Komatsu PC88MR-11E0 Excavator Shop Manual SEN06853-07 PDF

Description

Komatsu PC88MR-11E0 Hydraulic Excavator Shop Manual SEN06853-07 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC88MR-11E0 Hydraulic Excavator Shop Manual SEN06853-07 – PDF DOWNLOAD 

Language : English
Pages : 2578
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu PC88MR-11E0 Hydraulic Excavator Shop Manual SEN06853-07 – 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 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.

TABLE OF CONTENTS:

Komatsu PC88MR-11E0 Hydraulic Excavator Shop Manual SEN06853-07 – PDF DOWNLOAD 

Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 18
How to Read the Shop Manual 18
Safety Notice for Operation 20
Precautions to Prevent Fire 28
Procedures If Fire Occurs 30
Precautions When You Discard Waste Materials 31
Precautions When You Handle Hydraulic Equipment 32
Precautions When You Disconnect and Connect Pipings 35
Precautions When You Handle Electrical Equipment 42
Precautions When You Handle Fuel System Equipment 44
Precautions When You Handle Intake System Equipment 45
Practical Use of KOMTRAX 46
Disconnect and Connect Push-Pull Type Coupler 47
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 47
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 48
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 49
Precautions for Disconnection and Connection of Connectors 51
How to Disconnect and Connect Deutsch Connector 55
How to Disconnect and Connect Slide Lock Type Connector 56
How to Disconnect and Connect Connector with Lock to Pull 58
How to Disconnect and Connect Connector with Lock to Push 59
How to Disconnect and Connect Connector with Housing to Rotate 61
How to Read the Codes for Electric Cable 62
Explanation of Terms for Maintenance Standard 66
Standard Tightening Torque Table 69
Conversion Table 76
Abbreviation List 81
01 Specifications 87
Table of Contents 88
Specifications 89
Specification Drawing 89
Specification Drawing: PC88MR-11E0 89
Working Range Drawings 90
Working Range Drawings: PC88MR-11E0 90
Specifications 91
Specification: PC88MR-11E0 91
Weight Table 95
Weight Table: PC88MR-11E0 95
Fuel, Coolant, Lubricants (For European Union) 97
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 97
10 Structure and Function 99
Table of Contents 100
Boot-up System 103
Layout Drawing of Boot-up System 103
System Operating Lamp System 104
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 104
Function of System Operating Lamp System (Machine with Gateway Function Controller) 104
Battery Disconnect Switch 106
Function of Battery Disconnect Switch 106
Engine System 107
Layout Drawing of Engine System 107
Engine Control System 109
System Diagram of Engine Control 109
Function of Engine Control System 110
Auto-Deceleration System 112
System Diagram of Auto-Deceleration System 112
Function of Auto-Deceleration System 112
Operation of Auto-Deceleration System 113
Engine Automatic Warm-up System 114
System Diagram of Engine Automatic Warm-up System 114
Function of Engine Automatic Warm-up System 115
Overheat Prevention System 116
Function of Overheat Prevention System 116
Turbocharger Protection System 117
Function of Turbocharger Protection System 117
Automatic Idle Stop System 118
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) 118
Function of Automatic Idle Stop System 118
Component Parts of Engine System 121
PTO 121
Turbocharger 121
EGR System 124
EGR Valve 127
EGR Cooler 129
High Efficiency Breather System 130
High Efficiency Breather 131
Exhaust Throttle Valve 133
KDPF 134
Cooling System 138
Layout Drawing of Cooling System 138
Specifications of Cooling System 139
Control System 140
Layout Drawing of Control System 140
Machine Monitor System 142
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 142
Function of Machine Monitor System 142
KOMTRAX System 144
System Diagram of KOMTRAX System 144
Function of KOMTRAX System 144
Component Parts of Control System 145
Machine Monitor 145
Gateway Function Controller 158
Communication Terminal 161
Pump Controller 163
Resistor for PC-EPC Valve 167
CAN Terminating Resistor 167
Engine Controller 169
Fuel Control Dial 175
Hydraulic System 177
Layout Drawing of Hydraulic System 177
CLSS 180
Structure of CLSS 180
Function of CLSS 181
Engine and Pump Combined Control System 183
Engine and Pump Combined Control System Diagram 183
Function of Engine and Pump Combined Control System 184
Component Parts of Hydraulic System 187
Hydraulic Tank 188
Main Pump 190
Control Valve 205
Work Equipment System 269
Layout Drawing of Work Equipment System 269
PPC Lock System 271
System Diagram of PPC Lock 271
Function of PPC Lock System 271
Work Equipment and Travel Automatic Lock System 272
System Diagram of Lock Lever Automatic Lock System 272
Function of Work Equipment and Travel Automatic Lock System 272
Operation of Lock Lever Automatic Lock System 273
Overload Caution System 274
Overload Caution System Diagram 274
Function of Overload Caution System 275
Attachment Oil Flow Adjuster System 276
Attachment Oil Flow Adjuster System Diagram 276
Function of Attachment Oil Flow Adjuster System 277
Component Parts of Work Equipment System 278
Work Equipment and Swing PPC Valve 278
1st-Line Attachment PPC Valve (with EPC Valve) 282
Attachment Oil Flow Adjuster EPC Valve 288
Blade PPC Valve 288
Boom Swing PPC Valve 290
Solenoid Valve 292
Boom Anti-drop Valve 294
Arm Anti-Drop Valve 299
Multi-Control Valve 304
Pilot Circuit Accumulator 306
Attachment Circuit Accumulator (For Low Pressure Circuit) 307
Swing System 308
Layout Drawing of Swing System 308
Swing Control System Diagram 310
Function of Swing Control System 310
Component Parts of Swing System 312
Swing Motor 312
Swing Machinery 321
Swing Circle 323
Travel System 325
Layout Drawing of Travel System 325
System Diagram of Travel Control System 327
Function of Travel Control System 328
Component Parts of Travel System 330
Travel Motor 330
Travel PPC Valve 338
Center Swivel Joint 343
Undercarriage and Frame 344
Layout Drawing of Undercarriage 344
Specifications of Undercarriage 344
Idler Cushion 346
Structure of Idler Cushion 346
Specifications of Idler Cushion 346
Work Equipment 347
Structure of Work Equipment 347
Function of Work Equipment 348
Work Equipment Clearance Adjustment Shim 349
Function of Work Equipment Clearance Adjustment Shim 349
Bucket Clearance Adjustment Shim 350
Function of Bucket Clearance Adjustment Shim 350
CAB Related Parts 351
ROPS CAB 351
Structure of ROPS CAB 351
Function of ROPS CAB 351
CAB Mount 352
Structure of CAB Mount 352
Function of CAB Mount 353
Remove Wiring Harness Out of Cab 354
20 Standard Value Table 355
Table of Contents 356
Standard Value Table for Engine 357
Standard Value Table for Engine: PC88MR-11E0 357
Standard Value Table for Machine 359
Standard Value Table for Machine: PC88MR-11E0 359
Machine Posture and Procedures to Measure Performance 371
30 Testing and Adjusting 377
Table of Contents 378
Precautions Before Work 381
Related Information on Testing and Adjusting 382
Differences In Machine Monitor Symbols 382
Tools for Testing and Adjusting 383
Sketch of Tools for Testing and Adjusting 388
Engine and Cooling System 390
Examine Engine Speed 390
How to Examine Engine Speed 390
Examine Exhaust Gas Color 394
How to Examine Exhaust Gas Color with the Handy Smoke Checker 394
How to Examine Exhaust Gas Color with Smoke Meter 395
Examine and Adjust Valve Clearance 397
How to Examine Valve Clearance 397
How to Adjust Valve Clearance 398
Examine Compression Pressure 399
How to Examine Compression Pressure 399
Examine Blowby Pressure 402
How to Examine Blowby Pressure 402
Examine Engine Oil Pressure 404
How to Examine Engine Oil Pressure 404
Visual Check Inside of EGR Valve 406
How to do the Visual Check Inside of EGR Valve 406
Clean Inside of EGR Valve 408
How to Clean Inside of EGR Valve 408
Examine Fuel Pressure 411
How to Examine Fuel Pressure 411
Examine Fuel Return Rate and Leakage 413
How to Examine Fuel Return Rate and Leakage 415
Bleed Air from Fuel System 418
How to Bleed Air from Fuel System 418
Examine Fuel Circuit for Leakage 420
How to Examine Fuel System for Leakage 420
Handle Cylinder Cut-out Mode Operation 422
Handle No-Injection Cranking Operation 423
Examine Fan Belt 424
How to Examine Fan Belt 424
Examine Automatic Tensioner 425
How to Examine Automatic Tensioner 425
Write Injector Compensation Value to Engine Controller 427
How to Write Injector Compensation Value 427
Power Train 433
Examine Swing Circle Bearing Clearance 433
How to Examine Swing Circle Bearing Clearance 433
Undercarriage and Frame 434
Examine and Adjust Track Tension 434
How to Examine Track Tension 434
How to Adjust Track Tension 434
Hydraulic System 436
Release Remained Pressure in Hydraulic Circuit 436
How to Release Remained Pressure from Hydraulic Tank 436
How to Release Remained Pressure in Hydraulic Cylinder Circuit 436
How to Release Remained Pressure from Swing Motor Circuit 439
How to Release Remained Pressure from Travel Motor Circuit 439
How to Release Remained Pressure from Swing Cylinder Circuit 440
How to Release Remained Pressure from Blade Cylinder 440
Examine and Adjust Oil Pressure in Work Equipment and Travel Circuits 441
How to Examine Oil Pressure in Work Equipment and Travel Circuits 441
How to Adjust Oil Pressure in Work Equipment and Travel Circuits 449
How to Adjust Work Equipment and Travel Relief Pressure 450
Examine and Adjust Swing and Blade Circuit Oil Pressure 451
How to Examine Swing and Blade Relief Pressure 451
How to Adjust Swing Relief Pressure 453
How to Adjust Blade LOWER Relief Pressure 453
How to Adjust Blade RAISE Relief Pressure 454
Examine Oil Pressure of Control Circuit 455
How to Examine Oil Pressure in Control Circuit 455
Examine and adjust oil pressure in pump PC control circuit 457
How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 457
How to Examine Source Pressure of PC-EPC Valve 459
How to Examine PC-EPC Valve Output Pressure 460
How to Adjust Oil Pressure in Pump PC Control Circuit 461
Examine and Adjust Oil Pressure in Pump LS Control Circuit 463
How to Examine LS Differential Pressure with Machine Monitor 463
How to Examine LS Differential Pressure by Testing Tool 465
How to Adjust LS Valve 468
Examine Outlet Pressure of Solenoid Valve 469
How to Examine Outlet Pressure of Solenoid Valve 469
Operating Condition of Solenoid Valve 471
Examine PPC Valve Outlet Pressure 472
How to Examine PPC Valve Outlet Pressure 472
Examine and Adjust Travel Deviation 475
How to Examine Travel Deviation 475
How to Adjust Travel Deviation 476
Examine Parts Which Cause Hydraulic Drift of Work Equipment 478
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 478
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 478
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 479
Examine Oil Leakage 480
How to Examine Oil Leakage from Boom Cylinder 480
How to Examine Oil Leakage from Arm Cylinder 481
How to Examine Oil Leakage from Bucket Cylinder 481
How to Examine Oil Leakage from Boom Swing Cylinder 482
How to Examine Oil Leakage from Blade Cylinder 483
How to Examine Oil Leakage from Swing Motor 484
How to Examine Oil Leakage from Travel Motor 485
Bleed Air from Hydraulic System 487
How to Bleed Air from Hydraulic System 488
CAB Related Parts 493
How to Adjust Mirrors 493
Adjust Left Front Mirror (A) 494
How to Adjust Left Front Mirror (B) 495
How to Examine and Adjust Slide Door 496
How to Examine and Adjust Slide Door When It is Closed and Locked 496
How to Examine and Adjust Slide Door When It is Open and Locked 508
Electrical System 521
Set and Operate Machine Monitor 521
Operator Mode 525
Function to Show Technician Identification Status Screen 525
Function to Show Operator Identification Input Screen 525
Examine Function by LCD (Liquid Crystal Display) 526
Examine Function of Service Meter 526
Usage Limitation and Maintenance Password Change Function 527
Service Mode 530
How to Operate Service Mode 530
How to See Pre-defined Monitoring Information 532
How to Examine Monitoring Information 536
Abnormality Record Menu 546
How to See Maintenance Record 551
Maintenance Mode Setting 552
How to Set Phone Number Entry 556
Default Setting Menu 558
Testing Menu 568
Adjustment Menu 577
No-Injection Cranking Operation 591
KOMTRAX Settings Menu 594
How to Show Service Message 596
How to Start Up KOMTRAX System 598
Adjust Rearview Camera Angle 605
How to Adjust Rearview Camera Angle 605
Adjust Rightview Camera Angle 608
How to Adjust Right View Camera Angle 608
Set Region of Bluetooth(R) Compatible Radio 611
How to Set Region of Bluetooth(R) Compatible Radio 611
Handle Voltage Circuit of Engine Controller 613
Handle Battery Disconnect Switch 614
Examine Diodes 615
How to Examine Diodes by Digital Tester 615
How to Examine Diodes by Analog Tester 615
Pm Clinic 616
Pm Clinic Service 616
Pm Clinic Check Sheet: PC88MR-11E0 618
40 Troubleshooting 627
Table of Contents 628
Precautions Before Work 636
Related Information to Troubleshooting 637
General Troubleshooting Points 637
Troubleshooting Points for Aftertreatment System 638
Sequence of Events in Troubleshooting 646
Checks Before Troubleshooting 648
Inspection Procedure Before Troubleshooting 650
Walk-Around Check 650
Test in Accordance with Testing Procedure 652
Examine Fuel Level and Type 652
Examine Fuel Prefilter 653
Examine Water Separator, Drain Water and Sediment 653
How to Replace Fuel Prefilter Cartridge 654
Examine Fuel Main Filter 656
Examine Engine Oil Level (Oil Quantity in Oil Pan) 657
Examine Oil Level in PTO Gear Case 658
Examine Coolant Level (Expansion Tank) 660
Examine Air Cleaner Clogging 661
Clean Outer Element 661
Replace Element 663
Examine Hydraulic Oil Level 664
Examine Hydraulic Oil Strainer 666
Examine Hydraulic Oil Filter 668
Examine Oil Level in Swing Machinery Case 669
Examine Oil Level in Final Drive Case 670
Bleed Air from Fuel System 671
Bleed Air from Hydraulic System 671
How to Examine Electric Equipment 671
Preparation for Troubleshooting of Electrical System 676
Preparation for Troubleshooting of Machine Monitor 676
Preparation for Troubleshooting of Engine Controller 678
Preparation for Troubleshooting of Pump Controller 679
Preparation for Troubleshooting of Gateway Function Controller 679
How to Disconnect and Connect Connector with a Special Lock 680
Procedure for Troubleshooting 684
Symptom and Troubleshooting Numbers 687
Information Shown in Troubleshooting Table 692
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 694
Connector and Wiring Harness Identification Table 697
Connector Layout 703
Connector Contact Connection Table 709
T-Branch Box and T-Branch Adapter Table 756
Fuse Location Table 762
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 765
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 769
Failure Code Table 771
Troubleshooting by Failure Code (Display of Code) 784
Failure Code [6AZ0ZG] 784
Failure Code [879AKA] 786
Failure Code [879AKB] 787
Failure Code [879BKA] 788
Failure Code [879BKB] 790
Failure Code [879CKA] 792
Failure Code [879CKB] 793
Failure Code [879DKZ] 794
Failure Code [879EMC] 796
Failure Code [879FMC] 797
Failure Code [879GKX] 798
Failure Code [989L00] 800
Failure Code [989M00] 801
Failure Code [989N00] 802
Failure Code [A1U0N3] 803
Failure Code [A1U0N4] 805
Failure Code [A900FR] 807
Failure Code [A900N6] 808
Failure Code [A900NY] 809
Failure Code [AA10NX] 810
Failure Code [AB00KE] 812
Failure Code [AQ10MB] 814
Failure Code [AQ10N3] 816
Failure Code [AS00R2] 818
Failure Code [AS00R3] 819
Failure Code [AS00R4] 820
Failure Code [AS00R6] 821
Failure Code [B@BAZG] 822
Failure Code [B@BCNS] 823
Failure Code [B@BCQA] 824
Failure Code [B@BCZK] 826
Failure Code [B@HANS] 828
Failure Code [CA115] 830
Failure Code [CA122] 831
Failure Code [CA123] 833
Failure Code [CA131] 835
Failure Code [CA132] 837
Failure Code [CA144] 839
Failure Code [CA145] 841
Failure Code [CA153] 843
Failure Code [CA154] 846
Failure Code [CA187] 849
Failure Code [CA221] 851
Failure Code [CA222] 853
Failure Code [CA227] 855
Failure Code [CA234] 856
Failure Code [CA238] 857
Failure Code [CA239] 859
Failure Code [CA271] 861
Failure Code [CA272] 863
Failure Code [CA322] 865
Failure Code [CA324] 868
Failure Code [CA331] 871
Failure Code [CA343] 874
Failure Code [CA351] 875
Failure Code [CA352] 876
Failure Code [CA356] 878
Failure Code [CA357] 880
Failure Code [CA386] 883
Failure Code [CA435] 884
Failure Code [CA441] 886
Failure Code [CA442] 888
Failure Code [CA449] 889
Failure Code [CA451] 890
Failure Code [CA452] 892
Failure Code [CA515] 894
Failure Code [CA516] 896
Failure Code [CA553] 898
Failure Code [CA559] 899
Failure Code [CA689] 903
Failure Code [CA691] 905
Failure Code [CA692] 907
Failure Code [CA697] 909
Failure Code [CA698] 910
Failure Code [CA731] 911
Failure Code [CA778] 912
Failure Code [CA1117] 915
Failure Code [CA1664] 916
Failure Code [CA1691] 918
Failure Code [CA1695] 921
Failure Code [CA1696] 922
Failure Code [CA1879] 924
Failure Code [CA1881] 926
Failure Code [CA1883] 928
Failure Code [CA1896] 933
Failure Code [CA1921] 937
Failure Code [CA1922] 940
Failure Code [CA1961] 945
Failure Code [CA1993] 946
Failure Code [CA2185] 950
Failure Code [CA2186] 952
Failure Code [CA2249] 954
Failure Code [CA2272] 955
Failure Code [CA2311] 958
Failure Code [CA2349] 959
Failure Code [CA2353] 961
Failure Code [CA2357] 963
Failure Code [CA2637] 964
Failure Code [CA2639] 966
Failure Code [CA2765] 968
Failure Code [CA2777] 969
Failure Code [CA2973] 972
Failure Code [CA3133] 973
Failure Code [CA3134] 975
Failure Code [CA3135] 977
Failure Code [CA3251] 980
Failure Code [CA3253] 982
Failure Code [CA3254] 985
Failure Code [CA3255] 987
Failure Code [CA3256] 990
Failure Code [CA3311] 992
Failure Code [CA3312] 994
Failure Code [CA3313] 997
Failure Code [CA3314] 999
Failure Code [CA3315] 1000
Failure Code [CA3316] 1002
Failure Code [CA3317] 1004
Failure Code [CA3318] 1005
Failure Code [CA3319] 1007
Failure Code [CA3321] 1008
Failure Code [CA3322] 1010
Failure Code [CA3419] 1012
Failure Code [CA3421] 1014
Failure Code [CA3724] 1016
Failure Code [CA4151] 1017
Failure Code [CA4158] 1021
Failure Code [CA4161] 1022
Failure Code [CA4162] 1024
Failure Code [CA4163] 1026
Failure Code [CA4259] 1028
Failure Code [CA4264] 1030
Failure Code [CA4952] 1032
Failure Code [CA5271] 1034
Failure Code [CA5272] 1037
Failure Code [CA5383] 1040
Failure Code [CA5631] 1042
Failure Code [CA5938] 1044
Failure Code [CA6654] 1046
Failure Code [CA6887] 1047
Failure Code [CA6891] 1050
Failure Code [CA7681] 1051
Failure Code [CA7797] 1052
Failure Code [CA7798] 1053
Failure Code [CA7822] 1054
Failure Code [CA7869] 1055
Failure Code [D110KB] 1059
Failure Code [D19JKZ] 1061
Failure Code [D811MC] 1063
Failure Code [D862KA] 1064
Failure Code [D8ALKA] 1065
Failure Code [D8ALKB] 1067
Failure Code [D8AQKR] 1069
Failure Code [D8G1KT] 1074
Failure Code [D8G6KT] 1075
Failure Code [DA20MC] 1076
Failure Code [DA22KK] 1077
Failure Code [DA22KT] 1080
Failure Code [DA25KP] 1082
Failure Code [DA26KP] 1085
Failure Code [DA29KQ] 1087
Failure Code [DA2JKT] 1089
Failure Code [DA2JKY] 1090
Failure Code [DA2LKA] 1091
Failure Code [DA2LKB] 1093
Failure Code [DA2QKR] 1095
Failure Code [DA2RKR] 1101
Failure Code [DAF0MB] 1106
Failure Code [DAF0MC] 1107
Failure Code [DAF8KB] 1108
Failure Code [DAF9KQ] 1110
Failure Code [DAFGMC] 1111
Failure Code [DAFLKA] 1112
Failure Code [DAFLKB] 1114
Failure Code [DAFQKR] 1116
Failure Code [DAZ9KQ] 1122
Failure Code [DAZQKR] 1123
Failure Code [DB2QKR] 1127
Failure Code [DB2RKR] 1133
Failure Code [DDNRKA] 1138
Failure Code [DDNRKY] 1142
Failure Code [DDNS00] 1145
Failure Code [DFB1KZ] 1148
Failure Code [DFB2KZ] 1150
Failure Code [DFB3L8] 1152
Failure Code [DFB4L8] 1154
Failure Code [DFB5KZ] 1156
Failure Code [DFB6KZ] 1158
Failure Code [DGH2KA] 1160
Failure Code [DGH2KB] 1162
Failure Code [DHA4KA] 1163
Failure Code [DHAAMA] 1165
Failure Code [DHACMA] 1166
Failure Code [DHPAMA] 1167
Failure Code [DHS3MA] 1169
Failure Code [DHS4MA] 1171
Failure Code [DHS5MA] 1173
Failure Code [DHS8MA] 1175
Failure Code [DHS9MA] 1177
Failure Code [DHSAMA] 1179
Failure Code [DHSBMA] 1181
Failure Code [DHSCMA] 1183
Failure Code [DHSDMA] 1185
Failure Code [DHSPMA] 1187
Failure Code [DHSQMA] 1189
Failure Code [DHX1MA] 1191
Failure Code [DKULKA] 1193
Failure Code [DKULKB] 1196
Failure Code [DKULKY] 1199
Failure Code [DLM5KA] 1202
Failure Code [DLM5MB] 1205
Failure Code [DR21KX] 1208
Failure Code [DV20KB] 1210
Failure Code [DW43KA] 1212
Failure Code [DW43KB] 1214
Failure Code [DW43KY] 1216
Failure Code [DW45KA] 1218
Failure Code [DW45KB] 1222
Failure Code [DW45KY] 1226
Failure Code [DW4CKY] 1229
Failure Code [DWA2KA] 1232
Failure Code [DWA2KB] 1234
Failure Code [DWA2KY] 1236
Failure Code [DWJ0KA] 1238
Failure Code [DWJ0KB] 1240
Failure Code [DWJ0KY] 1242
Failure Code [DWN5KA] 1244
Failure Code [DWN5KB] 1247
Failure Code [DWN5KY] 1250
Failure Code [DXA8KA] 1253
Failure Code [DXA8KB] 1256
Failure Code [DXE7KA] 1259
Failure Code [DXE7KB] 1261
Failure Code [DXE7KY] 1263
Failure Code [DXE8KA] 1265
Failure Code [DXE8KB] 1267
Failure Code [DXE8KY] 1269
Failure Code [DXE9KA] 1271
Failure Code [DXE9KB] 1273
Failure Code [DXE9KY] 1275
Failure Code [DXEAKA] 1277
Failure Code [DXEAKB] 1279
Failure Code [DXEAKY] 1281
Failure Code [DY20KA] 1283
Failure Code [DY20MA] 1285
Failure Code [DY2CKB] 1287
Failure Code [DY2DKB] 1289
Failure Code [DY2EKB] 1291
Failure code [F311KA] 1293
Failure code [F311KB] 1295
Failure code [F312KA] 1297
Failure code [F312KB] 1299
Failure Code [F313KA] 1301
Failure Code [F313KB] 1302
Failure code [F314KA] 1303
Failure code [F314KB] 1305
Failure Code [F315KB] 1307
Failure Code [F315KY] 1309
Failure code [F316KB] 1311
Failure code [F316KY] 1313
Failure Code [F318KB] 1315
Failure Code [F318KY] 1316
Failure code [F31AKB] 1317
Failure code [F31AKY] 1319
Failure Code [F31BKB] 1321
Failure Code [F31BKY] 1323
Failure Code [F31CKB] 1325
Failure Code [F31CKY] 1327
Failure Code [F31DKB] 1329
Failure Code [F31DKY] 1331
Failure Code [F31EKB] 1333
Failure Code [F31EKY] 1335
Failure Code [FS10ZE] 1337
Troubleshooting of Electrical System (E-Mode) 1338
Engine Does Not Start (Engine Does Not Crank) 1338
Manual Preheating System Does Not Operate 1344
While Preheating is in Operation, Preheating Monitor Does Not Come On 1347
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1349
Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation 1352
Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation 1353
Charge Level Monitor Comes On in Red While Engine is in Operation 1354
Fuel Level Monitor Comes On in Red While Engine is in Operation 1355
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1356
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 1357
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1358
Fuel Gauge Does Not Move from Minimum or Maximum 1359
Display of Fuel Gauge is Different from Actual Fuel Level 1361
Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1362
Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1363
Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum 1364
Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1366
Some Areas of Machine Monitor Screen are Not Shown 1367
Function Switch Does Not Operate 1368
Automatic Warm-up System Does Not Operate (in Cold Weather) 1369
Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated 1370
Auto-Decelerator is Not Operated or Canceled with Lever 1371
Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated 1372
When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1373
Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated 1374
Travel Speed Does Not Change Even When You Change Travel Speed 1375
Alarm Buzzer Does Not Stop 1377
Service Meter is Not Shown While Starting Switch is in OFF Position 1378
Service Mode Cannot be Selected 1379
All Work Equipment, Swing, Travel Do Not Operate 1380
All Work Equipment, Swing, Travel Cannot be Locked 1384
Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position 1387
While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated 1390
Work Equipment Does Not Operate While Lock Lever Automatic Release Switch is in Release Position 1393
Travel Alarm Does Not Operate During Travel 1396
Travel Alarm Does Not Stop When Machine Stops 1398
Horn Does Not Sound 1400
Horn Does Not Stop 1402
Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated 1403
Windshield Wiper Does Not Operate When Wiper Switch is Operated 1404
When Window Washer Switch is Operated, Window Washer Does Not Operate 1406
“Boom Raise” is Not Shown Correctly with Monitoring Function 1407
“Boom Lower” is Not Shown Correctly with Monitoring Function 1408
“Arm OUT” is Not Shown Correctly with Monitoring Function 1409
“Arm IN” is Not Shown Correctly with Monitoring Function 1410
Bucket DUMP is Not Shown Correctly with Monitoring Function 1411
Bucket CURL is Not Shown Correctly with Monitoring Function 1412
Boom Swing Left is Not Shown Correctly with Monitoring Function 1413
Boom Swing Right is Not Shown Correctly with Monitoring Function 1414
Swing is Not Shown Correctly with Monitoring Function 1415
Travel is Not Shown Correctly with Monitoring Function 1416
Blade RAISE is Not Shown Correctly with Monitoring Function 1417
Blade LOWER is Not Shown Correctly with Monitoring Function 1419
KOMTRAX System Does Not Operate Correctly 1421
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1422
Information Shown in Troubleshooting Table (H-Mode) 1422
Failure Mode and Cause Table 1423
All Work Equipment, Swing and Travel Do Not Work 1435
All Work Equipment, Swing, and Travel Lack Speed or Power 1436
Fine Control Performance or Response is Unsatisfactory 1438
Unusual Noise is Heard from Around Hydraulic Pump 1439
Engine Speed Drops Largely or Engine Stops 1440
Boom Speed or Power is Low 1442
Arm Speed or Power is Low 1446
Bucket Speed or Power is Low 1449
Blade Speed or Power is Low 1452
Boom Swing Speed or Power is Low 1454
Work Equipment Does Not Move in Single Operation 1457
Hydraulic Drift of Boom is Large 1458
Hydraulic Drift of Arm is Large 1459
Hydraulic Drift of Bucket is Large 1460
Hydraulic Drift of Blade is Large 1461
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 1462
Time Lag of Work Equipment is Large 1463
Attachment Circuit Cannot be Changed 1465
Oil Flow in Attachment Circuit Cannot be Changed 1466
In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 1467
In Mixed Operation of Work Equipment or Swing and Travel, Travel Speed Falls Largely 1468
In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low 1470
Machine Does Not Travel Straight 1471
Machine is Not Steered Well or Steering Power is Low 1474
Travel Speed is Low 1477
One of Tracks Does Not Run 1480
Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 1482
Upper Structure Does Not Swing in Two Directions of Right and Left 1483
Machine Swings Only in One Direction 1485
Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left 1486
Swing Acceleration or Swing Speed is Low in Only One Direction 1487
Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 1488
Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 1489
Shock is Large When Upper Structure Stops Swing Operation 1490
Large Unusual Noise is Made When Upper Structure Stops Swing Operation 1491
Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 1492
Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 1493
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1494
Unusual Noise is Heard from Around Fan 1495
Troubleshooting of Engine (S-Mode) 1496
Information Shown in Troubleshooting Table (S-Mode) 1496
Engine Does Not Crank When Starting Switch is Turned to Start Position 1497
Engine Cranks but No Exhaust Smoke Comes Out 1498
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1499
Engine Startability is Unsatisfactory 1500
Engine Does Not Pick Up Smoothly 1502
Engine Stops During Operation 1504
Engine Does Not Rotate Smoothly 1506
Engine Lacks Output (or Lacks Power) 1507
Exhaust Color is Black (KDPF Becomes Clogged in Short Time) 1509
Engine Oil Consumption is Excessive 1511
Engine Oil Becomes Dirty Quickly 1512
Fuel Consumption is Excessive 1513
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 1514
Engine Oil Pressure Drops 1515
Fuel Mixes Into Engine Oil 1516
Water Mixes Into Engine Oil (Milky) 1517
Coolant Temperature Increases Too High (Overheat) 1518
Unusual Noise is Heard 1519
Vibration is Excessive 1521
Air Cannot be Bled from Fuel Circuit 1522
Active Regeneration is Done Frequently 1523
Active Regeneration Continues Long 1524
White Smoke is Exhausted During Active Regeneration 1525
50 Disassembly and Assembly 1527
Table of Contents 1528
Precautions Before Work 1533
Related Information on Disassembly and Assembly 1534
How to Read This Manual 1534
Coating Materials List 1535
Special Tool List 1540
Sketches of Special Tools 1557
Prepare 1560
Drain and Add Coolant 1560
How to Drain Coolant 1561
How to Add Coolant 1562
Drain and Add Hydraulic Oil 1563
How to Drain Hydraulic Oil 1564
How to Add Hydraulic Oil 1565
Drain and Add Fuel 1567
How to Drain Fuel 1568
How to Add Fuel 1568
Collect and Refill Refrigerant 1570
How to Collect Refrigerant 1570
How to Refill Refrigerant 1571
Engine and Cooling System 1572
Remove and Install Supply Pump Assembly 1572
How to Remove Supply Pump Assembly 1573
How to Install Supply Pump Assembly 1583
Remove and Install Injector Assembly 1592
How to Remove Injector Assembly 1593
How to Install Injector Assembly 1597
Remove and Install Cylinder Head Assembly 1604
How to Remove Cylinder Head Assembly 1606
How to Install Cylinder Head Assembly 1635
Remove and Install EGR Valve Assembly 1675
How to Remove EGR Valve Assembly 1676
How to Install EGR Valve Assembly 1677
Remove and Install EGR Cooler Assembly 1680
How to Remove EGR Cooler Assembly 1681
How to Install EGR Cooler Assembly 1687
Remove and Install Starter Assembly 1693
How to Remove Starting Motor Assembly 1694
How to Install Starting Motor Assembly 1696
Remove and Install Fan Belt 1699
How to Remove Fan Belt 1700
How to Install Fan Belt 1702
Remove and Install Automatic Tensioner 1704
How to Remove Auto-Tensioner 1704
How to Install Auto-Tensioner 1705
Remove and Install Expansion Tank Assembly 1706
How to Remove Expansion Tank Assembly 1707
How to Install Expansion Tank Assembly 1711
Remove and Install Radiator Assembly 1716
How to Remove Radiator Assembly 1717
How to Install Radiator Assembly 1720
Remove and Install Hydraulic Oil Cooler Assembly 1723
How to Remove Hydraulic Oil Cooler Assembly 1724
How to Install Hydraulic Oil Cooler Assembly 1733
Remove and Install Aftercooler Assembly 1742
How to Remove Aftercooler Assembly 1743
How to Install Aftercooler Assembly 1745
Remove and Install Engine and Main Pump Assembly 1748
How to Remove Engine and Main Pump Assembly 1750
How to Install Engine and Main Pump Assembly 1773
Remove and Install Engine Front Oil Seal 1798
How to Remove Engine Front Oil Seal 1799
How to Install Engine Front Oil Seal 1800
Remove and Install Engine Rear Oil Seal 1803
How to Remove Engine Rear Oil Seal 1804
How to Install Engine Rear Oil Seal 1806
Remove and Install Fuel Cooler Assembly 1810
How to Remove Fuel Cooler Assembly 1811
How to Install Fuel Cooler Assembly 1811
Remove and Install Engine Hood Assembly 1813
How to Remove Engine Hood Assembly 1813
How to Install Engine Hood Assembly 1816
Remove and Install KDPF Assembly 1819
How to Remove KDPF Assembly 1820
How to Install KDPF Assembly 1827
Disassemble and Assemble KDPF Assembly 1837
How to Disassemble KDPF Assembly 1839
How to Assemble KDPF Assembly 1843
Remove and Install Fuel Tank Assembly 1849
How to Remove Fuel Tank Assembly 1850
How to Install Fuel Tank Assembly 1855
Remove and Install Air Cleaner Assembly 1860
How to Remove Air Cleaner Assembly 1861
How to Install Air Cleaner Assembly 1862
Remove and Install Air Conditioner Compressor Assembly 1865
How to Remove Air Conditioner Compressor Assembly 1866
How to Install Air Conditioner Compressor Assembly 1868
Remove and Install Air Conditioner Condenser Assembly 1870
How to Remove Air Conditioner Condenser Assembly 1871
How to Install Air Conditioner Condenser Assembly 1873
Power Train 1875
Remove and Install Travel Motor and Final Drive Assembly 1875
How to Remove Travel Motor and Final Drive Assembly 1876
How to Install Travel Motor and Final Drive Assembly 1879
Disassemble and Assemble Travel Motor and Final Drive Assembly 1883
How to Disassemble Travel Motor and Final Drive Assembly 1892
How to Assemble Travel Motor and Final Drive Assembly 1912
Remove and Install Swing Motor and Swing Machinery Assembly 1931
How to Remove Swing Motor and Swing Machinery Assembly 1932
How to Install Swing Motor and Swing Machinery Assembly 1937
Disassemble and Assemble Swing Machinery Assembly 1942
How to Disassemble Swing Machinery Assembly 1943
How to Assemble Swing Machinery Assembly 1948
Remove and Install Swing Circle Assembly 1954
How to Remove Swing Circle Assembly 1954
How to Install Swing Circle Assembly 1955
Undercarriage and Frame 1956
Separate and Connect Track Assembly 1956
How to Separate Track Assembly 1957
How to Install Track Assembly 1957
Remove and Install Sprocket 1959
How to Remove Sprocket 1959
How to Install Sprocket 1960
Remove and Install Idler and Idler Cushion Assembly 1961
How to Remove Idler and Idler Cushion Assembly 1961
How to Install Idler and Idler Cushion Assembly 1962
Disassemble and Assemble Idler Assembly 1963
How to Disassemble Idler Assembly 1963
How to Assemble Idler Assembly 1964
Disassemble and Assemble Idler Cushion Assembly 1967
How to Disassemble Idler Cushion Assembly 1967
How to Assemble Idler Cushion Assembly 1968
Disassemble and Assemble Track Roller Assembly 1970
How to Disassemble Track Roller Assembly 1970
How to Assemble Track Roller Assembly 1972
Remove and Install Revolving Frame Assembly 1975
How to Remove Revolving Frame Assembly 1976
How to Install Revolving Frame Assembly 1982
Remove and Install Counterweight Assembly 1988
How to Remove Counterweight Assembly 1989
How to Install Counterweight Assembly 1994
Hydraulic System 2000
Remove and Install Center Swivel Joint Assembly 2000
How to Remove Center Swivel Joint Assembly 2001
How to Install Center Swivel Joint Assembly 2006
Disassemble and Assemble Center Swivel Joint Assembly 2012
How to Disassemble Center Swivel Joint Assembly 2012
How to Assemble Center Swivel Joint Assembly 2013
Remove and Install Hydraulic Tank Assembly 2014
How to Remove Hydraulic Tank Assembly 2015
How to Install Hydraulic Tank Assembly 2019
Remove and Install Main Pump Assembly 2023
How to Remove Main Pump Assembly 2024
How to Install Main Pump Assembly 2033
Remove and Install Control Valve Assembly 2042
How to Remove Control Valve Assembly 2044
How to Install Control Valve Assembly 2066
Disassemble and Assemble Control Valve Assembly 2088
How to Assemble Control Valve Assembly 2088
How to Replace Pressure Reducing Valve Cartridge Assembly 2090
Disassemble and Assemble Work Equipment PPC Valve Assembly 2093
How to Disassemble Work Equipment PPC Valve Assembly 2093
How to Assemble Work Equipment PPC Valve Assembly 2094
Disassemble and Assemble Travel PPC Valve Assembly 2096
How to Disassemble Travel PPC Valve Assembly 2096
How to Assemble Travel PPC Valve Assembly 2097
Work Equipment 2099
Remove and Install Blade Assembly 2099
How to Remove Blade Assembly 2100
How to Install Blade Assembly 2102
Remove and Install Work Equipment Assembly 2105
How to Remove Work Equipment Assembly 2107
How to Install Work Equipment Assembly 2111
Remove and Install Boom Swing Bracket 2116
How to Remove Boom Swing Bracket 2117
How to Install Boom Swing Bracket 2120
Remove and Install Boom Anti-drop Valve Assembly 2124
How to Remove Boom Anti-drop Valve Assembly 2125
How to Install Boom Anti-drop Valve Assembly 2128
Remove and Install Arm Anti-Drop Valve Assembly 2131
How to Remove Arm Anti-Drop Valve Assembly 2132
How to Install Arm Anti-Drop Valve Assembly 2135
Disassemble and Assemble Anti-Drop Valve Assembly 2137
How to Disassemble Anti-Drop Valve Assembly 2137
How to Assemble Anti-Drop Valve Assembly 2137
Disassemble and Assemble Boom Cylinder Assembly 2138
How to Disassemble Boom Cylinder Assembly 2138
How to Assemble Boom Cylinder Assembly 2140
Disassemble and Assemble Arm Cylinder Assembly 2143
How to Disassemble Arm Cylinder Assembly 2143
How to Assemble Arm Cylinder Assembly 2145
Disassemble and Assemble Bucket Cylinder Assembly 2149
How to Disassemble Bucket Cylinder Assembly 2149
How to Assemble Bucket Cylinder Assembly 2151
Disassemble and Assemble Blade Cylinder Assembly 2154
How to Disassemble Blade Cylinder Assembly 2154
How to Assemble Blade Cylinder Assembly 2156
Disassemble and Assemble Swing Cylinder Assembly 2159
How to Disassemble Swing Cylinder Assembly 2159
How to Assemble Swing Cylinder Assembly 2161
CAB Related Parts 2165
Remove and Install Operator Cab Assembly 2165
How to Remove Operator Cab Assembly 2166
How to Install Operator Cab Assembly 2182
Remove and Install Slide Door 2197
How to Remove Slide Door 2197
How to Install Slide Door 2197
Remove and Install Operator Cab Glass (Adhered Glass) 2199
How to Remove Operator Cab Glass (Adhered Glass) 2200
How to Install Operator Cab Glass (Adhered Glass) 2201
Remove and Install Front Window Assembly 2210
How to Remove Front Window Assembly 2210
How to Install Front Window Assembly 2212
Remove and Install Floor Frame Assembly 2214
How to Remove Floor Frame Assembly 2215
How to Install Floor Frame Assembly 2224
Remove and Install Air Conditioner Unit Assembly 2234
How to Remove Air Conditioner Unit Assembly 2235
How to Install Air Conditioner Unit Assembly 2248
Remove and Install Operator Seat 2261
How to Remove Operator Seat 2262
How to Install Operator Seat 2263
How to Remove and Install Seat Belt 2266
How to Remove Seat Belt 2267
How to Install Seatbelt 2267
Remove and Install Front Wiper Assembly 2268
How to Remove Front Wiper Assembly 2269
How to Install Front Wiper Assembly 2275
Electrical System 2281
Remove and Install Engine Controller Assembly 2281
How to Remove Engine Controller Assembly 2282
How to Install Engine Controller Assembly 2284
Remove and Install Pump Controller Assembly 2287
How to Remove Pump Controller Assembly 2288
How to Install Pump Controller Assembly 2290
Remove and Install Machine Monitor Assembly 2292
How to Remove Machine Monitor Assembly 2293
How to Install Machine Monitor Assembly 2298
Remove and Install Mass Air Flow and Temperature Sensor 2303
How to Remove Mass Air Flow and Temperature Sensor 2304
How to Install Mass Air Flow and Temperature Sensor 2305
Remove and Install KDPF Temperature Sensor 2306
How to Remove KDPF Temperature Sensor 2307
How to Install KDPF Temperature Sensor 2311
Remove and Install KDPF Differential Pressure Sensor 2315
How to Remove KDPF Differential Pressure Sensor 2316
How to Install KDPF Differential Pressure Sensor 2318
Remove and Install Camera Assembly 2320
How to Remove Camera Assembly 2320
How to Install Camera Assembly 2324
Remove and Install Gateway Function Controller 2328
How to Remove Gateway Function Controller 2329
How to Install Gateway Function Controller 2331
60 Maintenance Standard 2335
Table of Contents 2336
Engine and Cooling System 2337
Maintenance Standard for Engine Mount 2337
Maintenance Standard for PTO 2338
Maintenance Standard for Cooling System 2339
Power Train 2340
Maintenance Standard for Swing Circle 2340
Maintenance Standard for Swing Machinery 2342
Maintenance Standard for Sprocket 2344
Undercarriage and Frame 2345
Maintenance Standard for Track Frame and Idler Cushion 2345
Maintenance Standard for Idler 2347
Maintenance Standard for Track Roller 2349
Maintenance Standard for Carrier Roller 2350
Maintenance Standard for Track Shoes 2351
Maintenance Standard for Triple Shoes 2354
Maintenance Standard for Rubber Shoes 2355
Hydraulic System 2356
Maintenance Standard for Hydraulic Tank 2356
Maintenance Standard for Main Pump 2357
Maintenance Standard for Main Pump Servo Valve 2359
Maintenance Standard for PC-EPC Valve 2360
Maintenance Standard for Swing Motor 2361
Maintenance Standard for Travel Motor 2363
Maintenance Standard for Control Valve 2364
Maintenance Standard for Boom Anti-Drop Valve 2375
Maintenance Standard for Arm Anti-Drop Valve 2377
Maintenance Standard for Work Equipment and Swing PPC Valve 2379
Maintenance Standard for Blade PPC Valve 2382
Maintenance Standard for Boom Swing PPC Valve 2384
Maintenance Standard for Travel PPC Valve 2386
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2389
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2390
Maintenance Standard for Solenoid Valve 2392
Maintenance Standard for Attachment Oil Flow Adjuster EPC Valve 2393
Maintenance Standard for Attachment Circuit Accumulator (For Low Pressure Circuit) 2394
Maintenance Standard for Center Swivel Joint 2395
Work Equipment 2396
Maintenance Standard for Work Equipment Linkage 2396
Dimensions of Arm 2402
Dimensions of Bucket 2404
Maintenance Standard for Boom Cylinder 2406
Maintenance Standard for Arm Cylinder 2407
Maintenance Standard for Bucket Cylinder 2408
Maintenance Standard for Boom Swing Cylinder 2409
Maintenance Standard for Blade Cylinder 2410
80 Appendix 2411
Table of Contents 2412
Precautions Before Work 2414
Air Conditioner System 2415
Precautions for Refrigerant 2415
Air Conditioner Component 2416
Specifications of Air Conditioner 2418
Structure and Function of Refrigeration Cycle 2419
Outline of Refrigeration Cycle 2420
Component Parts of Air Conditioner System 2422
Air Conditioner Unit 2422
Configuration Diagram of Air Conditioner Unit 2422
Function of Air Conditioner Unit 2424
Component Parts of Air Conditioner Unit 2425
Function of Evaporator as Air Conditioner Unit Component 2426
Function of Heater Core as Air Conditioner Unit Component 2426
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2426
Function of Servo Motor as Air Conditioner Unit Component 2427
Structure of Expansion Valve as Air Conditioner Unit Component 2428
Function of Expansion Valve as Air Conditioner Unit Component 2428
Operate Expansion Valve as Air Conditioner Unit Component 2428
Function of Dual Pressure Switch 2429
Air Conditioner Controller 2430
Structure of Air Conditioner Controller 2430
Compressor 2431
Structure of Compressor 2431
Specifications of Compressor 2431
Function of Compressor 2431
Condenser 2432
Structure of Condenser 2432
Specifications of Condenser 2432
Function of Condenser 2432
Receiver Drier 2433
Structure of Receiver Dryer 2433
Specifications of Receiver Dryer 2433
Function of Receiver Dryer 2433
Air Conditioner Related Sensors 2434
Structure of Sunlight Sensor 2434
Function of Sunlight Sensor 2434
Structure of Outside Temperature Sensor 2434
Function of Outside Air Temperature Sensor 2434
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2436
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2438
System Diagram of Air Conditioner 2440
Input and Output Signals of Air Conditioner Controller 2441
Function of Air Conditioner Controller 2442
Locations of Air Conditioner Parts and Layout of Connectors 2443
Examine Air Leakage (Duct) 2449
How to Examine Air Leakage (Duct) 2449
Examine Air Conditioner with Self-Diagnosis Function 2450
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2451
Examine Vent (Mode) Changeover 2452
How to Examine Vent (Mode) Changeover 2452
Examine Fresh/Recirc Air Changeover 2453
How to Examine Fresh/Recirc Air Changeover 2453
Examine Sunlight Sensor 2454
How to Examine Sunlight Sensor 2454
Examine Refrigerant (Dual) Pressure Switch 2455
How to Examine Refrigerant (Dual) Pressure Switch 2455
Examine Relay 2457
How to Examine Relay 2457
Air Conditioner Troubleshooting Chart 1 2458
Air Conditioner Troubleshooting Chart 2 2459
Information Shown in Troubleshooting Table 2462
Failure Code [879AKA] 2463
Failure Code [879AKB] 2464
Failure Code [879BKA] 2465
Failure Code [879BKB] 2467
Failure Code [879CKA] 2469
Failure Code [879CKB] 2470
Failure Code [879DKZ] 2471
Failure Code [879EMC] 2473
Failure Code [879FMC] 2474
Failure Code [879GKX] 2475
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2477
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2479
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2482
Troubleshooting for Fresh/Recirc Air Changeover 2484
Troubleshooting by Gauge Pressure 2486
Connect Service Tool 2489
How to Connect Service Tool 2489
Precautions for Disconnection and Connection of Air Conditioner Piping 2491
Handle Compressor Oil 2493
90 Circuit Diagrams 2495
Table of Contents 2496
How to Read the Codes for Electric Cable 2497
Hydraulic Circuit Diagram 2501
Symbols Used in Hydraulic Circuit Diagram 2501
Hydraulic Circuit Diagram (1/2) 2505
Hydraulic Circuit Diagram (2/2) 2507
Hydraulic Circuit Diagram (at Boom RAISE Operation 1/2) 2509
Hydraulic Circuit Diagram (at Boom RAISE Operation 2/2) 2511
Hydraulic Circuit Diagram (at Left Swing Operation 1/2) 2513
Hydraulic Circuit Diagram (at Left Swing Operation 2/2) 2515
Hydraulic Circuit Diagram (at Boom RAISE and Left Swing Operation 1/2) 2517
Hydraulic Circuit Diagram (at Boom RAISE and Left Swing Operation 2/2) 2519
Electrical Circuit Diagram 2521
Symbols Used in Electric Circuit Diagram 2521
Electrical Circuit Diagram (Applicable Machine: 10001 to 10914) (1/9) 2525
Electrical Circuit Diagram (Applicable Machine: 10001 to 10914) (2/9) 2527
Electrical Circuit Diagram (Applicable Machine: 10001 to 10914) (3/9) 2529
Electrical Circuit Diagram (Applicable Machine: 10001 to 10914) (4/9) 2531
Electrical Circuit Diagram (Applicable Machine: 10001 to 10914) (5/9) 2533
Electrical Circuit Diagram (Applicable Machine: 10001 to 10914) (6/9) 2535
Electrical Circuit Diagram (Applicable Machine: 10001 to 10914) (7/9) 2537
Electrical Circuit Diagram (Applicable Machine: 10001 to 10914) (8/9) 2539
Electrical Circuit Diagram (Applicable Machine: 10001 to 10914) (9/9) 2541
Electrical Circuit Diagram (Applicable Machine: 10915 and Up) (1/9) 2543
Electrical Circuit Diagram (Applicable Machine: 10915 and Up) (2/9) 2545
Electrical Circuit Diagram (Applicable Machine: 10915 and Up) (3/9) 2547
Electrical Circuit Diagram (Applicable Machine: 10915 and Up) (4/9) 2549
Electrical Circuit Diagram (Applicable Machine: 10915 and Up) (5/9) 2551
Electrical Circuit Diagram (Applicable Machine: 10915 and Up) (6/9) 2553
Electrical Circuit Diagram (Applicable Machine: 10915 and Up) (7/9) 2555
Electrical Circuit Diagram (Applicable Machine: 10915 and Up) (8/9) 2557
Electrical Circuit Diagram (Applicable Machine: 10915 and Up) (9/9) 2559
Index 2561

S.V  21/12/24