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KOMATSU PW118MR-11 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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KOMATSU PW118MR-11 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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Description
KOMATSU PW118MR-11 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PW118MR-11 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
Language : English
Pages : 2382
Downloadable : Yes
File Type : PDF
SERIAL NUMBERS PW118MR-11 F30003 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PW118MR-11 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
00 INDEX AND FOREWORD........................................................................................................ 3 TABLE OF CONTENTS........................................................................................................ 4 FOREWORD, SAFETY AND GENERAL INFORMATION................................................................................. 24 IMPORTANT SAFETY NOTICE.............................................................................................. 24 FIRE PREVENTION...................................................................................................... 29 DISPOSE OF WASTE MATERIALS........................................................................................... 30 HOW TO READ THE SHOP MANUAL.......................................................................................... 31 Reading the symbols.............................................................................................. 31 Reading the signal word.......................................................................................... 32 Reading the unit................................................................................................. 32 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD........................................................................ 33 HANDLING EQUIPMENT OF FUEL SYSTEM DEVICES............................................................................ 35 HANDLING OF INTAKE SYSTEM PARTS...................................................................................... 36 HANDLING OF HYDRAULIC EQUIPMENT...................................................................................... 37 METHOD OF DISCONNECTING AND CONNECTING OF PUSH-PULL TYPE COUPLER..................................................... 39 Type 1........................................................................................................... 39 Type 2........................................................................................................... 40 Type 3........................................................................................................... 41 HANDLING OF ELECTRICAL EQUIPMENT..................................................................................... 42 HOW TO READ ELECTRIC WIRE CODE....................................................................................... 50 PRECAUTIONS WHEN PERFORMING OPERATION................................................................................ 53 PRACTICAL USE OF KOMTRAX............................................................................................. 58 STANDARD TIGHTENING TORQUE TABLE..................................................................................... 59 ABBREVIATION......................................................................................................... 65 CONVERSION TABLE..................................................................................................... 72 01 SPECIFICATION............................................................................................................. 77 CONTENTS................................................................................................................. 78 SPECIFICATIONS........................................................................................................... 79 OVERALL DIMENSIONS................................................................................................... 79 WORKING RANGE DRAWINGS............................................................................................... 80 SPECIFICATIONS....................................................................................................... 81 WEIGHT TABLE......................................................................................................... 86 TABLE OF FUEL, COOLANT, AND LUBRICANTS............................................................................... 88 10 STRUCTURE AND FUNCTION.................................................................................................... 89 CONTENTS................................................................................................................. 90 ABBREVIATION LIST........................................................................................................ 92 UREA SCR SYSTEM.......................................................................................................... 99 LAYOUT DRAWING OF UREA SCR SYSTEM.................................................................................... 99 Function of DEF injection system................................................................................. 103 Function of purge system......................................................................................... 103 Function of heating system....................................................................................... 104 INDUCEMENT STRATEGY.............................................................................................. 104 INDUCEMENT STRATEGY WHEN THE DEF LEVEL IN THE TANK BECOMES LOW................................................... 104 IINDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE DEF QUALITY OR IN THE UREA SCR SYSTEM DEVICES.............. 105 INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDOC SYSTEM BY THE UREA SCR SYSTEM DEVICES.................. 107 INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE EGR SYSTEM BY THE UREA SCR SYSTEM DEVICES................... 109 FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT................................................................ 110 INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40 HOURS................................................... 110 COMPONENT PARTS OF UREA SCR SYSTEM................................................................................... 112 DEF MIXING TUBE.................................................................................................. 112 STRUCTURE OF DEF MIXING TUBE..................................................................................... 112 FUNCTION OF DEF MIXING TUBE...................................................................................... 112 DEF TANK............................................................................................................. 115 STRUCTURE OF DEF TANK............................................................................................ 115 DEF TANK SENSOR.................................................................................................. 116 FUNCTION OF DEF TANK SENSOR...................................................................................... 116 DEF PUMP............................................................................................................. 117 STRUCTURE OF DEF PUMP............................................................................................ 117 DEF INJECTOR......................................................................................................... 118 STRUCTURE OF DEF INJECTOR........................................................................................ 118 FUNCTION OF DEF INJECTOR......................................................................................... 118 OPERATION OF DEF INJECTOR........................................................................................ 118 DEF HOSE............................................................................................................. 119 STRUCTURE OF DEF HOSE............................................................................................ 119 DEF TANK HEATING VALVE............................................................................................... 120 STRUCTURE OF DEF TANK HEATING VALVE.............................................................................. 120 BOOT-UP SYSTEM........................................................................................................... 121 LAYOUT DRAWING OF BOOT-UP SYSTEM..................................................................................... 121 Chassis part..................................................................................................... 121 ENGINE SYSTEM............................................................................................................ 122 LAYOUT DRAWING OF ENGINE SYSTEM...................................................................................... 122 COMPONENT PARTS OF ENGINE SYSTEM..................................................................................... 123 PTO.............................................................................................................. 123 STRUCTURE OF PTO................................................................................................. 123 SPECIFICATIONS OF PTO............................................................................................ 123 VARIABLE FLOW TURBOCHARGER....................................................................................... 124 EGR SYSTEM........................................................................................................... 127 LAYOUT DRAWING OF EGR SYSTEM..................................................................................... 127 FUNCTION OF EGR SYSTEM........................................................................................... 128 CIRCUIT DIAGRAM OF EGR SYSTEM.................................................................................... 128 OPERATION OF EGR SYSTEM.......................................................................................... 129 EGR VALVE............................................................................................................ 129 STRUCTURE OF EGR VALVE........................................................................................... 129 OPERATION OF EGR VALVE........................................................................................... 130 EGR COOLER........................................................................................................... 131 STRUCTURE OF EGR COOLER.......................................................................................... 131 General view and sectional view.................................................................................. 131 OPERATION OF EGR COOLER.......................................................................................... 132 KCCV SYSTEM.......................................................................................................... 132 LAYOUT DRAWING OF KCCV SYSTEM.................................................................................... 132 FUNCTION OF KCCV SYSTEM.......................................................................................... 133 OPERATION OF KCCV SYSTEM......................................................................................... 134 KCCV VENTILATOR...................................................................................................... 135 STRUCTURE OF KCCV VENTILATOR..................................................................................... 135 FUNCTION OF KCCV VENTILATOR...................................................................................... 135 OPERATION OF KCCV VENTILATOR..................................................................................... 135 CDR VALVE............................................................................................................ 136 OPERATION OF CDR VALVE........................................................................................... 136 EXHAUST THROTTLE VALVE............................................................................................... 137 STRUCTURE OF EXHAUST THROTTLE VALVE.............................................................................. 137 FUNCTION OF EXHAUST THROTTLE VALVE............................................................................... 137 OPERATION OF EXHAUST THROTTLE VALVE.............................................................................. 137 KDOC................................................................................................................. 138 STRUCTURE OF KDOC................................................................................................ 138 FUNCTION OF KDOC................................................................................................. 139 COOLING SYSTEM........................................................................................................... 140 LAYOUT DRAWING OF COOLING SYSTEM..................................................................................... 140 SPECIFICATIONS OF COOLING SYSTEM..................................................................................... 141 POWER TRAIN.............................................................................................................. 142 POWER TRAIN OVERVIEW................................................................................................. 142 SWING CIRCLE......................................................................................................... 144 SWING MACHINERY...................................................................................................... 145 UNDERCARRIAGE AND FRAME.................................................................................................. 147 FRONT AXLE........................................................................................................... 147 Pinion and differential.......................................................................................... 147 Brakes........................................................................................................... 149 Final reduction.................................................................................................. 150 Steering cylinder................................................................................................ 151 Steering and convergency angle................................................................................... 152 TRANSMISSION......................................................................................................... 153 HYDRAULIC SYSTEM......................................................................................................... 155 LAYOUT DRAWING OF HYDRAULIC SYSTEM................................................................................... 155 Chassis part..................................................................................................... 155 Around cab and floor............................................................................................. 156 HYDRAULIC TANK....................................................................................................... 157 HYDRAULIC PUMP....................................................................................................... 159 LS valve......................................................................................................... 165 PC valve......................................................................................................... 166 LS(PC)-EPC valve................................................................................................. 179 CONTROL VALVE........................................................................................................ 183 Outline.......................................................................................................... 184 CLSS................................................................................................................. 194 Structure of CLSS................................................................................................ 194 Function and operation by valve.................................................................................. 198 1. Unload valve.................................................................................................. 200 2. Introduction of LS pressure................................................................................... 203 3. LS bypass plug................................................................................................ 205 4. Pressure compensation valve................................................................................... 206 5. Surface area ratio of pressure compensation valve............................................................. 207 6. Travel LS bypass circuit...................................................................................... 207 7. Boom regeneration circuit..................................................................................... 210 9. LS select valve............................................................................................... 212 WORK EQUIPMENT SYSTEM.................................................................................................... 213 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM.............................................................................. 213 UNDERCARRIAGE PART................................................................................................... 215 VALVE CONTROL........................................................................................................ 216 SELF-REDUCING PRESSURE VALVE......................................................................................... 217 SWING MOTOR.......................................................................................................... 223 Safety valve with suction........................................................................................ 225 Operation of the modulating relief valve......................................................................... 227 Actuation of hydraulic timer valve............................................................................... 229 TRAVEL MOTOR......................................................................................................... 230 Function......................................................................................................... 231 Operation........................................................................................................ 232 WORK EQUIPMENT AND SWING PPC VALVE................................................................................... 234 Operation........................................................................................................ 236 BOOM SWING AND 2-PIECE BOOM PPC VALVE................................................................................ 240 TRAVEL PPC VALVE..................................................................................................... 241 BRAKES PUMP.......................................................................................................... 242 SWIVEL JOINT......................................................................................................... 244 SOLENOID VALVE....................................................................................................... 246 STEERING CONTROL SOLENOID VALVE GROUP................................................................................ 248 1-ATTACHMENT FLOW ADJUSTMENT EPC VALVE............................................................................... 249 2-ATTACHMENT FLOW ADJUSTMENT EPC VALVE............................................................................... 250 TRAVEL SPEED AND DIRECTION CONTROL SOLENOID VALVE.................................................................... 251 BOOM/OUTRIGGER SCHEMATIC............................................................................................. 252 UNDERCARRIAGE ATTACHMENT SCHEMATIC................................................................................... 253 ACCUMULATOR.......................................................................................................... 254 PPC CIRCUIT ACCUMULATOR.......................................................................................... 254 BRAKE CIRCUIT ACCUMULATOR........................................................................................ 255 HOLDING VALVE........................................................................................................ 256 Function......................................................................................................... 257 Operation........................................................................................................ 257 2-PIECE BOOM SAFETY VALVE............................................................................................ 260 BLADE/OUTRIGGERS SAFETY VALVE........................................................................................ 261 BOOM SWING SAFETY VALVE.............................................................................................. 262 HYDRAULIC QUICK COUPLER.............................................................................................. 263 Schematic........................................................................................................ 263 Operation........................................................................................................ 264 Hydraulic quick coupler solenoid valve........................................................................... 264 Specification.................................................................................................... 264 Quick coupler error logic........................................................................................ 265 Quick coupler indication logic................................................................................... 265 WORK EQUIPMENT........................................................................................................... 266 WORK EQUIPMENT....................................................................................................... 266 WORK EQUIPMENT SHIM.................................................................................................. 267 ELECTRICAL SYSTEM........................................................................................................ 268 ELECTRICAL CONTROL SYSTEM............................................................................................ 268 ENGINE CONTROL SYSTEM................................................................................................ 269 ENGINE CONTROL SYSTEM DIAGRAM.................................................................................... 269 FUNCTION OF ENGINE CONTROL SYSTEM.................................................................................... 270 Mechanism and function of engine starting system................................................................. 270 Mechanism and function of engine speed control system............................................................ 271 Mechanism and function of engine stopping system................................................................. 271 Mechanism and function of engine stopping system with engine shutdown secondary switch........................... 272 AUTO-DECELERATION SYSTEM............................................................................................. 273 AUTO-DECELERATION SYSTEM DIAGRAM................................................................................. 273 FUNCTION OF AUTO-DECELERATION SYSTEM............................................................................. 274 OPERATION OF AUTO-DECELERATION SYSTEM............................................................................ 274 When control lever is in NEUTRAL................................................................................. 274 When control lever is operated................................................................................... 274 ENGINE AUTOMATIC WARM-UP SYSTEM...................................................................................... 275 ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM.......................................................................... 275 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM...................................................................... 276 OVERHEAT PREVENTION SYSTEM........................................................................................... 277 FUNCTION OF OVERHEAT PREVENTION SYSTEM........................................................................... 277 TURBOCHARGER PROTECTION SYSTEM....................................................................................... 279 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM....................................................................... 279 AUTOMATIC IDLE STOP SYSTEM........................................................................................... 280 AUTOMATIC IDLE STOP SYSTEM DIAGRAM............................................................................... 280 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM........................................................................... 280 Operating conditions of auto idle stop system.................................................................... 280 Setting time..................................................................................................... 281 Abrupt engine stop is detected................................................................................... 281 Engine and pump combined control function........................................................................ 283 Swing control function........................................................................................... 288 Travel control function.......................................................................................... 290 2WS-4WS mode control............................................................................................. 295 Parking brake function (travel).................................................................................. 298 Autocruise control function...................................................................................... 299 PPC lock function................................................................................................ 300 Work equipment automatic lock function........................................................................... 302 SYSTEM OPERATING LAMP SYSTEM......................................................................................... 304 SYSTEM OPERATING LAMP SYSTEM DIAGRAM............................................................................. 304 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM......................................................................... 304 ON and OFF of system operating lamp.............................................................................. 304 Battery disconnect switch function............................................................................... 305 Refueling pump................................................................................................... 307 Oil flow adjuster function for attachment........................................................................ 308 CONTROL SYSTEM....................................................................................................... 310 LAYOUT DRAWING OF CONTROL SYSTEM................................................................................. 310 MACHINE MONITOR SYSTEM............................................................................................... 312 FUNCTION OF MACHINE MONITOR SYSTEM............................................................................... 312 COMPONENT PARTS OF CONTROL SYSTEM.................................................................................... 313 MACHINE MONITOR.................................................................................................. 313 INPUT AND OUTPUT SIGNALS OF MACHINE MONITOR...................................................................... 314 070-18P “CM01”................................................................................................... 314 070-12P “CM02”................................................................................................... 315 070-8P “CM04”.................................................................................................... 315 TYPES OF GAUGES AND METERS DISPLAYED ON MACHINE MONITOR.......................................................... 316 TYPES OF CAUTION LAMPS DISPLAYED ON MACHINE MONITOR.............................................................. 318 TYPES OF PILOT LAMPS DISPLAYED ON MACHINE MONITOR................................................................ 323 TYPES OF DISPLAY INDICATORS SIGNALLING THE STEERING MODE......................................................... 326 TYPES OF DISPLAY INDICATORS SIGNALLING TRAVELLING ON ROADS....................................................... 328 SERVICE MODE FUNCTION OF MACHINE MONITOR......................................................................... 330 KomVision CONTROLLER................................................................................................. 331 STRUCTURE OF KomVision CONTROLLER................................................................................ 331 INPUT AND OUTPUT SIGNALS OF KomVision CONTROLLER................................................................. 331 TYCO-81P“CN-CA01”................................................................................................ 331 KomVision SYSTEM..................................................................................................... 336 LAYOUT DRAWING OF KomVision SYSTEM............................................................................... 336 FUNCTION OF KomVision SYSTEM..................................................................................... 338 KomVision CAMERA..................................................................................................... 340 STRUCTURE OF KomVision CAMERA.................................................................................... 340 INPUT AND OUTPUT SIGNALS OF KomVision CAMERA..................................................................... 340 KOMTRAX SYSTEM....................................................................................................... 341 KOMTRAX SYSTEM DIAGRAM........................................................................................... 341 KOMTRAX terminal................................................................................................. 342 PUMP CONTROLLER...................................................................................................... 344 STRUCTURE OF PUMP CONTROLLER..................................................................................... 344 INPUT AND OUTPUT SIGNALS OF PUMP CONTROLLER...................................................................... 344 RESISTOR FOR PC-EPC VALVE........................................................................................ 348 STRUCTURE OF REGISTER FOR PC-EPC VALVE........................................................................... 348 General view..................................................................................................... 348 SPECIFICATIONS OF REGISTER FOR PC-EPC VALVE...................................................................... 348 FUNCTION OF RESISTOR FOR PC-EPC VALVE............................................................................ 348 CAN TERMINATING RESISTOR......................................................................................... 348 STRUCTURE OF CAN TERMINATING RESISTOR............................................................................ 348 General view..................................................................................................... 348 SPECIFICATIONS OF CAN TERMINATING RESISTOR....................................................................... 349 FUNCTION OF CAN TERMINATING RESISTOR............................................................................. 349 MACHINE CONTROLLER................................................................................................... 350 STRUCTURE OF MACHINE CONTROLLER.................................................................................. 350 INPUT AND OUTPUT SIGNALS OF MACHINE CONTROLLER................................................................... 350 ENGINE CONTROLLER.................................................................................................... 354 STRUCTURE OF ENGINE CONTROLLER................................................................................... 354 INPUT AND OUTPUT SIGNALS OF ENGINE CONTROLLER.................................................................... 354 FUEL CONTROL DIAL.................................................................................................... 360 STRUCTURE OF FUEL CONTROL DIAL................................................................................... 360 FUNCTION OF FUEL CONTROL DIAL.................................................................................... 360 CAB AND ITS ATTACHMENTS.................................................................................................. 361 CAB MOUNT AND CAB TIPPING STOPPER.................................................................................... 361 ROPS CAB............................................................................................................. 363 Take wiring harness out of cab................................................................................... 364 STEERING COLUMN...................................................................................................... 365 20 STANDARD VALUE TABLES..................................................................................................... 367 CONTENTS................................................................................................................. 368 ABBREVIATION LIST........................................................................................................ 369 STANDARD SERVICE VALUE TABLE............................................................................................. 376 STANDARD VALUE TABLE FOR ENGINE...................................................................................... 376 Performace....................................................................................................... 376 Air intake and exhaust system.................................................................................... 376 Main body........................................................................................................ 377 Fuel system...................................................................................................... 377 Lubrication system............................................................................................... 378 Cooling system................................................................................................... 378 Cooling fan...................................................................................................... 379 STANDARD VALUE TABLE FOR MACHINE..................................................................................... 380 Engine speed..................................................................................................... 380 SCR.............................................................................................................. 381 Travel of control lever.......................................................................................... 382 Control effort of control lever.................................................................................. 382 Hydraulic pressure............................................................................................... 383 Swing............................................................................................................ 385 Travel........................................................................................................... 387 Work equipment................................................................................................... 388 Pump performance................................................................................................. 393 Machine posture and procedure for measuring performance.......................................................... 394 30 TESTING AND ADJUSTING..................................................................................................... 399 CONTENTS................................................................................................................. 400 ABBREVIATION LIST........................................................................................................ 402 RELATED INFORMATION ON TESTING AND ADJUSTING............................................................................. 409 SKETCH OF TOOLS FOR TESTING AND ADJUSTING............................................................................ 409 Nipple........................................................................................................... 410 Socket........................................................................................................... 410 ENGINE AND COOLING SYSTEM................................................................................................ 411 TEST ENGINE SPEED.................................................................................................... 411 METHOD FOR TESTING ENGINE SPEED.................................................................................. 411 TEST EXHAUST GAS COLOR............................................................................................... 414 Tools for testing exhaust gas color.............................................................................. 414 METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER...................................................... 414 METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER.............................................................. 415 TEST THE CLEARANCE OF THE EXHAUST THROTTLE VALVE..................................................................... 416 Tools for measuring the clearance of the exhaust throttle valve.................................................. 416 METHOD FOR MEASURING THE CLEARANCE OF THE EXHAUST THROTTLE VALVE................................................. 416 TEST AND ADJUST VALVE CLEARANCE...................................................................................... 419 Tools for testing and adjusting valve clearance.................................................................. 419 METHOD FOR TESTING VALVE CLEARANCE............................................................................... 419 TEST COMPRESSION PRESSURE............................................................................................ 421 Tools for testing compression pressure........................................................................... 421 METHOD FOR TESTING COMPRESSION PRESSURE.......................................................................... 421 TEST BLOWBY PRESSURE................................................................................................. 424 Tools for testing blowby pressure................................................................................ 424 METHOD FOR TESTING BLOWBY PRESSURE............................................................................... 425 TEST ENGINE OIL PRESSURE............................................................................................. 427 Tools for testing engine oil pressure............................................................................ 427 METHOD FOR TESTING ENGINE OIL PRESSURE........................................................................... 427 TEST FUEL PRESSURE................................................................................................... 429 Tools for testing fuel pressure.................................................................................. 429 METHOD FOR TESTING FUEL PRESSURE................................................................................. 429 TEST FUEL RETURN RATE AND LEAKAGE.................................................................................... 431 Tools for testing fuel return rate and leakage................................................................... 431 METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE.................................................................. 433 BLEED AIR FROM FUEL SYSTEM........................................................................................... 435 METHOD FOR BLEEDING AIR FROM FUEL SYSTEM......................................................................... 436 TEST FUEL CIRCUIT FOR LEAKAGE........................................................................................ 437 Tools for testing fuel circuit for leakage....................................................................... 437 METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE...................................................................... 437 HANDLE CYLINDER CUT-OUT MODE OPERATION............................................................................... 439 HANDLE NO-INJECTION CRANKING OPERATION............................................................................... 440 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION.............................................................. 441 METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT.............................................................. 441 METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT............................................................. 442 TEST COOLING FAN SPEED............................................................................................... 444 METHOD FOR TESTING COOLING FAN SPEED............................................................................. 444 WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER............................................................... 445 Writing tools for compensation values of injector and controller................................................. 445 METHOD FOR WRITING INJECTOR COMPENSATION VALUE................................................................... 445 TEST SCR RELATED FUNCTIONS........................................................................................... 451 Type of SCR Service Test......................................................................................... 451 Test State Category.............................................................................................. 451 Parameter list of test state..................................................................................... 452 TEST DEF PUMP RAISED PRESSURE.................................................................................... 454 METHOD FOR TESTING DEF PUMP RAISED PRESSURE...................................................................... 455 TEST INJECTION AMOUNT FROM DEF INJECTOR.............................................................................. 458 Tools for testing of injection amount from DEF injector.......................................................... 458 METHOD FOR TESTING INJECTION AMOUNT FROM DEF INJECTOR............................................................ 459 TEST DEF LINE HEATER RELAY 1......................................................................................... 463 Tools for testing DEF line heater relay 1........................................................................ 463 METHOD FOR TESTING DEF LINE HEATER RELAY 1....................................................................... 463 TEST DEF LINE HEATER RELAY 2......................................................................................... 466 Testing tools for DEF line heater relay 2........................................................................ 466 METHOD FOR TESTING DEF LINE HEATER RELAY 2....................................................................... 466 TEST DEF PUMP HEATER RELAY........................................................................................... 469 Testing tools for DEF pump heater relay.......................................................................... 469 METHOD FOR TESTING DEF PUMP HEATER RELAY......................................................................... 469 TEST DEF TANK HEATER VALVE........................................................................................... 473 Tools for testing DEF tank heater valve.......................................................................... 473 METHOD FOR TESTING DEF TANK HEATER VALVE......................................................................... 473 TEST DENITRATION EFFICIENCY OF SCR................................................................................... 476 METHOD FOR TESTING DENITRATION EFFICIENCY OF SCR................................................................. 476 CLEAN DEFTANK........................................................................................................ 479 Tools for testing cleaning of DEF tank........................................................................... 479 METHOD FOR CLEANING DEF TANK..................................................................................... 479 POWER TRAIN.............................................................................................................. 484 TESTING SWING CIRCLE BEARING CLEARANCE............................................................................... 484 Tools for testing................................................................................................ 484 TESTING.......................................................................................................... 484 UNDERCARRIAGE AND FRAME.................................................................................................. 486 CHECKING LEAKAGES IN THE STEERING CYLINDERS.......................................................................... 486 TESTING AND ADJUSTING STEERING CIRCUIT OIL PRESSURE.................................................................. 487 Testing and adjusting tools for steering circuit oil pressure.................................................... 487 TESTING.......................................................................................................... 487 TESTING STEERING CIRCUIT RELIEF PRESSURE............................................................................. 489 TESTING THE BRAKING SYSTEM PRESSURE.................................................................................. 490 Testing tools for solenoid valve output pressure................................................................. 490 TESTING THE ACCUMULATOR PRE-CHARGE PRESSURE...................................................................... 491 TESTING THE BRAKING PRESSURE..................................................................................... 491 CHECK THE HYDRAULIC DRIFT OF THE BRAKING CIRCUIT................................................................. 491 TESTING THE BRAKE SYSTEM LEAKAGE..................................................................................... 492 IDENTIFICATION OF THE DEFECTIVE AXLE............................................................................. 492 IDENTIFICATION OF THE DEFECTIVE BRAKE GROUP...................................................................... 492 CHECKING WEAR IN THE BRAKE DISKS..................................................................................... 493 BLEEDING AIR FROM THE BRAKE LINES.................................................................................... 494 ADJUSTMENT OF THE SPEED SENSOR....................................................................................... 495 HYDRAULIC SYSTEM......................................................................................................... 496 RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT.................................................................. 496 RELEASING REMAINING PRESSURE..................................................................................... 496 CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS........................................................... 498 PREPARATION...................................................................................................... 499 RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT................................................................. 499 PRESSURE REDUCING PLUG........................................................................................... 499 TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS............................................. 501 Testing and adjusting tools for oil pressure in work equipment and travel circuits............................... 501 TESTING.......................................................................................................... 501 MEASURING METHOD BY USING MACHINE MONITOR........................................................................ 502 ADJUSTING........................................................................................................ 502 TESTING AND ADJUSTING SWING CIRCUIT OIL PRESSURE..................................................................... 504 Testing and adjusting tools for oil pressure in swing circuit.................................................... 504 TESTING.......................................................................................................... 504 ADJUSTING........................................................................................................ 505 TESTING OIL PRESSURE OF CONTROL CIRCUIT.............................................................................. 507 Testing and adjusting tools for oil pressure of control circuit.................................................. 507 TESTING.......................................................................................................... 507 INSPECTION AND ADJUSTMENT OF PUMP PC (VALVE INLET) CONTROL OIL PRESSURE.............................................. 508 MEASUREMENT...................................................................................................... 508 ADJUSTMENT....................................................................................................... 509 TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT........................................................ 510 Testing and adjusting tools for oil pressure in pump LS control circuit.......................................... 510 TESTING.......................................................................................................... 510 ADJUSTMENT....................................................................................................... 512 TESTING OUTLET PRESSURE OF SOLENOID VALVE............................................................................ 513 Testing tools for pressure of solenoid valve..................................................................... 513 TESTING SOLENOID OUTPUT PRESSURE................................................................................. 513 TESTING PPC VALVE OUTLET PRESSURE.................................................................................... 514 Connecting points of PPC piping.................................................................................. 514 Testing tools for PPC valve outlet pressure...................................................................... 515 TESTING.......................................................................................................... 515 ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES................................................................ 516 ADJUSTING........................................................................................................ 516 TRAVEL HYDRAULIC EQUIPMENT CHECKING PROCEDURE........................................................................ 517 UPPER PART COMPONENT OF SYSTEM................................................................................... 517 LOWER PART OF THE SYSTEM......................................................................................... 517 TESTING AND ADJUSTING THE AUTOMATIC DISPLACEMENT CONTROL OF TRAVEL MOTOR............................................. 518 Testing and adjusting tools for testing the automatic displacement control system in the travel motor............ 518 PREPARATION WORK................................................................................................. 518 TESTING.......................................................................................................... 519 ADJUSTMENT....................................................................................................... 519 WORK AFTER FINISHING TEST........................................................................................ 520 CHECKING FOR LEAKAGES IN THE TRAVEL MOTOR............................................................................ 521 TESTING.......................................................................................................... 521 PREPARATION WORK................................................................................................. 521 CHECKING......................................................................................................... 521 ISOLATING THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT........................................................ 522 TESTING.......................................................................................................... 522 TESTING OIL LEAKAGE.................................................................................................. 524 Testing tools for testing oil leakage............................................................................ 524 TESTING.......................................................................................................... 524 CHECKING FOR LEAKAGES IN THE TRAVEL MOTOR............................................................................ 528 CHECKING LEAKAGES IN THE STEERING CYLINDERS.......................................................................... 529 BLEEDING AIR FROM CIRCUIT............................................................................................ 530 BLEEDING AIR FROM HYDRAULIC PUMP................................................................................. 530 STARTING THE ENGINE.............................................................................................. 530 BLEEDING AIR FROM CYLINDER....................................................................................... 531 BLEEDING AIR FROM SWING MOTOR.................................................................................... 531 Bleeding air from travel motor................................................................................... 531 CHECK OF OIL LEVEL AND OPERATION................................................................................. 532 CAB AND ITS ATTACHMENTS.................................................................................................. 534 TESTING, CLEANING AND LUBRICATING SLIDE DOOR RAIL AND ROLLER......................................................... 534 TESTING.......................................................................................................... 534 ADJUSTING MIRRORS.................................................................................................... 535 ELECTRICAL SYSTEM........................................................................................................ 536 SET AND OPERATE MACHINE MONITOR...................................................................................... 536 Upper part of machine monitor.................................................................................... 537 Upper part of machine monitor (switch part)...................................................................... 537 Lower part of machine monitor (switch part)...................................................................... 537 Operator mode and service mode of machine monitor................................................................ 537 OPERATOR MODE.................................................................................................... 538 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN...................................................... 538 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN......................................................... 538 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)................................................................ 539 CHECKING FUNCTION OF SERVICE METER............................................................................... 539 METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD........................................................ 540 SERVICE MODE..................................................................................................... 542 METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION........................................................... 545 TABLE OF PRE-DEFINED MONITORING ITEMS............................................................................ 546 METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION........................................................... 554 TABLE OF SELF-DEFINE MONITORING.................................................................................. 557 ABNORMALITY RECORD MENU.......................................................................................... 567 METHOD FOR CONFIRMING ABNORMALITY RECORD (ELECTRICAL SYSTEMS).................................................... 568 METHOD FOR CONFIRMING MAINTENANCE RECORD......................................................................... 571 METHOD FOR OPERATING MAINTENANCE MODE SETTING.................................................................... 572 METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING.................................................................. 575 DEFAULT MENU..................................................................................................... 576 METHOD FOR SETTING DEFAULT (KEY-ON MODE)......................................................................... 576 METHOD FOR SETTING DEFAULT (UNIT)................................................................................ 578 METHOD FOR SETTING DEFAULT (WITH/WITHOUT ATTACHMENT)............................................................. 578 METHOD FOR SETTING DEFAULT (CAMERA).............................................................................. 579 METHOD FOR OPERATING TESTING MENU (AUTO IDLE STOP TIME FIXING)................................................... 581 METHOD FOR SETTING WITH DEFAULT SETTING MENU (CHASSIS ATTACHMENT)................................................ 582 METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT QUICK COUPLER)........................................ 583 DIAGNOSTIC TESTS MENU............................................................................................ 584 METHOD FOR OPERATING TESTING MENU (CYLINDER CUT-OUT OPERATION)................................................... 584 METHOD FOR OPERATING TESTING MENU (SCR SERVICE TEST)............................................................. 585 METHOD FOR OPERATING TESTING MENU (ENGINE CONTROLLER ACTIVE FAULT CLEAR)......................................... 587 METHOD FOR OPERATING TESTING MENU (RESET NUMBER OF ABRUPT ENGINE STOP BY AIS).................................... 588 METHOD FOR OPERATING TESTING MENU (FRONT STEERING FORCE 2WS MODE)................................................ 589 ADJUSTMENT MENU.................................................................................................. 590 METHOD FOR ADJUSTING WITH ADJUSTING MENU (PUMP ABSORPTION TORQUE)................................................ 590 METHOD FOR ADJUSTING WITH ADJUSTING MENU (ATTACHMENT FLOW ADJUSTMENT IN COMBINED OPERATION)...................... 591 METHOD FOR ADJUSTING WITH ADJUSTING MENU (ATTACHMENT EPC1-EPC4 ADJUSTMENT)....................................... 594 METHOD FOR PERFORMING NO-INJECTION CRANKING...................................................................... 595 METHOD FOR SETTING (MAX. TRAVEL SPEED)........................................................................... 597 KOMTRAX SETTINGS MENU............................................................................................ 598 METHOD FOR CONFIRMING KOMTRAX SETTINGS (TERMINAL STATUS)......................................................... 598 METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS AND COMMUNICATION STATUS)............................................ 599 METHOD FOR CONFIRMING KOMTRAX SETTINGS (MODEM STATUS)............................................................ 600 METHOD FOR DISPLAYING SERVICE MESSAGE............................................................................ 600 METHOD FOR STARTING UP KOMTRAX TERMINAL.............................................................................. 602 Method for starting-up KOMTRAX................................................................................... 602 When KOMTRAX terminal is replaced................................................................................ 602 Machine side inspection for KOMTRAX Communication opening........................................................ 602 ADJUST KomVision CAMERA ANGLE........................................................................................ 607 Tools for adjusting KomVision camera angle....................................................................... 607 METHOD FOR ADJUSTING KomVision CAMERA ANGLE...................................................................... 607 ADJUST KomVision RELATED ITEMS....................................................................................... 609 List of KomVision adjustment items............................................................................... 609 SETTING OF KomVision (MAIN SETTING).............................................................................. 609 METHOD FOR SETTING KomVision (MAIN SETTING)...................................................................... 609 SETTING OF KomVision (CAMERA SETTING)............................................................................ 611 METHOD FOR SETTING KomVision (CAMERA SETTING).................................................................... 611 SETTING OF KomVision (CAMERA CALIBRATION)........................................................................ 611 METHOD FOR SETTING OF KomVision (CAMERA CALIBRATION)............................................................. 611 Operating method for “Camera Position Setting”................................................................... 616 Fig.1............................................................................................................ 622 ADJUSTING HEADLIGHT LAMP ALIGNMENT FOR STREET CIRCULATION............................................................ 623 Checking......................................................................................................... 623 ADJUSTING........................................................................................................ 624 HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER........................................................................ 625 HANDLING BATTERY DISCONNECT SWITCH................................................................................... 626 TESTING DIODES....................................................................................................... 627 40 TROUBLESHOOTING........................................................................................................... 629 TABLE OF CONTENTS........................................................................................................ 630 ABBREVIATION LIST........................................................................................................ 643 RELATED INFORMATION ON TROUBLESHOOTING................................................................................... 650 GENERAL TROUBLESHOOTING POINTS....................................................................................... 650 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM........................................................................... 651 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................ 663 CHECKS BEFORE TROUBLESHOOTING........................................................................................ 665 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING.......................................................................... 667 WALK-AROUND CHECK................................................................................................ 667 TESTING IN ACCORDANCE WITH TESTING PROCEDURE......................................................................... 669 CHECK OF FUEL LEVEL AND TYPE..................................................................................... 669 CHECK FUEL PREFILTER............................................................................................. 670 WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT............................................................... 670 METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE.................................................................... 671 METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE.................................................................. 673 METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL...................................................... 675 METHOD FOR CHECKING OIL LEVEL IN PTO GEAR CASE, ADDING OIL....................................................... 676 METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT................................................................ 677 METHOD FOR CHECKING AIR CLEANER.................................................................................. 678 METHOD FOR CLEANING AIR CLEANER OUTER ELEMENT.................................................................... 678 METHOD FOR CHANGING AIR CLEANER ELEMENT.......................................................................... 681 METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL...................................................... 682 METHOD FOR CHANGING OIL IN HYDRAULIC TANK, CLEANING HYDRAULIC TANK STRAINER...................................... 684 METHOD FOR REPLACING HYDRAULIC OIL FILTER ELEMENT................................................................ 686 METHOD FOR CHECKING OIL LEVEL IN SWING MACHINERY CASE, ADDING OIL................................................ 687 METHOD FOR CHECKING THE OIL LEVELS IN THE TRANSMISSION REDUCTION GEAR............................................ 688 METHOD FOR CHECKING THE FRONT AXLE OIL LEVEL..................................................................... 688 METHOD FOR CHECKING THE REAR AXLE OIL LEVEL...................................................................... 689 BLEED AIR FROM FUEL SYSTEM....................................................................................... 689 BLEED AIR FROM HYDRAULIC SYSTEM.................................................................................. 689 METHOD FOR CHECKING ELECTRIC EQUIPMENT........................................................................... 690 PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM................................................................. 695 PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR............................................................... 695 PREPARATION FOR TROUBLESHOOTING OF MACHINE CONTROLLER............................................................ 696 PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER............................................................. 696 PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER............................................................... 696 PREPARATION FOR TROUBLESHOOTING OF KOMTRAX....................................................................... 699 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK.............................................. 699 PROCEDURE FOR TESTING AND TROUBLESHOOTING............................................................................ 704 SYMPTOM AND TROUBLESHOOTING NUMBERS.................................................................................. 707 INFORMATION IN TROUBLESHOOTING TABLE............................................................................. 707 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM.................................. 709 CONNECTOR LIST AND LAYOUT............................................................................................ 711 LAYOUT OF CONNECTORS (1/17)...................................................................................... 719 LAYOUT OF CONNECTORS (2/17)...................................................................................... 720 LAYOUT OF CONNECTORS (3/17)...................................................................................... 721 LAYOUT OF CONNECTORS (4/17)...................................................................................... 722 LAYOUT OF CONNECTORS (5/17)...................................................................................... 723 LAYOUT OF CONNECTORS (6/17)...................................................................................... 724 LAYOUT OF CONNECTORS (7/17)...................................................................................... 725 LAYOUT OF CONNECTORS (8/17)...................................................................................... 726 LAYOUT OF CONNECTORS (9/17)...................................................................................... 727 LAYOUT OF CONNECTORS (10/17)..................................................................................... 728 LAYOUT OF CONNECTORS (11/17)..................................................................................... 729 LAYOUT OF CONNECTORS (12/17)..................................................................................... 730 LAYOUT OF CONNECTORS (13/17)..................................................................................... 731 LAYOUT OF CONNECTORS (14/17)..................................................................................... 732 LAYOUT OF CONNECTORS (15/17)..................................................................................... 733 LAYOUT OF CONNECTORS (16/17)..................................................................................... 734 LAYOUT OF CONNECTORS (17/17)..................................................................................... 735 CONNECTOR CONTACT IDENTIFICATION..................................................................................... 736 FUSE LOCATION TABLE.................................................................................................. 776 CONNECTION TABLE OF FUSE BOX..................................................................................... 776 FAILURE CODES TABLE.................................................................................................. 779 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)........................................................................ 795 FAILURE CODE [2G00MA]................................................................................................ 795 FAILURE CODE [6AZ0ZG]................................................................................................ 796 FAILURE CODE [6B2JMA]................................................................................................ 798 FAILURE CODE [879AKA]................................................................................................ 799 FAILURE CODE [879AKB]................................................................................................ 800 FAILURE CODE [879BKA]................................................................................................ 801 FAILURE CODE [879BKB]................................................................................................ 802 FAILURE CODE [879CKA]................................................................................................ 803 FAILURE CODE [879CKB]................................................................................................ 804 FAILURE CODE [879DKZ]................................................................................................ 805 FAILURE CODE [879EMC]................................................................................................ 806 FAILURE CODE [879FMC]................................................................................................ 807 FAILURE CODE [879GKX]................................................................................................ 808 FAILURE CODE [989L00]................................................................................................ 809 FAILURE CODE [989M00]................................................................................................ 810 FAILURE CODE [989N00]................................................................................................ 811 FAILURE CODE [A1U0N3]................................................................................................ 812 FAILURE CODE [A1U0N4]................................................................................................ 814 FAILURE CODE [A900FR]................................................................................................ 816 FAILURE CODE [A900N6]................................................................................................ 817 FAILURE CODE [A900NY]................................................................................................ 818 FAILURE CODE [AA10NX]................................................................................................ 819 FAILURE CODE [AB00KE]................................................................................................ 821 FAILURE CODE [AQ10MB]................................................................................................ 823 FAILURE CODE [AQ10N3]................................................................................................ 825 FAILURE CODE [AS00R2]................................................................................................ 826 FAILURE CODE [AS00R3]................................................................................................ 827 FAILURE CODE [AS00R4]................................................................................................ 828 FAILURE CODE [AS00R5]................................................................................................ 829 FAILURE CODE [AS00R6]................................................................................................ 830 FAILURE CODE [AS00ZK]................................................................................................ 831 FAILURE CODE [AS10KM]................................................................................................ 832 FAILURE CODE [AS10NR]................................................................................................ 833 FAILURE CODE [AS10NT]................................................................................................ 834 FAILURE CODE [B@BAZG]................................................................................................ 835 FAILURE CODE [B@BAZK]................................................................................................ 836 FAILURE CODE [B@BCNS]................................................................................................ 837 FAILURE CODE [CA115]................................................................................................. 838 FAILURE CODE [CA122]................................................................................................. 839 FAILURE CODE [CA123]................................................................................................. 841 FAILURE CODE [CA131]................................................................................................. 843 FAILURE CODE [CA132]................................................................................................. 845 FAILURE CODE [CA144]................................................................................................. 847 FAILURE CODE [CA145]................................................................................................. 849 FAILURE CODE [CA153]................................................................................................. 851 FAILURE CODE [CA154]................................................................................................. 853 FAILURE CODE [CA187]................................................................................................. 855 FAILURE CODE [CA221]................................................................................................. 857 FAILURE CODE [CA222]................................................................................................. 859 FAILURE CODE [CA227]................................................................................................. 861 FAILURE CODE [CA234]................................................................................................. 862 FAILURE CODE [CA238]................................................................................................. 863 FAILURE CODE [CA239]................................................................................................. 865 FAILURE CODE [CA249]................................................................................................. 867 FAILURE CODE [CA256]................................................................................................. 869 FAILURE CODE [CA271]................................................................................................. 871 FAILURE CODE [CA272]................................................................................................. 873 FAILURE CODE [CA322]................................................................................................. 875 FAILURE CODE [CA324]................................................................................................. 877 FAILURE CODE [CA331]................................................................................................. 879 FAILURE CODE [CA332]................................................................................................. 881 FAILURE CODE [CA343]................................................................................................. 883 FAILURE CODE [CA351]................................................................................................. 884 FAILURE CODE [CA352]................................................................................................. 885 FAILURE CODE [CA356]................................................................................................. 887 FAILURE CODE [CA357]................................................................................................. 889 FAILURE CODE [CA386]................................................................................................. 891 FAILURE CODE [CA435]................................................................................................. 892 FAILURE CODE [CA441]................................................................................................. 894 FAILURE CODE [CA442]................................................................................................. 896 FAILURE CODE [CA449]................................................................................................. 897 FAILURE CODE [CA451]................................................................................................. 898 FAILURE CODE [CA452]................................................................................................. 900 FAILURE CODE [CA515]................................................................................................. 902 FAILURE CODE [CA516]................................................................................................. 904 FAILURE CODE [CA553]................................................................................................. 906 FAILURE CODE [CA555]................................................................................................. 907 FAILURE CODE [CA556]................................................................................................. 908 FAILURE CODE [CA559]................................................................................................. 909 FAILURE CODE [CA689]................................................................................................. 913 FAILURE CODE [CA691]................................................................................................. 915 FAILURE CODE [CA692]................................................................................................. 917 FAILURE CODE [CA697]................................................................................................. 920 FAILURE CODE [CA698]................................................................................................. 921 FAILURE CODE [CA731]................................................................................................. 922 FAILURE CODE [CA778]................................................................................................. 924 FAILURE CODE [CA1117]................................................................................................ 929 FAILURE CODE [CA1664]................................................................................................ 930 FAILURE CODE [CA1669]................................................................................................ 932 FAILURE CODE [CA1673]................................................................................................ 933 FAILURE CODE [CA1677]................................................................................................ 934 FAILURE CODE [CA1678]................................................................................................ 935 FAILURE CODE [CA1682]................................................................................................ 936 FAILURE CODE [CA1683]................................................................................................ 938 FAILURE CODE [CA1684]................................................................................................ 940 FAILURE CODE [CA1686]................................................................................................ 942 FAILURE CODE [CA1691]................................................................................................ 943 FAILURE CODE [CA1694]................................................................................................ 945 FAILURE CODE [CA1695]................................................................................................ 947 FAILURE CODE [CA1696]................................................................................................ 948 FAILURE CODE [CA1712]................................................................................................ 950 FAILURE CODE [CA1713]................................................................................................ 952 FAILURE CODE [CA1714]................................................................................................ 954 FAILURE CODE [CA1715]................................................................................................ 955 FAILURE CODE [CA1776]................................................................................................ 956 FAILURE CODE [CA1777]................................................................................................ 959 FAILURE CODE [CA1843]................................................................................................ 962 FAILURE CODE [CA1844]................................................................................................ 964 FAILURE CODE [CA1845]................................................................................................ 966 FAILURE CODE [CA1887]................................................................................................ 968 FAILURE CODE [CA1896]................................................................................................ 970 FAILURE CODE [CA1938]................................................................................................ 971 FAILURE CODE [CA1942]................................................................................................ 973 FAILURE CODE [CA1961]................................................................................................ 974 FAILURE CODE [CA2185]................................................................................................ 975 FAILURE CODE [CA2186]................................................................................................ 976 FAILURE CODE [CA2249]................................................................................................ 978 FAILURE CODE [CA2272]................................................................................................ 979 FAILURE CODE [CA2311]................................................................................................ 982 FAILURE CODE [CA2349]................................................................................................ 983 FAILURE CODE [CA2353]................................................................................................ 985 FAILURE CODE [CA2357]................................................................................................ 987 FAILURE CODE [CA2636]................................................................................................ 988 FAILURE CODE [CA2637]................................................................................................ 991 FAILURE CODE [CA2765]................................................................................................ 993 FAILURE CODE [CA2771]................................................................................................ 994 FAILURE CODE [CA2976]................................................................................................1000 FAILURE CODE [CA3142]................................................................................................1002 FAILURE CODE [CA3143]................................................................................................1003 FAILURE CODE [CA3144]................................................................................................1004 FAILURE CODE [CA3146]................................................................................................1006 FAILURE CODE [CA3147]................................................................................................1007 FAILURE CODE [CA3148]................................................................................................1008 FAILURE CODE [CA3151]................................................................................................1010 FAILURE CODE [CA3165]................................................................................................1016 FAILURE CODE [CA3229]................................................................................................1018 FAILURE CODE [CA3231]................................................................................................1020 FAILURE CODE [CA3232]................................................................................................1022 FAILURE CODE [CA3235]................................................................................................1026 FAILURE CODE [CA3239]................................................................................................1028 FAILURE CODE [CA3241]................................................................................................1031 FAILURE CODE [CA3242]................................................................................................1034 FAILURE CODE [CA3251]................................................................................................1036 FAILURE CODE [CA3313]................................................................................................1038 FAILURE CODE [CA3314]................................................................................................1039 FAILURE CODE [CA3315]................................................................................................1040 FAILURE CODE [CA3419]................................................................................................1042 FAILURE CODE [CA3421]................................................................................................1044 FAILURE CODE [CA3497]................................................................................................1046 FAILURE CODE [CA3498]................................................................................................1047 FAILURE CODE [CA3543]................................................................................................1048 FAILURE CODE [CA3545]................................................................................................1053 FAILURE CODE [CA3547]................................................................................................1055 FAILURE CODE [CA3558]................................................................................................1056 FAILURE CODE [CA3559]................................................................................................1058 FAILURE CODE [CA3562]................................................................................................1060 FAILURE CODE [CA3563]................................................................................................1062 FAILURE CODE [CA3567]................................................................................................1065 FAILURE CODE [CA3568]................................................................................................1068 FAILURE CODE [CA3571]................................................................................................1071 FAILURE CODE [CA3572]................................................................................................1073 FAILURE CODE [CA3574]................................................................................................1075 FAILURE CODE [CA3575]................................................................................................1077 Loaded Diagnostics Operation to Clear Failure Code...............................................................1078 FAILURE CODE [CA3577]................................................................................................1079 FAILURE CODE [CA3578]................................................................................................1081 FAILURE CODE [CA3582]................................................................................................1083 FAILURE CODE [CA3583]................................................................................................1089 FAILURE CODE [CA3596]................................................................................................1091 FAILURE CODE [CA3649]................................................................................................1094 FAILURE CODE [CA3681]................................................................................................1096 FAILURE CODE [CA3682]................................................................................................1101 FAILURE CODE [CA3713]................................................................................................1106 FAILURE CODE [CA3717]................................................................................................1109 FAILURE CODE [CA3718]................................................................................................1110 FAILURE CODE [CA3724]................................................................................................1111 FAILURE CODE [CA3725]................................................................................................1112 FAILURE CODE [CA3748]................................................................................................1114 FAILURE CODE [CA3755]................................................................................................1117 FAILURE CODE [CA3866]................................................................................................1119 FAILURE CODE [CA3867]................................................................................................1122 FAILURE CODE [CA3868]................................................................................................1125 FAILURE CODE [CA3899]................................................................................................1129 FAILURE CODE [CA3911]................................................................................................1131 FAILURE CODE [CA3912]................................................................................................1135 FAILURE CODE [CA3918]................................................................................................1137 FAILURE CODE [CA3921]................................................................................................1139 FAILURE CODE [CA3928]................................................................................................1140 FAILURE CODE [CA3932]................................................................................................1141 FAILURE CODE [CA3933]................................................................................................1143 FAILURE CODE [CA3934]................................................................................................1145 FAILURE CODE [CA3935]................................................................................................1148 FAILURE CODE [CA3936]................................................................................................1150 FAILURE CODE [CA4152]................................................................................................1152 FAILURE CODE [CA4155]................................................................................................1156 FAILURE CODE [CA4156]................................................................................................1158 FAILURE CODE [CA4157]................................................................................................1161 FAILURE CODE [CA4159]................................................................................................1163 FAILURE CODE [CA4164]................................................................................................1164 FAILURE CODE [CA4165]................................................................................................1166 FAILURE CODE [CA4166]................................................................................................1168 FAILURE CODE [CA4168]................................................................................................1169 FAILURE CODE [CA4169]................................................................................................1172 FAILURE CODE [CA4171]................................................................................................1174 FAILURE CODE [CA4249]................................................................................................1177 FAILURE CODE [CA4251]................................................................................................1179 FAILURE CODE [CA4261]................................................................................................1181 FAILURE CODE [CA4277]................................................................................................1183 FAILURE CODE [CA4281]................................................................................................1185 FAILURE CODE [CA4459]................................................................................................1189 FAILURE CODE [CA4461]................................................................................................1191 FAILURE CODE [CA4533]................................................................................................1194 FAILURE CODE [CA4534]................................................................................................1195 FAILURE CODE [CA4731]................................................................................................1196 FAILURE CODE [CA4732]................................................................................................1197 FAILURE CODE [CA4739]................................................................................................1198 FAILURE CODE [CA4768]................................................................................................1199 FAILURE CODE [CA4769]................................................................................................1201 FAILURE CODE [CA4842]................................................................................................1203 FAILURE CODE [CA4952]................................................................................................1206 FAILURE CODE [CA5115]................................................................................................1208 FAILURE CODE [CA5179]................................................................................................1211 FAILURE CODE [CA5181]................................................................................................1213 FAILURE CODE [CA5271]................................................................................................1215 FAILURE CODE [CA5272]................................................................................................1217 FAILURE CODE [CA5273]................................................................................................1219 FAILURE CODE [CA5274]................................................................................................1221 FAILURE CODE [CA5275]................................................................................................1222 FAILURE CODE [CA5276]................................................................................................1224 FAILURE CODE [CA5277]................................................................................................1226 FAILURE CODE [CA5387]................................................................................................1227 FAILURE CODE [CA5388]................................................................................................1229 FAILURE CODE [CA5389]................................................................................................1231 FAILURE CODE [CA5391]................................................................................................1233 FAILURE CODE [CA5392]................................................................................................1237 FAILURE CODE [CA5393]................................................................................................1238 FAILURE CODE [CA5394]................................................................................................1241 FAILURE CODE [CA5395]................................................................................................1243 FAILURE CODE [CA5396]................................................................................................1245 FAILURE CODE [CA5631]................................................................................................1246 FAILURE CODE [CA5938]................................................................................................1247 FAILURE CODE [D110KB]................................................................................................1248 FAILURE CODE [D19JKZ]................................................................................................1250 FAILURE CODE [D19QKB]................................................................................................1252 FAILURE CODE [D19QKY]................................................................................................1254 FAILURE CODE [D1EMKA]................................................................................................1256 FAILURE CODE [D1EMKB]................................................................................................1258 FAILURE CODE [D1EMKY]................................................................................................1260 FAILURE CODE [D811MC]................................................................................................1262 FAILURE CODE [D862KA]................................................................................................1263 FAILURE CODE [D8ALKA]................................................................................................1264 FAILURE CODE [D8ALKB]................................................................................................1266 FAILURE CODE [D8AQKR]................................................................................................1268 FAILURE CODE [DA20MC]................................................................................................1270 FAILURE CODE [DA22KK]................................................................................................1271 FAILURE CODE [DA25KP]................................................................................................1274 FAILURE CODE [DA26KP]................................................................................................1277 FAILURE CODE [DA29KQ]................................................................................................1279 FAILURE CODE [DA2LKA]................................................................................................1281 FAILURE CODE [DA2LKB]................................................................................................1283 FAILURE CODE [DA2QKR]................................................................................................1285 FAILURE CODE [DA2RKR]................................................................................................1288 FAILURE CODE [DAB0KT]................................................................................................1289 FAILURE CODE [DAC3KB]................................................................................................1290 FAILURE CODE [DAC3KY]................................................................................................1292 FAILURE CODE [DAF0MB]................................................................................................1294 FAILURE CODE [DAF0MC]................................................................................................1295 FAILURE CODE [DAF8KB]................................................................................................1296 FAILURE CODE [DAF9KQ]................................................................................................1298 FAILURE CODE [DAFGMC]................................................................................................1299 FAILURE CODE [DAFLKA]................................................................................................1300 FAILURE CODE [DAFLKB]................................................................................................1302 FAILURE CODE [DAFQKR]................................................................................................1304 FAILURE CODE [DAZ9KQ]................................................................................................1305 FAILURE CODE [DAZQKR]................................................................................................1306 FAILURE CODE [DB2QKR]................................................................................................1311 FAILURE CODE [DB2RKR]................................................................................................1316 FAILURE CODE [DBP0KM]................................................................................................1320 FAILURE CODE [DBP0KT]................................................................................................1321 FAILURE CODE [DBPQKR]................................................................................................1322 Circuit diagram related to KomVision controller power supply.....................................................1326 FAILURE CODE [DCS0KT]................................................................................................1327 FAILURE CODE [DCS0MC]................................................................................................1328 FAILURE CODE [DCS2KK]................................................................................................1329 FAILURE CODE [DCS5KP]................................................................................................1332 FAILURE CODE [DCS7KP]................................................................................................1334 FAILURE CODE [DCS9KQ]................................................................................................1336 FAILURE CODE [DCSLKA]................................................................................................1337 FAILURE CODE [DCSLKB]................................................................................................1339 FAILURE CODE [DCSQKR]................................................................................................1341 FAILURE CODE [DCSRKR]................................................................................................1344 FAILURE CODE [DDK8KA]................................................................................................1346 FAILURE CODE [DDK8KB]................................................................................................1348 FAILURE CODE [DDKNKA]................................................................................................1350 FAILURE CODE [DDKNKB]................................................................................................1352 FAILURE CODE [DDKPKA]................................................................................................1354 FAILURE CODE [DDKPKB]................................................................................................1356 FAILURE CODE [DDNRKA]................................................................................................1358 FAILURE CODE [DDNRKY]................................................................................................1360 FAILURE CODE [DDNS00]................................................................................................1362 FAILURE CODE [DDP4KX]................................................................................................1364 FAILURE CODE [DDP6L5]................................................................................................1366 FAILURE CODE [DDQ1KA]................................................................................................1368 FAILURE CODE [DDQ1KB]................................................................................................1370 FAILURE CODE [DDWCKZ]................................................................................................1372 FAILURE CODE [DDWMKZ]................................................................................................1374 FAILURE CODE [DFB1KZ]................................................................................................1376 FAILURE CODE [DFB2KZ]................................................................................................1379 FAILURE CODE [DFB3L8]................................................................................................1382 Information......................................................................................................1382 FAILURE CODE [DFB4L8]................................................................................................1383 Information......................................................................................................1383 FAILURE CODE [DFB5KZ]................................................................................................1384 FAILURE CODE [DFB6KZ]................................................................................................1387 FAILURE CODE [DGH2KA]................................................................................................1390 FAILURE CODE [DGH2KB]................................................................................................1392 FAILURE CODE [DHA4KA]................................................................................................1394 FAILURE CODE [DHPAMA]................................................................................................1396 FAILURE CODE [DHS3MA]................................................................................................1398 FAILURE CODE [DHS4MA]................................................................................................1401 FAILURE CODE [DHS5KX]................................................................................................1404 FAILURE CODE [DHS8MA]................................................................................................1407 FAILURE CODE [DHS9MA]................................................................................................1410 FAILURE CODE [DHSAMA]................................................................................................1413 FAILURE CODE [DHSBMA]................................................................................................1416 FAILURE CODE [DHSCMA]................................................................................................1419 FAILURE CODE [DHSDMA]................................................................................................1422 FAILURE CODE [DHSPMA]................................................................................................1425 FAILURE CODE [DHSQMA]................................................................................................1428 FAILURE CODE [DHU1KA]................................................................................................1431 FAILURE CODE [DHU1KY]................................................................................................1433 FAILURE CODE [DHUCKA]................................................................................................1435 FAILURE CODE [DHUCKY]................................................................................................1437 FAILURE CODE [DHUGKA]................................................................................................1439 FAILURE CODE [DHUGKY]................................................................................................1441 FAILURE CODE [DHX1MA]................................................................................................1443 FAILURE CODE [DKULKA]................................................................................................1445 FAILURE CODE [DKULKB]................................................................................................1447 FAILURE CODE [DKULKY]................................................................................................1449 FAILURE CODE [DLM5KA]................................................................................................1451 Circuit diagram related to fan clutch............................................................................1452 FAILURE CODE [DLM5MB]................................................................................................1453 Circuit diagram related to fan clutch............................................................................1454 FAILURE CODE [DLT4KA]................................................................................................1455 FAILURE CODE [DLT4KB]................................................................................................1457 FAILURE CODE [DNCHMC]................................................................................................1459 FAILURE CODE [DNCJL4]................................................................................................1462 FAILURE CODE [DNCKMC]................................................................................................1465 FAILURE CODE [DNCLMC]................................................................................................1468 FAILURE CODE [DR10KA]................................................................................................1471 Circuit diagram related to rear camera...........................................................................1472 Circuit diagram related to right camera..........................................................................1472 Circuit diagram related to left camera...........................................................................1472 Circuit diagram related to right front camera (optional).........................................................1472 FAILURE CODE [DR21KX]................................................................................................1473 FAILURE CODE [DUMBKA]................................................................................................1475 Circuit diagram related to system operating lamp.................................................................1476 FAILURE CODE [DUMBKB]................................................................................................1477 Circuit diagram related to system operating lamp.................................................................1478 FAILURE CODE [DV20KB]................................................................................................1479 FAILURE CODE [DW44KA]................................................................................................1481 FAILURE CODE [DW44KB]................................................................................................1483 FAILURE CODE [DW44KY]................................................................................................1485 FAILURE CODE [DW45KA]................................................................................................1487 FAILURE CODE [DW45KB]................................................................................................1490 FAILURE CODE [DW45KY]................................................................................................1493 FAILURe CODE [DW4AKA]................................................................................................1495 FAILURE CODE [DW4AKB]................................................................................................1497 FAILURE CODE [DW4AKY]................................................................................................1499 FAILURE CODE [DW4CKY]................................................................................................1500 FAILURE CODE [DW4MKA]................................................................................................1502 FAILURE CODE [DW4MKB]................................................................................................1504 FAILURE CODE [DW4MKY]................................................................................................1506 FAILURE CODE [DW4YKA]................................................................................................1507 FAILURE CODE [DW4YKB]................................................................................................1509 FAILURE CODE [DW4YKY]................................................................................................1511 FAILURE CODE [DW4ZKA]................................................................................................1512 FAILURE CODE [DW4ZKB]................................................................................................1514 FAILURE CODE [DW4ZKY]................................................................................................1516 FAILURE CODE [DW91KA]................................................................................................1517 FAILURE CODE [DW91KB]................................................................................................1519 FAILURE CODE [DW91KY]................................................................................................1521 FAILURE CODE [DWB1KA]................................................................................................1523 FAILURE CODE [DWB1KB]................................................................................................1525 FAILURE CODE [DWB2KA]................................................................................................1527 FAILURE CODE [DWB2KB]................................................................................................1529 FAILURE CODE [DWB2KY]................................................................................................1531 FAILURE CODE [DWB3KA]................................................................................................1533 FAILURE CODE [DWB3KB]................................................................................................1535 FAILURE CODE [DWB3KY]................................................................................................1537 FAILURE CODE [DWB4KA]................................................................................................1539 FAILURE CODE [DWB4KB]................................................................................................1541 FAILURE CODE [DWB4KY]................................................................................................1543 FAILURE CODE [DWB5KA]................................................................................................1545 FAILURE CODE [DWB5KB]................................................................................................1547 FAILURE CODE [DWB5KY]................................................................................................1549 FAILURE CODE [DWD2KA]................................................................................................1551 FAILURE CODE [DWD2KB]................................................................................................1553 FAILURE CODE [DWD2KY]................................................................................................1555 FAILURE CODE [DWD3KA]................................................................................................1557 FAILURE CODE [DWD3KB]................................................................................................1559 FAILURE CODE [DWD3KY]................................................................................................1561 FAILURE CODE [DWD4KA]................................................................................................1563 FAILURE CODE [DWD4KB]................................................................................................1565 FAILURE CODE [DWD4KY]................................................................................................1567 FAILURE CODE [DWD5KA]................................................................................................1569 FAILURE CODE [DWD5KB]................................................................................................1571 FAILURE CODE [DWD5KY]................................................................................................1573 FAILURE CODE [DWN5KA]................................................................................................1575 FAILURE CODE [DWN5KB]................................................................................................1577 FAILURE CODE [DWN5KY]................................................................................................1579 Circuit diagram related to fan clutch............................................................................1580 FAILURE CODE [DXA8KA]................................................................................................1581 FAILURE CODE [DXA8KB]................................................................................................1583 FAILURE CODE [DXE0KA]................................................................................................1585 FAILURE CODE [DXE7KA]................................................................................................1586 FAILURE CODE [DXE7KB]................................................................................................1588 FAILURE CODE [DXE7KY]................................................................................................1590 FAILURE CODE [DXE8KA]................................................................................................1592 FAILURE CODE [DXE8KB]................................................................................................1594 FAILURE CODE [DXE8KY]................................................................................................1596 FAILURE CODE [DXE9KA]................................................................................................1598 FAILURE CODE [DXE9KB]................................................................................................1600 FAILURE CODE [DXE9KY]................................................................................................1602 FAILURE CODE [DXEAKA]................................................................................................1604 FAILURE CODE [DXEAKB]................................................................................................1606 FAILURE CODE [DXEAKY]................................................................................................1608 FAILURE CODE [DY20KA]................................................................................................1610 FAILURE CODE [DY20MA]................................................................................................1612 FAILURE CODE [DY2CKB]................................................................................................1614 FAILURE CODE [DY2DKB]................................................................................................1616 FAILURE CODE [DY2EKB]................................................................................................1618 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)............................................................................1620 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)....................................................................1620 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...........................................................................1626 E-3 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP................................................1629 E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING..................................1631 E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING....................................1634 E-6 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING.....................................1635 E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING.........................................1636 E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....................................................1637 E-9 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING......................................................1638 E-10 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.....................................1639 E-11 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING............................................1640 E-12 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM........................................................1641 E-13 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM........................................................1642 Circuit diagram related to fuel level sensor.....................................................................1643 E-14 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL............................................................1644 E-15 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM..................................1645 E-16 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE.............................1646 E-17 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...................................1647 E-18 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE..................................1649 E-19 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED..........................................................1650 E-20 FUNCTION SWITCH DOES NOT OPERATE................................................................................1651 E-21 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD SEASON).........................................................1652 E-22 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF.........1653 E-23 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER.........................................................1654 E-24 WHEN WORKING MODE SWITCH OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED...............................1655 E-25 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED...............................1656 E-26 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE......................................1657 E-27 ALARM BUZZER CANNOT BE CANCELED.................................................................................1658 E-28 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION........................................1659 E-29 SERVICE MODE CANNOT BE SELECTED.................................................................................1660 E-30 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE.................................................1661 E-31 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK..................................................1664 E-32 UPPER STRUCTURE DOES NOT SWING WHILE SWING PARKING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION................1666 E-33 SWING BRAKE DOES NOT OPERATE WHILE SWING PARKING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION..................1668 E-34 WORK EQUIPMENT DOES NOT OPERATE WHILE LOCK LEVER AUTOMATIC RELEASE SWITCH IS IN RELEASE POSITION (EMERGENCY)....1670 E-35 ALARM DOES NOT SOUND DURING TRAVEL..............................................................................1672 E-36 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED...........................................................1673 E-37 HORN DOES NOT SOUND.............................................................................................1674 E-38 HORN DOES NOT STOP SOUNDING.....................................................................................1677 E-39 WIPER DOES NOT OPERATE WHILE WIPER SWITCH IS OPERATED...........................................................1678 E-40 WINDOW WASHER DOES NOT OPERATE WHILE WINDOW WASHER SWITCH IS OPERATED...........................................1680 E-41 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.........................................1682 E-42 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.........................................1683 E-43 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION............................................1684 E-44 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.............................................1685 E-45 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................1686 E-46 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................1687 E-47 BOOM SWING LEFT IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION.............................................1688 E-48 BOOM SWING RIGHT IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION............................................1689 E-49 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION..............................................1690 E-50 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.............................................1691 E-51 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY........................................................................1692 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)..............................................................1693 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (H-MODE)..............................................................1693 SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS.....................................................................1694 FAILURE MODE AND CAUSE TABLE.........................................................................................1696 H-1 ALL OF WORK EQUIPMENTS, SWING AND TRAVEL OPERATIONS LACK SPEED OR POWER..........................................1709 H-2 ENGINE SPEED DROPS SIGNIFICANTLY OR ENGINE STALLS................................................................1711 H-3 ANY OF WORK EQUIPMENT, SWING AND TRAVEL DOES NOT WORK............................................................1712 H-4 UNUSUAL SOUND IS HEARD FROM AROUND HYDRAULIC PUMP................................................................1713 H-5 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR.....................................................................1714 H-6 BOOM SPEED OR POWER IS LOW.......................................................................................1715 H-7 2-PIECE BOOM SPEED OR POWER IS LOW...............................................................................1717 H-8 ARM SPEED OR POWER IS LOW........................................................................................1719 H-9 BUCKET SPEED OR POWER IS LOW.....................................................................................1721 H-10 BOOM SWING SPEED OR POWER IS LOW................................................................................1723 H-11 BLADE/OUTRIGGER SPEED OR POWER IS LOW...........................................................................1725 H-12 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION................................................................1727 H-13 HYDRAULIC DRIFT OF BOOM IS LARGE................................................................................1728 H-14 HYDRAULIC DRIFT OF 2-PIECE BOOM IS LARGE........................................................................1729 H-15 HYDRAULIC DRIFT OF ARM IS LARGE.................................................................................1730 H-16 HYDRAULIC DRIFT OF BUCKET IS LARGE..............................................................................1731 H-17 HYDRAULIC DRIFT OF BLADE/OUTRIGGERS IS LARGE....................................................................1732 H-18 TIME LAG OF WORK EQUIPMENT IS LARGE.............................................................................1733 H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER.............................1734 H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW.........................................1735 H-21 IN COMBINED OPERATION OF WORK EQUIPMENT OR SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY.........................1736 H-22 TRAVEL SPEED IS SLOW............................................................................................1737 H-23 TRAVEL POWER IS LOW.............................................................................................1738 H-24 TRAVEL SPEED IS TOO SLOW OR FAST................................................................................1739 H-25 WHEELS DO NOT RUN...............................................................................................1740 H-26 UPPER STRUCTURE DOES NOT SWING TO THE RIGHT OR LEFT.............................................................1741 H-27 UPPER STRUCTURE SWING ONLY TO THE RIGHT OR LEFT.................................................................1742 H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT.....................................1743 H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION.............................1744 H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)...............................1745 H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (EITHER RIGHT OR LEFT)..............................1746 H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING..............................................................1747 H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING................................................1748 H-34 SWING DRIFT ON A SLOPE IS LARGE WHILE SWING PARKING BRAKE IS APPLIED............................................1749 H-35 SWING DRIFT ON A SLOPE IS LARGE WHILE SWING PARKING BRAKE IS RELEASED...........................................1750 H-36 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CONTROLLED.............................................................1751 H-37 PARKING BRAKE DOESN’T WORK......................................................................................1752 H-38 SERVICE BRAKE DOESN’T WORK......................................................................................1753 H-39 STEERING SYSTEM DOESN’T WORK OR DOESN’T WORK PROPERLY (2WS, 4WS-R, 4WS-C).......................................1754 TROUBLESHOOTING OF ENGINE (S-MODE).......................................................................................1755 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)..............................................................1755 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...........................................1756 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT.......................................................................1757 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...................1758 S-4 ENGINE STARTABILITY IS POOR......................................................................................1759 S-5 ENGINE DOES NOT PICK UP SMOOTHLY.................................................................................1761 S-6 ENGINE STOPS DURING OPERATION....................................................................................1763 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE.................................................................................1765 S-8 ENGINE LACKS POWER...............................................................................................1766 S-9 EXHAUST SMOKE IS BLACK...........................................................................................1768 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE.............................................................................1770 S-11 OIL BECOMES CONTAMINATED QUICKLY................................................................................1771 S-12 FUEL CONSUMPTION IS EXCESSIVE...................................................................................1772 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...........................................1773 S-14 OIL PRESSURE DROPS..............................................................................................1774 S-15 FUEL MIXES INTO ENGINE OIL......................................................................................1775 S-16 WATER MIXES INTO ENGINE OIL (MILKY).............................................................................1776 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)................................................................1777 S-18 UNUSUAL NOISE IS HEARD..........................................................................................1779 S-19 VIBRATION IS EXCESSIVE..........................................................................................1781 S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT............................................................................1782 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY......................................................................1783 S-22 ACTIVE REGENERATION TAKES TIME..................................................................................1784 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION.............................................................1785 S-24 DEF CONSUMPTION IS EXCESSIVE....................................................................................1786 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)........................................................................1788 S-26 FOREIGN MATERIALS ENTER.........................................................................................1789 50 DISASSEMBLY AND ASSEMBLY..................................................................................................1791 CONTENTS.................................................................................................................1792 ABBREVIATION LIST....................................................................................................1794 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY..........................................................................1801 HOW TO READ THIS MANUAL..............................................................................................1801 Reading the special tools list...................................................................................1801 Reading the work procedures......................................................................................1801 Reading the symbols..............................................................................................1801 Reading the signal word..........................................................................................1802 Reading the unit.................................................................................................1802 COATING MATERIALS LIST...............................................................................................1803 Adhesive.........................................................................................................1803 Liquid gasket....................................................................................................1804 Molybdenum disulfide lubricant...................................................................................1804 Seizure prevention compound......................................................................................1805 Grease...........................................................................................................1805 Primer...........................................................................................................1806 Adhesive.........................................................................................................1806 Caulking material................................................................................................1806 ENGINE AND COOLING SYSTEM................................................................................................1807 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY..............................................................................1807 METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY.........................................................................1807 METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY.......................................................................1811 REMOVAL AND INSTALL INJECTOR ASSEMBLY................................................................................1815 METHOD FOR REMOVING INJECTOR ASSEMBLY............................................................................1815 METHOD FOR INSTALLING INJECTOR ASSEMBLY..........................................................................1821 REMOVE AND INSTALL EGR VALVE ASSEMBLY................................................................................1827 METHOD FOR REMOVING EGR VALVE ASSEMBLY...........................................................................1827 METHOD FOR INSTALLING EGR VALVE ASSEMBLY.........................................................................1828 REMOVE AND INSTALL STARTER ASSEMBLY..................................................................................1829 METHOD FOR REMOVING STARTER ASSEMBLY.............................................................................1829 METHOD FOR INSTALLING STARTER ASSEMBLY...........................................................................1830 REMOVE AND INSTALL ALTERNATOR BELT...............................................................................1831 METHOD FOR REMOVING ALTERNATOR BELT..............................................................................1831 METHOD FOR INSTALLING ALTERNATOR BELT............................................................................1833 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY..............................................................................1834 METHOD FOR REMOVING AFTERCOOLER ASSEMBLY.........................................................................1834 METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY.......................................................................1835 REMOVAL AND INSTALL OF FAN CLUTCH ASSEMBLY...........................................................................1836 METOD FOR REMOVING FAN CLUTCH ASSEMBLY...........................................................................1836 METOD FOR INSTALLING FAN CLUTCH ASSEMBLY.........................................................................1838 REMOVE AND INSTALL ENGINE FRONT OIL SEAL.............................................................................1839 METHOD FOR REMOVING ENGINE FRONT OIL SEAL........................................................................1839 METHOD FOR INSTALLING ENGINE FRONT OIL SEAL......................................................................1840 REMOVE AND INSTALL FUEL COOLER ASSEMBLY..............................................................................1841 METHOD FOR REMOVING FUEL COOLER ASSEMBLY.........................................................................1841 METHOD FOR INSTALLING FUEL COOLER ASSEMBLY.......................................................................1841 REMOVAL AND INSTALL KDOC AND SCR ASSEMBLY............................................................................1842 METHOD FOR REMOVING KDOC AND SCR ASSEMBLY........................................................................1843 METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY......................................................................1849 REMOVAL AND INSTALL BELLOWS PIPE ASSEMBLY............................................................................1856 METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY........................................................................1856 METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY......................................................................1859 REMOVAL AND INSTALL KDOC ASSEMBLY....................................................................................1862 METHOD FOR REMOVING KDOC ASSEMBLY................................................................................1862 METHOD FOR INSTALLING KDOC ASSEMBLY..............................................................................1864 REMOVAL AND INSTALL SCR ASSEMBLY.....................................................................................1866 METHOD FOR REMOVING SCR ASSEMBLY.................................................................................1866 METHOD FOR INSTALLING SCR ASSEMBLY...............................................................................1869 REMOVE AND INSTALL DEF TANK..........................................................................................1873 METOD FOR REMOVING DEF TANK......................................................................................1873 METOD FOR INSTALLING DEF TANK....................................................................................1878 REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY...................................................................1879 METOD FOR REMOVING DEF TANK SENSOR FLANGE........................................................................1879 METOD FOR INSTALLING DEF TANK SENSOR FLANGE ASSEMBLY.............................................................1884 REMOVE AND INSTALL DEF TANK SENSOR...................................................................................1886 METHOD FOR REMOVING DEF TANK SENSOR..............................................................................1886 METHOD FOR INSTALLING DEF TANK SENSOR............................................................................1886 REMOVE AND INSTALL DEF TANK STRAINER.................................................................................1888 METHOD FOR REMOVING DEF TANK STRAINER............................................................................1888 METHOD FOR INSTALLING DEF TANK STRAINER..........................................................................1888 REMOVAL AND INSTALL KCCV ASSEMBLY....................................................................................1889 METHOD FOR REMOVING KCCV ASSEMBLY................................................................................1889 METHOD FOR INSTALLING KCCV ASSEMBLY..............................................................................1891 REMOVAL AND INSTALL DEF MIXING TUBE..................................................................................1893 METHOD FOR REMOVING DEF MIXING TUBE..............................................................................1893 METHOD FOR INSTALLING DEF MIXING TUBE............................................................................1897 REMOVAL AND INSTALL DEF INJECTOR.....................................................................................1902 METHOD FOR REMOVING DEF INJECTOR.................................................................................1902 METHOD FOR INSTALLING DEF INJECTOR...............................................................................1905 REMOVE AND INSTALL DEF PUMP..........................................................................................1909 METHOD FOR REMOVING DEF PUMP.....................................................................................1909 METHOD FOR INSTALLING DEF PUMP...................................................................................1912 REMOVE AND INSTALL AIR CLEANER ASSEMBLY..............................................................................1917 METHOD FOR REMOVING AIR CLEANER ASSEMBLY.........................................................................1917 METHOD FOR INSTALLING AIR CLEANER ASSEMBLY.......................................................................1918 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY................................................................1920 METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY...........................................................1920 METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY.........................................................1921 POWER TRAIN..............................................................................................................1923 REMOVE AND INSTALL SWING MOTOR.......................................................................................1923 METHOD FOR REMOVING SWING MOTOR..................................................................................1923 METHOD FOR INSTALLING SWING MOTOR................................................................................1927 REMOVE AND INSTALL SWING MACHINERY ASSEMBLY..........................................................................1928 METHOD FOR REMOVING SWING MACHINERY..............................................................................1928 METHOD FOR INSTALLING SWING MACHINERY............................................................................1928 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY.................................................1929 METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY................................................................1929 METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY...................................................................1935 UNDERCARRIAGE AND FRAME..................................................................................................1943 REMOVAL AND INSTALLATION OF TWIN-TYPE WHEELS.........................................................................1943 METHOD FOR REMOVING TWIN-TYPE WHEELS.............................................................................1943 METHOD FOR INSTALLING TWIN-TYPE WHEELS...........................................................................1946 DISASSEMBLY AND ASSEMBLY OF REAR AXLE................................................................................1947 METHOD FOR DISASSEMBLING HYDRAULIC NEGATIVE BRAKE................................................................1947 METHOD FOR ASSEMBLING HYDRAULIC NEGATIVE BRAKE...................................................................1950 METHOD FOR DISASSEMBLING STEERING CASE...........................................................................1958 METHOD FOR ASSEMBLING STEERING CASE..............................................................................1960 METHOD FOR DISASSEMBLING U-JOINT.................................................................................1963 METHOD FOR ASSEMBLING U-JOINT....................................................................................1964 METHOD FOR DISASSEMBLING PLANETARY REDUCTION GEAR................................................................1967 METHOD FOR ASSEMBLING PLANETARY REDUCTION GEAR...................................................................1971 METHOD FOR REMOVING STEERING CYLINDER............................................................................1977 METHOD FOR DISASSEMBLING STEERING CYLINDER.......................................................................1978 METHOD FOR ASSEMBLING STEERING CYLINDER..........................................................................1980 METHOD FOR INSTALLATING STEERING CYLINDER........................................................................1982 METHOD FOR DISASSEMBLING DIFFERENTIAL UNIT.......................................................................1987 METHOD FOR ASSEMBLING DIFFERENTIAL UNIT..........................................................................1992 METHOD FOR DISASSEMBLING BEVEL PINION............................................................................1998 METHOD FOR ASSEMBLING BEVEL PINION...............................................................................2000 REMOVAL AND INSTALL GEAR BOX.........................................................................................2008 METHOD FOR REMOVING GEAR BOX.....................................................................................2008 METHOD FOR INSTALLING GEAR BOX...................................................................................2009 DISASSEMBLY AND ASSEMBLY OF GEAR BOX.................................................................................2010 METHOD FOR DISASSEMBLING GEAR BOX................................................................................2010 METHOD FOR ASSEMBLING GEAR BOX...................................................................................2020 REMOVAL AND INSTALL FRONT AXLE.......................................................................................2031 METHOD FOR REMOVING FRONT AXLE...................................................................................2031 METHOD FOR REMOVING FRONT AXLE...................................................................................2032 DISASSEMBLY AND ASSEMBLY OF FRONT AXLE...............................................................................2033 METHOD FOR REPLACING BRAKING DISCS...............................................................................2033 METHOD FOR DISASSEMBLING STEERING CASE...........................................................................2037 METHOD FOR ASSEMBLING STEERING CASE..............................................................................2039 METHOD FOR DISASSEMBLING U-JOINT.................................................................................2042 METHOD FOR ASSEMBLING U-JOINT....................................................................................2044 METHOD FOR DISASSEMBLING PLANETARY REDUCTION GEAR................................................................2046 METHOD FOR ASSEMBLING PLANETARY REDUCTION GEAR...................................................................2050 METHOD FOR REMOVING STEERING CYLINDER............................................................................2056 METHOD FOR DISASSEMBLING STEERING CYLINDER.......................................................................2057 METHOD FOR ASSEMBLING STEERING CYLINDER..........................................................................2059 METHOD FOR INSTALLATING STEERING CYLINDER........................................................................2061 METHOD FOR DISASSEMBLING DIFFERENTIAL UNIT.......................................................................2066 METHOD FOR ASSEMBLING DIFFERENTIAL UNIT..........................................................................2071 METHOD FOR DISASSEMBLING BEVEL PINION............................................................................2077 METHOD FOR ASSEMBLING BEVEL PINION...............................................................................2080 REMOVAL AND INSTALL AXLE LOCKING CYLINDERS...........................................................................2088 METHOD FOR REMOVING AXLE LOCKING CYLINDERS.......................................................................2088 METHOD FOR INSTALLING AXLE LOCKING CYLINDERS.....................................................................2088 REMOVAL AND INSTALL OF COUNTERWEIGHT.................................................................................2089 METHOD FOR REMOVING COUNTERWEIGHT................................................................................2089 METHOD FOR INSTALLING COUNTERWEIGHT..............................................................................2093 HYDRAULIC SYSTEM.........................................................................................................2094 REMOVAL AND INSTALL TRAVEL MOTOR.....................................................................................2094 METHOD FOR REMOVING TRAVEL MOTOR.................................................................................2094 METHOD FOR INSTALLING OF TRAVEL MOTOR............................................................................2095 REMOVAL AND INSTALL BOOM SWING CYLINDER ASSEMBLY.....................................................................2096 METHOD FOR REMOVING BOOM SWING CYLINDER ASSEMBLY.................................................................2096 METHOD FOR INSTALLING BOOM SWING CYLINDER ASSEMBLY...............................................................2098 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY........................................................2099 METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY.......................................................2099 METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY..........................................................2099 REMOVAL AND INSTALL CYLINDER FOR OUTRIGGERS OR BLADE.................................................................2101 METHOD FOR REMOVING CYLINDER FOR OUTRIGGERS OR BLADE.............................................................2101 METHOD FOR INSTALLING CYLINDER FOR OUTRIGGERS OR BLADE...........................................................2102 DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY.................................................................2103 METHOD FOR DISASSEMBLING OF HYDRAULIC CYLINDER ASSEMBLY..........................................................2104 METHOD FOR ASSEMBLING OF HYDRAULIC CYLINDER ASSEMBLY.............................................................2107 REMOVAL AND INSTALL BRAKE PEDAL ASSEMBLY.............................................................................2112 METHOD FOR REMOVING BRAKE PEDAL ASSEMBLY.........................................................................2112 METHOD FOR INSTALLING BRAKE PEDAL ASSEMBLY.......................................................................2113 WORK EQUIPMENT...........................................................................................................2114 REMOVAL AND INSTALL WORK EQUIPMENT ASSEMBLY..........................................................................2114 METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY......................................................................2114 METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY....................................................................2116 REMOVAL AND INSTALL BOOM SWING BRACKET...............................................................................2117 METHOD FOR REMOVING BOOM SWING BRACKET...........................................................................2117 METHOD FOR INSTALLING BOOM SWING BRACKET.........................................................................2119 REMOVAL AND INSTALL BLADE AND OUTRIGGERS.............................................................................2121 METHOD FOR REMOVING BLADE AND OUTRIGGERS.........................................................................2121 METHOD FOR INSTALLING BLADE AND OUTRIGGERS.......................................................................2121 REMOVAL AND INSTALL BLADE AND OUTRIGGERS ARMS........................................................................2122 METHOD FOR REMOVING BLADE AND OUTRIGGERS ARMS....................................................................2122 METHOD FOR INSTALLING BLADE AND OUTRIGGERS ARMS..................................................................2122 CAB AND ITS ATTACHMENTS..................................................................................................2123 REMOVAL AND INSTALL OPERATOR'S CAB ASSEMBLY..........................................................................2123 METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY......................................................................2123 METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY....................................................................2128 REMOVAL AND INSTALL OPERATOR'S CAB DOOR..............................................................................2130 METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY....................................................................2130 REMOVAL AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS).............................................................2134 METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)...........................................................2136 METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS).........................................................2136 REMOVAL AND INSTALL FRONT WINDOW ASSEMBLY............................................................................2146 METHOD FOR REMOVING FRONT WINDOW ASSEMBLY........................................................................2147 METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY......................................................................2147 REMOVAL AND INSTALL AIR CONDITIONER UNIT ASSEMBLY....................................................................2148 METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY................................................................2148 METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY..............................................................2154 REMOVAL AND INSTALL OPERATOR'S SEAT..................................................................................2155 METHOD FOR REMOVING OPERATOR'S SEAT..............................................................................2155 METHOD FOR INSTALLING OPERATOR'S SEAT............................................................................2155 REMOVAL AND INSTALL SEAT BELT........................................................................................2156 METHOD FOR REMOVING SEAT BELT....................................................................................2156 METHOD FOR INSTALLING SEAT BELT..................................................................................2157 ELECTRICAL SYSTEM........................................................................................................2158 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY........................................................................2158 METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY...................................................................2158 METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY.................................................................2160 REMOVAL AND INSTALL PUMP CONTROLLER ASSEMBLY.........................................................................2161 METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY.....................................................................2161 METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY...................................................................2161 REMOVAL AND INSTALL MACHINE MONITOR ASSEMBLY.........................................................................2162 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY.....................................................................2162 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY...................................................................2164 REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY.....................................................................2165 METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY................................................................2165 METHOD FOR INSTALLING KomVision CONTROLLER.......................................................................2166 REMOVAL AND INSTALL STEERING COLUMN SWITCHES.........................................................................2168 METHOD FOR REMOVING STEERING COLUMN SWITCHES.....................................................................2168 METHOD FOR INSTALLING STEERING COLUMN SWITCHES...................................................................2168 REMOVAL AND INSTALL TRAVEL SPEED SENSOR..............................................................................2169 METHOD FOR REMOVING TRAVEL SPEED SENSOR..........................................................................2169 METHOD FOR INSTALLING TRAVEL SPEED SENSOR........................................................................2169 REMOVAL AND INSTALL STEERING SENSOR..................................................................................2171 METHOD FOR REMOVING STEERING SENSOR..............................................................................2171 METHOD FOR INSTALLING STEERING SENSOR............................................................................2172 REMOVAL AND INSTALL REVOLVING FRAME SWING POSITION SENSOR............................................................2173 METHOD FOR REMOVING REVOLVING FRAME SWING POSITION SENSOR........................................................2173 METHOD FOR INSTALLING REVOLVING FRAME SWING POSITION SENSOR......................................................2173 REMOVAL AND INSTALL DIRECTION INDICATOR, HEAD LIGHT DIPPER BEAM CONTROL GROUP........................................2174 METHOD FOR REMOVING DIRECTION INDICATOR, HEAD LIGHT DIPPER BEAM CONTROL GROUP....................................2174 METHOD FOR INSTALLING DIRECTION INDICATOR, HEAD LIGHT DIPPER BEAM CONTROL GROUP..................................2174 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR..............................................................2175 METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR.........................................................2175 METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR.......................................................2177 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR....................................................................2178 METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR...............................................................2178 METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR.............................................................2179 REMOVE AND INSTALL SCR TEMPERATURE SENSOR............................................................................2180 METHOD FOR REMOVING SCR TEMPERATURE SENSOR.......................................................................2180 METHOD FOR INSTALLING SCR TEMPERATURE SENSOR.....................................................................2182 REMOVE AND INSTALL KomVision CAMERA..................................................................................2184 METHOD FOR REMOVING KomVision CAMERA.............................................................................2184 METHOD FOR INSTALLING KomVision CAMERA...........................................................................2186 REMOVAL AND INSTALL KOMTRAX TERMINAL ASSEMBLY........................................................................2189 METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY....................................................................2189 METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY..................................................................2189 60 MAINTENANCE STANDARD......................................................................................................2191 CONTENTS.................................................................................................................2192 ABBREVIATION LIST........................................................................................................2193 ENGINE AND COOLING SYSTEM................................................................................................2200 ENGINE MOUNT.........................................................................................................2200 PTO..................................................................................................................2201 COOLING SYSTEM.......................................................................................................2202 POWER TRAIN SYSTEM.......................................................................................................2203 SWING CIRCLE.........................................................................................................2203 SWING MACHINERY......................................................................................................2204 UNDERCARRIAGE AND FRAME..................................................................................................2206 FRONT AXLE...........................................................................................................2206 Pinion and differential..........................................................................................2206 Brakes...........................................................................................................2208 Final reduction..................................................................................................2209 Steering cylinder................................................................................................2210 TRANSMISSION.........................................................................................................2211 HYDRAULIC SYSTEM.........................................................................................................2213 CONTROL VALVE........................................................................................................2213 (1/4)............................................................................................................2214 (2/4)............................................................................................................2216 (3/4)............................................................................................................2218 (4/4)............................................................................................................2219 HYDRAULIC TANK.......................................................................................................2220 SWING MOTOR..........................................................................................................2221 SELF-REDUCING PRESSURE VALVE.........................................................................................2223 PPC VALVE............................................................................................................2224 Work equipment and swing PPC valve...............................................................................2224 BOOM SWING AND 2-PIECE BOOM PPC VALVE................................................................................2227 TRAVEL MOTOR.........................................................................................................2229 SOLENOID VALVE.......................................................................................................2230 STEERING CONTROL SOLENOID VALVE......................................................................................2231 1-ATTACHMENT FLOW ADJUSTMENT EPC VALVE...............................................................................2232 2-ATTACHMENT FLOW ADJUSTMENT EPC VALVE...............................................................................2233 TRAVEL SPEED AND DIRECTION CONTROL SOLENOID VALVE....................................................................2234 BLADE SAFETY VALVE...................................................................................................2235 HOLDING VALVE........................................................................................................2236 CAB AND ITS ATTACHMENTS..................................................................................................2238 CAB MOUNT AND CAB TIPPING STOPPER....................................................................................2238 WORK EQUIPMENT...........................................................................................................2239 WORK EQUIPMENT.......................................................................................................2239 Dimensions of arm................................................................................................2243 Dimensions of bucket.............................................................................................2249 WORK EQUIPMENT CYLINDER..............................................................................................2251 Boom cylinder....................................................................................................2251 2-piece boom cylinder............................................................................................2252 Arm cylinder.....................................................................................................2253 Bucket cylinder..................................................................................................2254 Boom swing cylinder..............................................................................................2255 Blade/outrigger cylinder.........................................................................................2256 80 APPENDIX..................................................................................................................2257 Contents.................................................................................................................2258 Air conditioner components...............................................................................................2259 Precautions for refrigerant..........................................................................................2259 Air conditioner component............................................................................................2260 Specifications...................................................................................................2262 Configuration and function of refrigeration cycle....................................................................2263 Outline of refrigeration cycle.......................................................................................2264 Air conditioner unit.................................................................................................2266 Function.........................................................................................................2267 Functions of major components....................................................................................2268 Dual pressure switch.................................................................................................2271 Function.........................................................................................................2271 Air conditioner controller...........................................................................................2272 Compressor...........................................................................................................2273 Specification....................................................................................................2273 Function.........................................................................................................2273 Condenser............................................................................................................2274 Specification....................................................................................................2274 Function.........................................................................................................2274 Receiver drier.......................................................................................................2275 Function.........................................................................................................2275 Specification....................................................................................................2275 Sunlight sensor......................................................................................................2276 Function.........................................................................................................2276 Output characteristics...........................................................................................2276 Outer temperature sensor (outside air temperature sensor)............................................................2277 Function.........................................................................................................2277 Procedure for testing and troubleshooting............................................................................2278 Circuit diagram and arrangement of connector pins....................................................................2280 System diagram.......................................................................................................2282 Input and output signals of the air conditioner controller...........................................................2283 Function.........................................................................................................2283 Air conditioner unit.................................................................................................2285 Parts and connectors layout..........................................................................................2287 Details..........................................................................................................2287 Testing air leakage (duct)...........................................................................................2293 Testing with self-diagnosis function.................................................................................2295 Testing outline..................................................................................................2295 How to open the electrical system abnormality record screen in service mode of the machine monitor...............2295 Testing vent (mode) changeover.......................................................................................2298 Testing..........................................................................................................2298 Testing FRESH/RECIRC air changeover..................................................................................2299 Testing..........................................................................................................2299 Testing sunlight sensor..............................................................................................2300 Testing..........................................................................................................2300 Testing (dual) pressure switch for refrigerant.......................................................................2301 Testing..........................................................................................................2301 Testing relays.......................................................................................................2303 Testing..........................................................................................................2303 Troubleshooting chart 1..............................................................................................2304 Troubleshooting chart 2..............................................................................................2305 Information in troubleshooting table.................................................................................2308 Failure code list related to air conditioner.........................................................................2309 Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit..........................................................2310 Failure code [879AKB] A/C Recirc Air Temp Sens Short.................................................................2311 Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit...........................................................2312 Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit..........................................................2314 Failure code [879CKA] Ventilating Sensor Open Circuit................................................................2316 Failure code [879CKB] Ventilating Sensor Short Circuit...............................................................2317 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit..........................................................2318 Failure code [879EMC] Ventilation Damper Malfunction.................................................................2320 Failure code [879FMC] Air Mix Damper Malfunction.....................................................................2321 Failure code [879GKX] Refrigerant Press Input Sig Out of Range.......................................................2322 A-1 Troubleshooting for power supply system (Air conditioner does not operate).......................................2323 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)........................................2325 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)...............................2328 A-4 Troubleshooting for FRESH/RECIRC air changeover..................................................................2330 Troubleshooting with gauge pressure..................................................................................2332 Connection of service tool...........................................................................................2335 Precautions for disconnecting and connecting refrigerant piping......................................................2337 Handling of compressor oil...........................................................................................2339 90 DIAGRAMS AND DRAWINGS.....................................................................................................2341 Contents.................................................................................................................2342 ABBREVIATION LIST........................................................................................................2343 HYDRAULIC CIRCUIT DIAGRAM................................................................................................2350 SYMBOLS IN HYDRAULIC CIRCUIT DIAGRAM.................................................................................2350 HYDRAULIC CIRCUIT DIAGRAM (1/2)......................................................................................2353 HYDRAULIC CIRCUIT DIAGRAM (2/2)......................................................................................2355 ELECTRIC CIRCUIT DIAGRAM.................................................................................................2357 SYMBOLS IN ELECTRIC CIRCUIT DIAGRAM..................................................................................2357 ELECTRICAL CIRCUIT DIAGRAM (1/11)....................................................................................2361 ELECTRICAL CIRCUIT DIAGRAM (2/11)....................................................................................2363 ELECTRICAL CIRCUIT DIAGRAM (3/11)....................................................................................2365 ELECTRICAL CIRCUIT DIAGRAM (4/11)....................................................................................2367 ELECTRICAL CIRCUIT DIAGRAM (5/11)....................................................................................2369 ELECTRICAL CIRCUIT DIAGRAM (6/11)....................................................................................2371 ELECTRICAL CIRCUIT DIAGRAM (7/11)....................................................................................2373 ELECTRICAL CIRCUIT DIAGRAM (8/11)....................................................................................2375 ELECTRICAL CIRCUIT DIAGRAM (9/11)....................................................................................2377 ELECTRICAL CIRCUIT DIAGRAM (10/11)...................................................................................2379 ELECTRICAL CIRCUIT DIAGRAM (11/11)...................................................................................2381
DESCRIPTION:
General precautions
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when hitting parts with a hammer.
2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with two or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
S.S 24/12/24
