2QKR] 1516
FAILURE CODE [DA2RKR] 1521
FAILURE CODE [DAF0KM] 1526
FAILURE CODE [DAF0MB] 1527
FAILURE CODE [DAF0MC] 1528
FAILURE CODE [DAF8KB] 1529
FAILURE CODE [DAF9KQ] 1530
FAILURE CODE [DAFGMC] 1531
FAILURE CODE [DAFLKA] 1532
FAILURE CODE [DAFLKB] 1534
FAILURE CODE [DAFQKR] 1536
FAILURE CODE [DAZ9KQ] 1540
FAILURE CODE [DAZQKR] 1541
FAILURE CODE [DB2QKR] 1545
FAILURE CODE [DB2RKR] 1550
FAILURE CODE [DBP0KM] 1555
FAILURE CODE [DBP0KT] 1556
FAILURE CODE [DBP5KB] 1557
FAILURE CODE [DBP5KY] 1560
FAILURE CODE [DBPQKR] 1563
FAILURE CODE [DDNRKA] 1568
FAILURE CODE [DDNRKY] 1570
FAILURE CODE [DDNS00] 1572
FAILURE CODE [DGE5KB] 1574
FAILURE CODE [DGH2KA] 1575
FAILURE CODE [DGH2KB] 1577
FAILURE CODE [DHA4KA] 1579
FAILURE CODE [DHAAMA] 1581
FAILURE CODE [DHACMA] 1583
FAILURE CODE [DHPAMA] 1585
FAILURE CODE [DHPBMA] 1587
FAILURE CODE [DHS3MA] 1589
FAILURE CODE [DHS4MA] 1592
FAILURE CODE [DHS8MA] 1595
FAILURE CODE [DHS9MA] 1598
FAILURE CODE [DHSAMA] 1601
FAILURE CODE [DHSBMA] 1604
FAILURE CODE [DHSCMA] 1607
FAILURE CODE [DHSDMA] 1610
FAILURE CODE [DHSFMA] 1613
FAILURE CODE [DHSGMA] 1616
FAILURE CODE [DHSHMA] 1619
FAILURE CODE [DHSJMA] 1622
FAILURE CODE [DHSVMA] 1625
FAILURE CODE [DKULKA] 1627
FAILURE CODE [DKULKB] 1629
FAILURE CODE [DKULKY] 1631
FAILURE CODE [DLM3KA] 1633
FAILURE CODE [DLM3KB] 1635
FAILURE CODE [DLM3MB] 1637
FAILURE CODE [DR10KA] 1638
FAILURE CODE [DR12KA] 1641
FAILURE CODE [DR20KA] 1643
FAILURE CODE [DR21KX] 1645
FAILURE CODE [DR30KA] 1647
FAILURE CODE [DR31KX] 1649
FAILURE CODE [DR40KA] 1651
FAILURE CODE [DUMBKA] 1653
FAILURE CODE [DUMBKB] 1655
FAILURE CODE [DV20KB] 1657
FAILURE CODE [DW43KA] 1658
FAILURE CODE [DW43KB] 1660
FAILURE CODE [DW43KY] 1662
FAILURE CODE [DW45KA] 1663
FAILURE CODE [DW45KB] 1666
FAILURE CODE [DW45KY] 1669
FAILURE CODE [DW48KA] 1671
FAILURE CODE [DW48KB] 1673
FAILURE CODE [DW48KY] 1675
FAILURE CODE [DW4CKY] 1676
FAILURE CODE [DW4XKA] 1678
FAILURE CODE [DW4XKB] 1680
FAILURE CODE [DW4XKY] 1682
FAILURE CODE [DW7BKA] 1683
FAILURE CODE [DW7BKB] 1685
FAILURE CODE [DW7BKY] 1687
FAILURE CODE [DWK0KA] 1688
FAILURE CODE [DWK0KB] 1690
FAILURE CODE [DWK0KY] 1692
FAILURE CODE [DWK2KA] 1693
FAILURE CODE [DWK2KB] 1695
FAILURE CODE [DWK2KY] 1697
FAILURE CODE [DWK8KA] 1698
FAILURE CODE [DWK8KB] 1700
FAILURE CODE [DWK8KY] 1702
FAILURE CODE [DX16KA] 1703
FAILURE CODE [DX16KB] 1705
FAILURE CODE [DXA2KA] 1706
FAILURE CODE [DXA2KB] 1709
FAILURE CODE [DXA3KA] 1711
FAILURE CODE [DXA3KB] 1714
FAILURE CODE [DY20KA] 1716
FAILURE CODE [DY20MA] 1718
FAILURE CODE [DY2CKB] 1720
FAILURE CODE [DY2DKB] 1722
FAILURE CODE [DY2EKB] 1724
FAILURE CODE [DY2FMA] 1726
FAILURE CODE [DY2GKM] 1728
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1730
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1730
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1736
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1739
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1741
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1743
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1746
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1747
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1748
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1749
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1750
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1751
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1752
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1753
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1754
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1755
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1756
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 1758
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1759
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1760
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1761
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 1763
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 1764
E-23 FUNCTION SWITCH DOES NOT OPERATE 1765
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 1766
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1767
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1768
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 1769
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1770
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 1771
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1772
E-31 ALARM BUZZER CANNOT BE CANCELED 1773
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 1774
E-33 SERVICE MODE CANNOT BE SELECTED 1775
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1776
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 1779
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 1781
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 1784
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 1786
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 1788
E-40 ALARM DOES NOT SOUND DURING TRAVEL 1789
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1791
E-42 HORN DOES NOT SOUND 1792
E-43 HORN DOES NOT STOP SOUNDING 1795
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 1797
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 1798
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1800
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1801
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1802
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1803
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1804
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1805
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1806
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1807
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1808
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1809
E-56 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1811
E-57 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 1812
E-58 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1814
E-59 STEP LIGHT DOES NOT LIGHT UP 1815
E-60 STEP LIGHT DOES NOT GO OUT 1817
E-61 BOOM SHOCKLESS FUNCTION CANNOT BE CANCELED 1819
E-62 BOOM SHOCKLESS FUNCTION DOES NOT WORK 1821
E-63 ELECTRIC GREASE GUN DOES NOT WORK 1822
E-64 ELECTRIC GREASE GUN DOES NOT STOP 1824
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1825
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1825
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 1826
H-3 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 1828
H-4 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1829
H-5 TRAVEL SPEED OR POWER IS LOW 1830
H-6 AUTO-DECELERATION FUNCTION CANNOT BE CANCELED 1831
H-7 SPEED OR POWER OF BOOM IS LOW 1832
H-8 ARM SPEED OR POWER IS LOW 1834
H-9 BUCKET SPEED OR POWER IS LOW 1835
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1836
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE 1837
H-12 HYDRAULIC DRIFT OF ARM IS LARGE 1838
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE 1839
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1840
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 1841
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1842
H-17 MACHINE DOES NOT TRAVEL STRAIGHT 1843
H-18 SPEED OF BOOM AND BUCKET IS SLOW AT COMBINED OPERATION OF ARM, BOOM AND BUCKET 1844
H-19 SPEED OF BOOM, ARM, SWING AND TRAVEL IS SLOW AT COMBINED OPERATION OF BUCKET, BOOM AND ARM 1845
H-20 SWING SPEED IS SLOW AT COMBINED OPERATION OF ARM AND SWING 1846
H-21 TRAVEL DEVIATION IS LARGE AT START OF TRAVELING 1847
H-22 TRAVEL DEVIATION IS LARGE AT COMBINED OPERATION 1849
H-23 ONE OF TRACKS DOES NOT RUN 1850
H-24 TRAVEL SPEED DOES NOT CHANGE 1852
H-25 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1853
H-26 SWINGS ONLY IN ONE DIRECTION 1854
H-27 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 1855
H-28 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1856
H-29 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1857
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1858
H-31 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 1859
H-32 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 1860
H-33 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 1861
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1862
H-35 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 1863
H-36 UNUSUAL NOISE IS HEARD FROM AROUND FAN 1864
TROUBLESHOOTING OF ENGINE (S-MODE) 1865
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1865
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1866
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1867
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1868
S-4 ENGINE STARTABILITY IS POOR 1869
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1871
S-6 ENGINE STOPS DURING OPERATION 1873
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1875
S-8 ENGINE LACKS POWER 1876
S-9 KDPF GETS CLOGGED IN A SHORT TIME 1878
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1880
S-11 OIL BECOMES CONTAMINATED QUICKLY 1881
S-12 FUEL CONSUMPTION IS EXCESSIVE 1882
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1883
S-14 OIL PRESSURE DROPS 1884
S-15 FUEL MIXES INTO ENGINE OIL 1886
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1887
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 1888
S-18 UNUSUAL NOISE IS HEARD 1889
S-19 VIBRATION IS EXCESSIVE 1890
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 1891
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 1892
S-22 ACTIVE REGENERATION TAKES TIME 1894
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1896
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1897
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 1899
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1900
50 DISASSEMBLY AND ASSEMBLY 1901
CONTENTS 1902
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1907
HOW TO READ THIS MANUAL 1907
COATING MATERIALS LIST 1909
SPECIAL TOOLS LIST 1913
SKETCHES OF SPECIAL TOOLS 1930
ENGINE AND COOLING SYSTEM 1937
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1937
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1937
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1940
REMOVE AND INSTALL INJECTOR ASSEMBLY 1945
METHOD FOR REMOVING INJECTOR ASSEMBLY 1945
METHOD FOR INSTALLING INJECTOR ASSEMBLY 1950
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 1959
METHOD FOR REMOVING FUEL DOSER ASSEMBLY 1959
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY 1960
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 1962
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1963
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1973
REMOVE AND INSTALL EGR VALVE ASSEMBLY 1990
METHOD FOR REMOVING EGR VALVE ASSEMBLY 1990
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 1992
REMOVE AND INSTALL EGR COOLER ASSEMBLY 1994
METHOD FOR REMOVING EGR COOLER ASSEMBLY 1994
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 1997
REMOVE AND INSTALL STARTER ASSEMBLY 2001
METHOD FOR REMOVING STARTER ASSEMBLY 2001
METHOD FOR INSTALLING STARTER ASSEMBLY 2001
REMOVE AND INSTALL ALTERNATOR BELT 2003
METHOD FOR REMOVING ALTERNATOR BELT 2003
METHOD FOR INSTALLING ALTERNATOR BELT 2004
REMOVE AND INSTALL RADIATOR ASSEMBLY 2006
METHOD FOR REMOVING RADIATOR ASSEMBLY 2006
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2009
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2013
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2013
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2016
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2020
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2020
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2022
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 2025
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2025
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2034
REMOVE AND INSTALL ENGINE PTO AND HYDRAULIC ASSEMBLY 2043
METHOD FOR REMOVING ENGINE PTO AND HYDRAULIC ASSEMBLY 2043
METHOD FOR INSTALLING ENGINE PTO AND HYDRAULIC ASSEMBLY 2054
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2065
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2065
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2066
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2069
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2069
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2071
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2078
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2078
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2083
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2088
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2088
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2091
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2095
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2096
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2102
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2107
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2107
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2108
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2110
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2110
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2111
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2117
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2117
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2117
REMOVE AND INSTALL KDPF ASSEMBLY 2118
METHOD FOR REMOVING KDPF ASSEMBLY 2118
METHOD FOR INSTALLING KDPF ASSEMBLY 2122
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2131
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2132
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2136
REMOVE AND INSTALL SCR ASSEMBLY 2141
METHOD FOR REMOVING SCR ASSEMBLY 2141
METHOD FOR INSTALLING SCR ASSEMBLY 2143
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2147
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2148
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2154
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 2166
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 2166
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 2168
REMOVE AND INSTALL KCCV ASSEMBLY 2176
METHOD FOR REMOVING KCCV ASSEMBLY 2176
METHOD FOR INSTALLING KCCV ASSEMBLY 2177
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2180
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2180
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2185
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2192
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2192
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2195
REMOVE AND INSTALL AdBlue/DEF PUMP 2199
METHOD FOR REMOVING AdBlue/DEF PUMP 2199
METHOD FOR INSTALLING AdBlue/DEF PUMP 2202
REMOVE AND INSTALL AdBlue/DEF HOSE 2205
METHOD FOR REMOVING AdBlue/DEF HOSE 2206
METHOD FOR INSTALLING AdBlue/DEF HOSE 2214
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2220
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2220
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2221
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2222
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2222
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2223
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2224
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2224
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2225
POWER TRAIN 2226
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY 2226
METHOD FOR DISASSEMBLING PTO ASSEMBLY 2226
METHOD FOR ASSEMBLING PTO ASSEMBLY 2227
REMOVE AND INSTALL PTO ASSEMBLY 2230
METHOD FOR REMOVING PTO ASSEMBLY 2230
METHOD FOR INSTALLING PTO ASSEMBLY 2231
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2234
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2234
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2235
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2236
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2237
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2242
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2251
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2251
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2252
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2254
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 2254
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2258
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2263
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 2263
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 2264
UNDERCARRIAGE AND FRAME 2265
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 2265
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING 2265
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 2266
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2268
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY 2268
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY 2269
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2270
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY 2270
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY 2270
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD 2272
METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD 2274
METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD 2275
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2278
METHOD FOR SEPARATING TRACK ASSEMBLY 2278
METHOD FOR INSTALLING TRACK ASSEMBLY 2279
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2281
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2281
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2282
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2283
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2283
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2284
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2287
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 2287
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2288
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2290
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2290
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2291
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 2294
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2294
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2295
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2297
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2297
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2298
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2300
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2300
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2300
HYDRAULIC SYSTEM 2303
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2303
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2303
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2304
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2305
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2306
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2307
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2308
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2308
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2310
REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY 2313
METHOD FOR REMOVING HYDRAULIC PUMP ASSEMBLY 2313
METHOD FOR INSTALLING HYDRAULIC PUMP ASSEMBLY 2315
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2321
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2321
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2324
REMOVE AND INSTALL SWING MOTOR ASSEMBLY 2328
METHOD FOR REMOVING SWING MOTOR ASSEMBLY 2328
METHOD FOR INSTALLING SWING MOTOR ASSEMBLY 2329
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2330
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2330
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2331
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2333
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2333
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2334
DISASSEMBLE AND ASSEMBLE GREASE GUN ASSEMBLY 2336
METHOD FOR DISASSEMBLING GREASE GUN ASSEMBLY 2336
METHOD FOR ASSEMBLING GREASE GUN ASSEMBLY 2336
WORK EQUIPMENT 2337
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY 2337
METHOD FOR REMOVING BUCKET CYLINDER ASSEMBLY 2337
METHOD FOR INSTALLING BUCKET CYLINDER ASSEMBLY 2338
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY 2340
METHOD FOR REMOVING ARM CYLINDER ASSEMBLY 2340
METHOD FOR INSTALLING ARM CYLINDER ASSEMBLY 2341
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY 2343
METHOD FOR REMOVING BOOM CYLINDER ASSEMBLY 2343
METHOD FOR INSTALLING BOOM CYLINDER ASSEMBLY 2344
REMOVE AND INSTALL BUCKET ASSEMBLY 2346
METHOD FOR REMOVING BUCKET ASSEMBLY 2346
METHOD FOR INSTALLING BUCKET ASSEMBLY 2347
REMOVE AND INSTALL ARM ASSEMBLY 2348
METHOD FOR REMOVING ARM ASSEMBLY 2348
METHOD FOR INSTALLING ARM ASSEMBLY 2350
REMOVE AND INSTALL BOOM ASSEMBLY 2352
METHOD FOR REMOVING BOOM ASSEMBLY 2352
METHOD FOR INSTALLING BOOM ASSEMBLY 2353
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2355
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2355
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2357
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY 2358
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY 2359
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2360
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2361
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2363
CAB AND ITS ATTACHMENTS 2368
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2368
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY 2368
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY 2375
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 2384
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2386
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2386
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2396
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 2396
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 2399
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 2405
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2405
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2408
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2413
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2413
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2418
REMOVE AND INSTALL OPERATOR’S SEAT 2425
METHOD FOR REMOVING OPERATOR’S SEAT 2425
METHOD FOR INSTALLING OPERATOR’S SEAT 2427
REMOVE AND INSTALL SEAT BELT 2430
METHOD FOR REMOVING SEAT BELT 2430
METHOD FOR INSTALLING SEAT BELT 2430
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 2432
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2432
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2437
ELECTRICAL SYSTEM 2446
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2446
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2446
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2447
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 2450
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2450
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2452
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2455
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY 2455
METHOD FOR INSTALLING KomVision CONTROLLER 2456
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2457
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2457
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2459
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2463
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2463
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2464
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2465
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2465
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2466
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2468
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2468
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2470
REMOVE AND INSTALL KomVision CAMERA 2472
METHOD FOR REMOVING KomVision CAMERA 2472
METHOD FOR INSTALLING KomVision CAMERA 2473
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2475
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2475
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2477
60 MAINTENANCE STANDARD 2479
CONTENTS 2480
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
AIR CONDITIONER SYSTEM 2550
PRECAUTIONS FOR REFRIGERANT 2550
AIR CONDITIONER COMPONENT 2551
SPECIFICATIONS OF AIR CONDITIONER 2553
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2554
OUTLINE OF REFRIGERATION CYCLE 2555
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2557
AIR CONDITIONER UNIT 2557
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2557
FUNCTION OF AIR CONDITIONER UNIT 2559
COMPONENT PARTS OF AIR CONDITIONER UNIT 2561
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2562
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2562
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2562
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 2562
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2563
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2563
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2563
FUNCTION OF DUAL PRESSURE SWITCH 2564
AIR CONDITIONER CONTROLLER 2565
STRUCTURE OF AIR CONDITIONER CONTROLLER 2565
COMPRESSOR 2566
STRUCTURE OF COMPRESSOR 2566
SPECIFICATIONS OF COMPRESSOR 2566
FUNCTION OF COMPRESSOR 2566
CONDENSER 2567
STRUCTURE OF CONDENSER 2567
SPECIFICATIONS OF CONDENSER 2567
FUNCTION OF CONDENSER 2567
RECEIVER DRIER 2568
STRUCTURE OF RECEIVER DRIER 2568
SPECIFICATIONS OF RECEIVER DRIER 2568
FUNCTION OF RECEIVER DRIER 2568
SENSORS FOR AIR CONDITIONER SYSTEM 2569
STRUCTURE OF SUNLIGHT SENSOR 2569
FUNCTION OF SUNLIGHT SENSOR 2569
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 2569
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2569
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2571
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2573
AIR CONDITIONER SYSTEM DIAGRAM 2575
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2576
FUNCTION OF AIR CONDITIONER CONTROLLER 2577
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2578
TESTING AIR LEAKAGE (DUCT) 2582
METHOD FOR TESTING AIR LEAKAGE (DUCT) 2582
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2584
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2585
TEST VENT (MODE) CHANGEOVER 2586
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2586
TESTING FRESH/RECIRC AIR CHANGEOVER 2588
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2588
TEST SUNLIGHT SENSOR 2589
METHOD FOR TESTING SUNLIGHT SENSOR 2589
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2590
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2590
TEST RELAYS 2591
METHOD FOR TESTING RELAYS 2591
AIR CONDITIONER TROUBLESHOOTING CHART 1 2592
AIR CONDITIONER TROUBLESHOOTING CHART 2 2593
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2596
FAILURE CODE [879AKA] 2598
FAILURE CODE [879AKB] 2599
FAILURE CODE [879BKA] 2600
FAILURE CODE [879BKB] 2602
FAILURE CODE [879CKA] 2604
FAILURE CODE [879CKB] 2605
FAILURE CODE [879DKZ] 2606
FAILURE CODE [879EMC] 2608
FAILURE CODE [879FMC] 2609
FAILURE CODE [879GKX] 2610
TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2612
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2614
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2617
TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 2619
TROUBLESHOOTING USING GAUGE PRESSURE 2621
CONNECTION OF SERVICE TOOL 2624
METHOD FOR CONNECTING SERVICE TOOL 2624
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2626
HANDLE COMPRESSOR OIL 2628
FAILURE CODE [DBP0KT] 2630
90 CIRCUIT DIAGRAMS 2631
CONTENTS 2632
HYDRAULIC CIRCUIT DIAGRAM 2633
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2633
HYDRAULIC CIRCUIT DIAGRAM(1/3) 2637
HYDRAULIC CIRCUIT DIAGRAM(2/3) 2639
HYDRAULIC CIRCUIT DIAGRAM(3/3) 2641
ELECTRICAL CIRCUIT DIAGRAM 2643
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2643
ELECTRICAL CIRCUIT DIAGRAM (1/10) 2647
ELECTRICAL CIRCUIT DIAGRAM (2/10) 2649
ELECTRICAL CIRCUIT DIAGRAM (3/10) 2651
ELECTRICAL CIRCUIT DIAGRAM (4/10) 2653
ELECTRICAL CIRCUIT DIAGRAM (5/10) 2655
ELECTRICAL CIRCUIT DIAGRAM (6/10) 2657
ELECTRICAL CIRCUIT DIAGRAM (7/10) 2659
ELECTRICAL CIRCUIT DIAGRAM (8/10) 2661
ELECTRICAL CIRCUIT DIAGRAM (9/10) 2663
ELECTRICAL CIRCUIT DIAGRAM (10/10) 2665
INDEX 2667

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