Komatsu PC138US-11E0 Hydraulic Excavator Shop Manual SEN06905-01 – PDF DOWNLOAD
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DESCRIPTION:
Komatsu PC138US-11E0 Hydraulic Excavator Shop Manual SEN06905-01 – PDF DOWNLOAD
SERIAL NUMBERS 59832 and up
FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE SHOP MANUAL:
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
VIDEO PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu PC138US-11E0 Hydraulic Excavator Shop Manual SEN06905-01 – PDF DOWNLOAD
COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
FOREWORD, SAFETY, BASIC INFORMATION 22
HOW TO READ THE SHOP MANUAL 22
SAFETY NOTICE FOR OPERATION 24
PRECAUTIONS TO PREVENT FIRE 32
ACTIONS IF FIRE OCCURS 34
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 35
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 36
PRECAUTIONS FOR DEF 37
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 37
PRECAUTIONS FOR ADDING 37
PRECAUTIONS FOR STORING 37
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 37
THE OTHER PRECAUTIONS 37
STORE AdBlue/DEF 38
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 39
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 42
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 49
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 51
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 52
PRACTICAL USE OF KOMTRAX 53
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 54
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 54
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 55
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 56
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 58
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 62
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 63
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 65
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 68
HOW TO READ ELECTRICAL WIRE CODE 69
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 73
STANDARD TIGHTENING TORQUE TABLE 76
CONVERSION TABLE 83
ABBREVIATION LIST 88
01 SPECIFICATIONS 91
CONTENTS 92
SPECIFICATIONS 93
SPECIFICATION DRAWING 93
SPECIFICATION DRAWING: PC138US-11E0 93
WORKING RANGE DRAWINGS 95
WORKING RANGE DRAWINGS: PC138US-11E0 95
SPECIFICATIONS 96
SPECIFICATIONS: PC138US-11E0 96
WEIGHT TABLE 100
WEIGHT TABLE: PC138US-11E0 100
FUEL, COOLANT, LUBRICANT 102
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 102
10 STRUCTURE AND FUNCTION 105
CONTENTS 106
UREA SCR SYSTEM 109
LAYOUT DRAWING OF UREA SCR SYSTEM 109
UREA SCR SYSTEM DIAGRAM 111
FUNCTION OF UREA SCR SYSTEM 112
FUNCTION OF AdBlue/DEF SYSTEM 112
INDUCEMENT STRATEGY 115
COMPONENT PARTS OF UREA SCR SYSTEM 123
AdBlue/DEF MIXING TUBE 123
SCR ASSEMBLY 124
AdBlue/DEF TANK 126
AdBlue/DEF PUMP 128
AdBlue/DEF INJECTOR 129
AdBlue/DEF HOSE 130
AdBlue/DEF TANK HEATING VALVE 131
BOOT-UP SYSTEM 132
LAYOUT DRAWING OF BOOT-UP SYSTEM 132
SYSTEM OPERATING LAMP SYSTEM 133
SYSTEM DIAGRAM OF SYSTEM OPERATING LAMP SYSTEM 133
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 133
BATTERY DISCONNECT SWITCH 134
FUNCTION OF BATTERY DISCONNECT SWITCH 134
ENGINE SYSTEM 135
LAYOUT DRAWING OF ENGINE SYSTEM 135
ENGINE CONTROL SYSTEM 137
SYSTEM DIAGRAM OF ENGINE CONTROL SYSTEM 137
FUNCTION OF ENGINE CONTROL SYSTEM 138
AUTO-DECELERATION SYSTEM 140
AUTO-DECELERATION SYSTEM DIAGRAM 140
FUNCTION OF AUTO-DECELERATION SYSTEM 140
OPERATION OF AUTO-DECELERATION SYSTEM 141
ENGINE AUTOMATIC WARM-UP SYSTEM 142
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 142
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 143
OVERHEAT PREVENTION SYSTEM 144
FUNCTION OF OVERHEAT PREVENTION SYSTEM 144
TURBOCHARGER PROTECTION SYSTEM 146
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 146
AUTOMATIC IDLE STOP SYSTEM 147
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 147
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 147
COMPONENT PARTS OF ENGINE SYSTEM 150
PTO 150
VARIABLE FLOW TURBOCHARGER 151
EGR SYSTEM 154
EGR VALVE 157
EGR COOLER 160
KCCV SYSTEM 162
KCCV VENTILATOR 165
EXHAUST THROTTLE VALVE 167
KDPF 168
COOLING SYSTEM 172
LAYOUT DRAWING OF COOLING SYSTEM 172
SPECIFICATIONS OF COOLING SYSTEM 173
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 174
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 174
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 175
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 176
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 176
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 176
COMPONENT PARTS OF COOLING SYSTEM 178
FAN CLUTCH 178
CONTROL SYSTEM 179
LAYOUT DRAWING OF CONTROL SYSTEM 179
MACHINE MONITOR SYSTEM 181
SYSTEM DIAGRAM OF MACHINE MONITOR 181
FUNCTION OF MACHINE MONITOR SYSTEM 181
KomVision SYSTEM 183
LAYOUT DRAWING OF KomVision SYSTEM 183
KomVision SYSTEM DIAGRAM 185
FUNCTION OF KomVision SYSTEM 185
KOMTRAX SYSTEM 187
SYSTEM DIAGRAM OF KOMTRAX SYSTEM 187
FUNCTION OF KOMTRAX SYSTEM 187
COMPONENT PARTS OF CONTROL SYSTEM 188
MACHINE MONITOR 188
KomVision CONTROLLER 205
KomVision CAMERA 209
GATEWAY FUNCTION CONTROLLER 210
COMMUNICATION TERMINAL 213
PUMP CONTROLLER 214
RESISTOR FOR PC-EPC VALVE 218
CAN TERMINATING RESISTOR 219
ENGINE CONTROLLER 220
FUEL CONTROL DIAL 227
HYDRAULIC SYSTEM 229
LAYOUT DRAWING OF HYDRAULIC SYSTEM 229
CLSS 231
STRUCTURE OF CLSS 231
FUNCTION OF CLSS 232
ENGINE AND PUMP COMBINED CONTROL SYSTEM 234
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 234
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 235
COMPONENT PARTS OF HYDRAULIC SYSTEM 239
HYDRAULIC TANK 239
MAIN PUMP 241
CONTROL VALVE 268
WORK EQUIPMENT SYSTEM 328
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 328
STRUCTURE OF VALVE CONTROL 331
PPC LOCK SYSTEM 332
PPC LOCK SYSTEM DIAGRAM 332
FUNCTION OF PPC LOCK SYSTEM 332
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 333
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 333
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 333
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 334
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 335
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 335
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 336
TOOL CONTROL SYSTEM 337
TOOL CONTROL SYSTEM DIAGRAM 337
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 339
WORK EQUIPMENT AND SWING PPC VALVE 339
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 344
BLADE PPC VALVE 352
SOLENOID VALVE 354
VARIABLE BACK PRESSURE SOLENOID VALVE 357
MULTI-CONTROL VALVE 358
ARM DUMP QUICK RETURN VALVE 359
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE 361
PILOT CIRCUIT ACCUMULATOR 364
ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) 365
SWING SYSTEM 366
LAYOUT DRAWING OF SWING SYSTEM 366
SWING CONTROL SYSTEM DIAGRAM 368
FUNCTION OF SWING CONTROL SYSTEM 369
COMPONENT PARTS OF SWING SYSTEM 371
SWING MOTOR 371
SWING MACHINERY 381
SWING CIRCLE 383
TRAVEL SYSTEM 384
LAYOUT DRAWING OF TRAVEL SYSTEM 384
TRAVEL CONTROL SYSTEM DIAGRAM 386
FUNCTION OF TRAVEL CONTROL SYSTEM 387
COMPONENT PARTS OF TRAVEL SYSTEM 390
TRAVEL MOTOR 390
TRAVEL PPC VALVE 400
CENTER SWIVEL JOINT 404
UNDERCARRIAGE AND FRAME 406
LAYOUT DRAWING OF UNDERCARRIAGE 406
SPECIFICATIONS OF UNDERCARRIAGE 406
IDLER CUSHION 407
STRUCTURE OF IDLER CUSHION 407
SPECIFICATIONS OF IDLER CUSHION 407
WORK EQUIPMENT 408
STRUCTURE OF WORK EQUIPMENT 408
FUNCTION OF WORK EQUIPMENT 409
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 410
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 410
BUCKET CLEARANCE ADJUSTMENT SHIM 411
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 411
CAB AND ITS ATTACHMENTS 412
ROPS CAB 412
STRUCTURE OF ROPS CAB 412
FUNCTION OF ROPS CAB 412
CAB MOUNT 413
STRUCTURE OF CAB MOUNT 413
FUNCTION OF CAB MOUNT 413
TAKE WIRING HARNESS OUT OF CAB 415
20 STANDARD VALUE TABLE 417
CONTENTS 418
STANDARD VALUE TABLE FOR ENGINE 419
STANDARD VALUE TABLE FOR ENGINE:PC138US-11E0 419
STANDARD VALUE TABLE FOR MACHINE 423
STANDARD VALUE TABLE FOR MACHINE:PC138US-11E0 423
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 437
30 TESTING AND ADJUSTING 441
CONTENTS 442
RELATED INFORMATION ON TESTING AND ADJUSTING 445
TOOLS FOR TESTING AND ADJUSTING 445
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 452
ENGINE AND COOLING SYSTEM 454
TEST ENGINE SPEED 454
METHOD FOR TESTING ENGINE SPEED 454
TEST EXHAUST GAS COLOR 457
TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 457
TEST EXHAUST GAS COLOR BY SMOKE METER 458
TEST THE CLEARANCE OF THE EXHAUST THROTTLE VALVE 460
MEASURE CLEARANCE OF THE EXHAUST THROTTLE VALVE 460
TEST AND ADJUST VALVE CLEARANCE 463
METHOD FOR TESTING VALVE CLEARANCE 463
METHOD FOR ADJUSTING VALVE CLEARANCE 464
TEST COMPRESSION PRESSURE 465
METHOD FOR TESTING COMPRESSION PRESSURE 465
TEST BLOWBY PRESSURE 468
METHOD FOR TESTING BLOWBY PRESSURE 468
TEST ENGINE OIL PRESSURE 470
TEST ENGINE OIL PRESSURE 470
VISUAL CHECK INSIDE OF EGR VALVE 472
VISUAL CHECK INSIDE OF EGR VALVE 472
CLEAN INSIDE OF EGR VALVE 474
CLEAN INSIDE OF EGR VALVE 474
TEST FUEL PRESSURE 477
TEST FUEL PRESSURE 477
TEST FUEL RETURN RATE AND LEAKAGE 479
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 480
BLEED AIR FROM FUEL SYSTEM 483
BLEED AIR FROM FUEL SYSTEM 483
TEST FUEL CIRCUIT FOR LEAKAGE 485
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 485
HANDLE CYLINDER CUT-OUT MODE OPERATION 487
HANDLE NO-INJECTION CRANKING OPERATION 488
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 489
CHECK AIR CONDITIONER COMPRESSOR BELT 489
ADJUST AIR CONDITIONER COMPRESSOR BELT 489
TEST ALTERNATOR BELT 491
METHOD FOR TESTING ALTERNATOR BELT 491
TEST AUTOMATIC TENSIONER 492
METHOD FOR TESTING AUTOMATIC TENSIONER 492
TEST COOLING FAN SPEED 494
METHOD FOR TESTING COOLING FAN SPEED 494
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 495
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 495
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 496
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 496
TEST SCR RELATED FUNCTIONS 502
TEST AdBlue/DEF PUMP RAISED PRESSURE 506
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 509
TEST AdBlue/DEF LINE HEATER RELAY 1 514
TEST AdBlue/DEF LINE HEATER RELAY 2 518
TEST AdBlue/DEF PUMP HEATER RELAY 521
TEST AdBlue/DEF TANK HEATER VALVE 525
TEST DENITRATION EFFICIENCY OF SCR 529
CLEAN AdBlue/DEF TANK 532
METHOD FOR CLEANING AdBlue/DEF TANK 532
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 537
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 537
CLEAN AdBlue/DEF PUMP 539
CLEAN AdBlue/DEF PUMP 539
POWER TRAIN 545
TEST SWING CIRCLE BEARING CLEARANCE 545
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 545
UNDERCARRIAGE AND FRAME 546
TEST AND ADJUST TRACK TENSION 546
METHOD FOR TESTING TRACK TENSION 546
METHOD FOR ADJUSTING TRACK TENSION 546
HYDRAULIC SYSTEM 548
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 548
RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK 548
RELEASE REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 548
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 549
RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 550
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS 551
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS 551
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS 558
TEST OIL PRESSURE OF CONTROL CIRCUIT 560
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 560
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 562
METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 562
METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE 563
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 564
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 566
TEST LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 566
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE 568
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 569
METHOD FOR ADJUSTING LS VALVE 571
TEST OUTLET PRESSURE OF SOLENOID VALVE 572
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 572
OPERATING CONDITION OF SOLENOID VALVE 573
METHOD FOR TESTING OUTLET PRESSURE OF VARIABLE BACK PRESSURE SOLENOID VALVE 574
OPERATING CONDITION OF VARIABLE BACK PRESSURE SOLENOID VALVE 576
TEST PPC VALVE OUTLET PRESSURE 577
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 577
TEST ATTACHMENT CIRCUIT OIL PRESSURE 579
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 579
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 580
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 580
TEST AND ADJUST TRAVEL DEVIATION 581
METHOD FOR TESTING TRAVEL DEVIATION 581
METHOD FOR ADJUSTING TRAVEL DEVIATION 581
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 584
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 584
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 584
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 585
TEST OIL LEAKAGE 586
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 586
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 587
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 587
METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER 588
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 588
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 589
BLEED AIR FROM HYDRAULIC CIRCUIT 591
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 592
TEST AND CHARGE ACCUMULATOR (MANUFACTURED BY EAGLE INDUSTRY CO , LTD ) NITROGEN GAS PRESSURE FOR ATTACHMENT 595
TEST ACCUMULATOR (MANUFACTURED BY EAGLE INDUSTRY CO , LTD ) NITROGEN GAS PRESSURE FOR ATTACHMENT 595
CAB AND ITS ATTACHMENTS 599
TEST CAB TIPPING STOPPER 599
METHOD FOR TESTING CAB TIPPING STOPPER 599
ADJUST MIRRORS 600
ADJUST MACHINE LEFT FRONT MIRROR (A) 600
ADJUST MACHINE REAR MIRROR (B) 601
ELECTRICAL SYSTEM 602
SET AND OPERATE MACHINE MONITOR 602
OPERATOR MODE 607
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 607
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 607
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 608
CHECKING FUNCTION OF SERVICE METER 608
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 608
SERVICE MODE 612
OPERATE SERVICE MODE 612
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 615
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 621
ABNORMALITY RECORD MENU 632
CHECK MAINTENANCE RECORD 636
MAINTENANCE MODE SETTING 637
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 641
DEFAULT MENU 643
DIAGNOSTIC TESTS MENU 656
ADJUSTMENT MENU 667
METHOD FOR PERFORMING NO-INJECTION CRANKING 691
KOMTRAX SETTINGS MENU 693
METHOD FOR DISPLAYING SERVICE MESSAGE 695
START UP KOMTRAX SYSTEM 697
STOP USING OF KOMTRAX SYSTEM 703
ADJUST KomVision CAMERA ANGLE 705
ADJUST KomVision CAMERA ANGLE 706
ADJUST KomVision CAMERA ANGLE (RIGHT REAR CAMERA) 707
ADJUST KomVision RELATED ITEMS 709
SETTING OF KomVision (MAIN SETTING) 710
SETTING OF KomVision (CAMERA SETTING) 713
SETTING OF KomVision (CAMERA CALIBRATION) 715
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 728
BATTERY DISCONNECT SWITCH 729
TEST DIODES 730
METHOD FOR TESTING DIODE USING DIGITAL TESTER 730
METHOD FOR TESTING DIODE USING ANALOG TESTER 730
Pm CLINIC 731
Pm CLINIC SERVICE 731
PM CLINIC CHECK SHEET: PC138US-11E0 732
40 TROUBLESHOOTING 741
CONTENTS 742
RELATED INFORMATION ON TROUBLESHOOTING 753
GENERAL TROUBLESHOOTING POINTS 753
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEM 754
SEQUENCE OF EVENTS IN TROUBLESHOOTING 766
CHECKS BEFORE TROUBLESHOOTING 768
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 770
WALK-AROUND CHECK 770
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 772
CHECK FUEL LEVEL AND TYPE 772
CHECK FUEL PREFILTER 773
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 773
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 773
CHECK MAIN FILTER 775
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 776
CHECK OIL LEVEL IN PTO GEAR CASE 777
CHECK COOLANT LEVEL (RESERVOIR TANK) 778
CHECK CLOGGING OF AIR CLEANER 778
OUTER ELEMENT – CLEAN 779
ELEMENTS – REPLACE 781
CHECK HYDRAULIC OIL LEVEL 782
CHECK HYDRAULIC OIL STRAINER 784
CHECK HYDRAULIC FILTER 784
CHECK OIL LEVEL IN SWING MACHINERY CASE 785
CHECK OIL LEVEL IN FINAL DRIVE CASE 786
BLEED AIR FROM FUEL SYSTEM 786
BLEED AIR FROM HYDRAULIC SYSTEM 786
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 787
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 792
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 792
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 792
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 793
PREPARATION FOR TROUBLESHOOTING OF GATEWAY FUNCTION CONTROLLER 793
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 794
PROCEDURE FOR TESTING AND TROUBLESHOOTING 799
SYMPTOM AND TROUBLESHOOTING NUMBERS 802
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 807
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 809
CONNECTOR LIST AND LAYOUT 812
CONNECTOR CONTACT IDENTIFICATION 826
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 866
FUSE LOCATION TABLE 872
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 875
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 879
FAILURE CODE TABLE 881
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 899
FAILURE CODE [6AZ0ZG] 899
FAILURE CODE [879AKA] 901
FAILURE CODE [879AKB] 903
FAILURE CODE [879BKA] 905
FAILURE CODE [879BKB] 907
FAILURE CODE [879CKA] 909
FAILURE CODE [879CKB] 910
FAILURE CODE [879DKZ] 911
FAILURE CODE [879EMC] 914
FAILURE CODE [879FMC] 915
FAILURE CODE [879GKX] 916
FAILURE CODE [989L00] 918
FAILURE CODE [989M00] 919
FAILURE CODE [989N00] 920
FAILURE CODE [A1U0N3] 921
FAILURE CODE [A1U0N4] 923
FAILURE CODE [A900FR] 925
FAILURE CODE [A900N6] 926
FAILURE CODE [A900NY] 927
FAILURE CODE [AA10NX] 928
FAILURE CODE [AB00KE] 930
FAILURE CODE [AQ10MB] 933
FAILURE CODE [AQ10N3] 935
FAILURE CODE [AS00R2] 937
FAILURE CODE [AS00R3] 938
FAILURE CODE [AS00R4] 939
FAILURE CODE [AS00R6] 940
FAILURE CODE [AS10KM] 941
FAILURE CODE [AS10NR] 942
FAILURE CODE [AS10NT] 943
FAILURE CODE [AU10QA] 944
FAILURE CODE [B@BAZG] 945
FAILURE CODE [B@BAZK] 946
FAILURE CODE [B@BCNS] 948
FAILURE CODE [B@BCQA] 949
FAILURE CODE [B@BCZK] 951
FAILURE CODE [B@HANS] 953
FAILURE CODE [CA115] 955
FAILURE CODE [CA122] 957
FAILURE CODE [CA123] 961
FAILURE CODE [CA131] 965
FAILURE CODE [CA132] 968
FAILURE CODE [CA144] 971
FAILURE CODE [CA145] 975
FAILURE CODE [CA153] 978
FAILURE CODE [CA154] 982
FAILURE CODE [CA187] 986
FAILURE CODE [CA221] 988
FAILURE CODE [CA222] 992
FAILURE CODE [CA227] 995
FAILURE CODE [CA234] 996
FAILURE CODE [CA238] 998
FAILURE CODE [CA239] 1000
FAILURE CODE [CA249] 1002
FAILURE CODE [CA256] 1005
FAILURE CODE [CA271] 1008
FAILURE CODE [CA272] 1011
FAILURE CODE [CA322] 1013
FAILURE CODE [CA324] 1017
FAILURE CODE [CA331] 1021
FAILURE CODE [CA332] 1025
FAILURE CODE [CA343] 1029
FAILURE CODE [CA351] 1030
FAILURE CODE [CA352] 1031
FAILURE CODE [CA356] 1034
FAILURE CODE [CA357] 1037
FAILURE CODE [CA386] 1041
FAILURE CODE [CA435] 1042
FAILURE CODE [CA441] 1044
FAILURE CODE [CA442] 1047
FAILURE CODE [CA449] 1048
FAILURE CODE [CA451] 1049
FAILURE CODE [CA452] 1052
FAILURE CODE [CA515] 1055
FAILURE CODE [CA516] 1057
FAILURE CODE [CA553] 1060
FAILURE CODE [CA555] 1062
FAILURE CODE [CA556] 1064
FAILURE CODE [CA559] 1066
FAILURE CODE [CA689] 1072
FAILURE CODE [CA691] 1077
FAILURE CODE [CA692] 1080
FAILURE CODE [CA697] 1083
FAILURE CODE [CA698] 1084
FAILURE CODE [CA731] 1085
FAILURE CODE [CA778] 1088
FAILURE CODE [CA1117] 1095
FAILURE CODE [CA1664] 1097
FAILURE CODE [CA1669] 1100
FAILURE CODE [CA1673] 1102
FAILURE CODE [CA1677] 1104
FAILURE CODE [CA1678] 1106
FAILURE CODE [CA1682] 1108
FAILURE CODE [CA1683] 1111
FAILURE CODE [CA1684] 1114
FAILURE CODE [CA1686] 1117
FAILURE CODE [CA1691] 1119
FAILURE CODE [CA1694] 1122
FAILURE CODE [CA1695] 1124
FAILURE CODE [CA1696] 1125
FAILURE CODE [CA1712] 1128
FAILURE CODE [CA1713] 1131
FAILURE CODE [CA1714] 1134
FAILURE CODE [CA1715] 1136
FAILURE CODE [CA1776] 1138
FAILURE CODE [CA1777] 1141
FAILURE CODE [CA1843] 1145
FAILURE CODE [CA1844] 1148
FAILURE CODE [CA1883] 1152
FAILURE CODE [CA1885] 1157
FAILURE CODE [CA1887] 1160
FAILURE CODE [CA1896] 1163
FAILURE CODE [CA1921] 1167
FAILURE CODE [CA1922] 1171
FAILURE CODE [CA1938] 1176
FAILURE CODE [CA1942] 1179
FAILURE CODE [CA1961] 1181
FAILURE CODE [CA1993] 1182
FAILURE CODE [CA2185] 1187
FAILURE CODE [CA2186] 1189
FAILURE CODE [CA2249] 1191
FAILURE CODE [CA2272] 1192
FAILURE CODE [CA2311] 1196
FAILURE CODE [CA2349] 1197
FAILURE CODE [CA2353] 1200
FAILURE CODE [CA2357] 1203
FAILURE CODE [CA2636] 1204
FAILURE CODE [CA2637] 1208
FAILURE CODE [CA2639] 1210
FAILURE CODE [CA2765] 1212
FAILURE CODE [CA2771] 1213
FAILURE CODE [CA2777] 1221
FAILURE CODE [CA2976] 1224
FAILURE CODE [CA3135] 1228
FAILURE CODE [CA3142] 1231
FAILURE CODE [CA3143] 1232
FAILURE CODE [CA3144] 1233
FAILURE CODE [CA3146] 1236
FAILURE CODE [CA3147] 1237
FAILURE CODE [CA3148] 1238
FAILURE CODE [CA3151] 1241
FAILURE CODE [CA3165] 1247
FAILURE CODE [CA3229] 1250
FAILURE CODE [CA3231] 1253
FAILURE CODE [CA3232] 1255
FAILURE CODE [CA3235] 1260
FAILURE CODE [CA3239] 1263
FAILURE CODE [CA3241] 1267
FAILURE CODE [CA3242] 1271
FAILURE CODE [CA3251] 1274
FAILURE CODE [CA3255] 1277
FAILURE CODE [CA3256] 1280
FAILURE CODE [CA3312] 1282
FAILURE CODE [CA3313] 1285
FAILURE CODE [CA3314] 1287
FAILURE CODE [CA3315] 1288
FAILURE CODE [CA3318] 1290
FAILURE CODE [CA3322] 1292
FAILURE CODE [CA3419] 1294
FAILURE CODE [CA3421] 1296
FAILURE CODE [CA3497] 1298
FAILURE CODE [CA3498] 1300
FAILURE CODE [CA3545] 1302
FAILURE CODE [CA3547] 1305
FAILURE CODE [CA3558] 1307
FAILURE CODE [CA3559] 1310
FAILURE CODE [CA3562] 1313
FAILURE CODE [CA3563] 1316
FAILURE CODE [CA3567] 1321
FAILURE CODE [CA3568] 1325
FAILURE CODE [CA3571] 1329
FAILURE CODE [CA3572] 1332
FAILURE CODE [CA3574] 1335
FAILURE CODE [CA3575] 1338
FAILURE CODE [CA3577] 1340
FAILURE CODE [CA3578] 1343
FAILURE CODE [CA3582] 1346
FAILURE CODE [CA3583] 1352
FAILURE CODE [CA3596] 1355
FAILURE CODE [CA3649] 1358
FAILURE CODE [CA3681] 1361
FAILURE CODE [CA3682] 1368
FAILURE CODE [CA3713] 1375
FAILURE CODE [CA3717] 1379
FAILURE CODE [CA3718] 1381
FAILURE CODE [CA3724] 1383
FAILURE CODE [CA3725] 1384
FAILURE CODE [CA3748] 1387
FAILURE CODE [CA3755] 1389
FAILURE CODE [CA3866] 1391
FAILURE CODE [CA3867] 1396
FAILURE CODE [CA3868] 1400
FAILURE CODE [CA3899] 1405
FAILURE CODE [CA3911] 1408
FAILURE CODE [CA3912] 1413
FAILURE CODE [CA3918] 1416
FAILURE CODE [CA3921] 1419
FAILURE CODE [CA3928] 1424
FAILURE CODE [CA3932] 1425
FAILURE CODE [CA3933] 1428
FAILURE CODE [CA3934] 1431
FAILURE CODE [CA3935] 1435
FAILURE CODE [CA3936] 1438
FAILURE CODE [CA4152] 1440
FAILURE CODE [CA4155] 1445
FAILURE CODE [CA4156] 1448
FAILURE CODE [CA4157] 1452
FAILURE CODE [CA4159] 1454
FAILURE CODE [CA4164] 1456
FAILURE CODE [CA4165] 1459
FAILURE CODE [CA4166] 1462
FAILURE CODE [CA4168] 1464
FAILURE CODE [CA4169] 1467
FAILURE CODE [CA4171] 1469
FAILURE CODE [CA4249] 1472
FAILURE CODE [CA4251] 1474
FAILURE CODE [CA4261] 1476
FAILURE CODE [CA4277] 1480
FAILURE CODE [CA4281] 1485
FAILURE CODE [CA4459] 1488
FAILURE CODE [CA4461] 1491
FAILURE CODE [CA4533] 1496
FAILURE CODE [CA4534] 1497
FAILURE CODE [CA4731] 1499
FAILURE CODE [CA4732] 1501
FAILURE CODE [CA4739] 1503
FAILURE CODE [CA4768] 1505
FAILURE CODE [CA4769] 1508
FAILURE CODE [CA4842] 1511
FAILURE CODE [CA4952] 1516
FAILURE CODE [CA5115] 1518
FAILURE CODE [CA5179] 1522
FAILURE CODE [CA5181] 1525
FAILURE CODE [CA5271] 1528
FAILURE CODE [CA5272] 1531
FAILURE CODE [CA5273] 1534
FAILURE CODE [CA5274] 1537
FAILURE CODE [CA5275] 1539
FAILURE CODE [CA5276] 1542
FAILURE CODE [CA5277] 1545
FAILURE CODE [CA5383] 1547
FAILURE CODE [CA5387] 1549
FAILURE CODE [CA5388] 1551
FAILURE CODE [CA5389] 1554
FAILURE CODE [CA5391] 1556
FAILURE CODE [CA5392] 1562
FAILURE CODE [CA5393] 1564
FAILURE CODE [CA5394] 1567
FAILURE CODE [CA5395] 1570
FAILURE CODE [CA5396] 1573
FAILURE CODE [CA5631] 1575
FAILURE CODE [CA5938] 1577
FAILURE CODE [D110KB] 1579
FAILURE CODE [D19JKZ] 1581
FAILURE CODE [D811MC] 1584
FAILURE CODE [D862KA] 1585
FAILURE CODE [D8ALKA] 1587
FAILURE CODE [D8ALKB] 1590
FAILURE CODE [D8AQKR] 1592
FAILURE CODE [D8ARKR] 1597
FAILURE CODE [D8G1KT] 1602
FAILURE CODE [D8G6KT] 1603
FAILURE CODE [DA20MC] 1604
FAILURE CODE [DA22KK] 1605
FAILURE CODE [DA22KT] 1609
FAILURE CODE [DA25KP] 1612
FAILURE CODE [DA26KP] 1617
FAILURE CODE [DA29KQ] 1620
FAILURE CODE [DA2JKT] 1623
FAILURE CODE [DA2JKY] 1624
FAILURE CODE [DA2LKA] 1625
FAILURE CODE [DA2LKB] 1628
FAILURE CODE [DA2QKR] 1630
FAILURE CODE [DA2RKR] 1637
FAILURE CODE [DAF0KM] 1644
FAILURE CODE [DAF0MB] 1645
FAILURE CODE [DAF0MC] 1646
FAILURE CODE [DAF8KB] 1647
FAILURE CODE [DAF9KQ] 1649
FAILURE CODE [DAFGMC] 1651
FAILURE CODE [DAFLKA] 1652
FAILURE CODE [DAFLKB] 1655
FAILURE CODE [DAFQKR] 1657
FAILURE CODE [DAZ9KQ] 1663
FAILURE CODE [DAZQKR] 1665
FAILURE CODE [DB2QKR] 1670
FAILURE CODE [DB2RKR] 1677
FAILURE CODE [DBP0KM] 1685
FAILURE CODE [DBP0KT] 1686
FAILURE CODE [DBP5KB] 1687
FAILURE CODE [DBP5KY] 1690
FAILURE CODE [DBPQKR] 1693
FAILURE CODE [DDNRKA] 1699
FAILURE CODE [DDNRKY] 1702
FAILURE CODE [DDNS00] 1705
FAILURE CODE [DFB1KZ] 1708
FAILURE CODE [DFB2KZ] 1711
FAILURE CODE [DFB3L8] 1714
FAILURE CODE [DFB4L8] 1716
FAILURE CODE [DFB5KZ] 1718
FAILURE CODE [DFB6KZ] 1721
FAILURE CODE [DGH2KA] 1724
FAILURE CODE [DGH2KB] 1726
FAILURE CODE [DHA4KA] 1728
FAILURE CODE [DHAAMA] 1730
FAILURE CODE [DHACMA] 1732
FAILURE CODE [DHPAMA] 1734
FAILURE CODE [DHS3MA] 1737
FAILURE CODE [DHS4MA] 1740
FAILURE CODE [DHS8MA] 1743
FAILURE CODE [DHS9MA] 1746
FAILURE CODE [DHSAMA] 1749
FAILURE CODE [DHSBMA] 1752
FAILURE CODE [DHSCMA] 1755
FAILURE CODE [DHSDMA] 1758
FAILURE CODE [DHSFMA] 1761
FAILURE CODE [DHSGMA] 1764
FAILURE CODE [DHSHMA] 1767
FAILURE CODE [DHSJMA] 1770
FAILURE CODE [DHSKMA] 1773
FAILURE CODE [DHSLMA] 1775
FAILURE CODE [DHX1MA] 1777
FAILURE CODE [DKULKA] 1778
FAILURE CODE [DKULKB] 1780
FAILURE CODE [DKULKY] 1783
FAILURE CODE [DLM5KA] 1785
FAILURE CODE [DLM5MB] 1789
FAILURE CODE [DR10KA] 1791
FAILURE CODE [DR12KA] 1796
FAILURE CODE [DR20KA] 1798
FAILURE CODE [DR21KX] 1800
FAILURE CODE [DR30KA] 1801
FAILURE CODE [DR31KX] 1803
FAILURE CODE [DR40KA] 1804
FAILURE CODE [DUMBKA] 1806
FAILURE CODE [DUMBKB] 1809
FAILURE CODE [DV00KA] 1811
FAILURE CODE [DV00KB] 1812
FAILURE CODE [DV20KB] 1813
FAILURE CODE [DW43KA] 1815
FAILURE CODE [DW43KB] 1817
FAILURE CODE [DW43KY] 1819
FAILURE CODE [DW45KA] 1821
FAILURE CODE [DW45KB] 1825
FAILURE CODE [DW45KY] 1829
FAILURE CODE [DW4CKY] 1831
FAILURE CODE [DW91KA] 1833
FAILURE CODE [DW91KB] 1835
FAILURE CODE [DW91KY] 1837
FAILURE CODE [DWA2KA] 1839
FAILURE CODE [DWA2KB] 1841
FAILURE CODE [DWA2KY] 1843
FAILURE CODE [DWJ0KA] 1845
FAILURE CODE [DWJ0KB] 1847
FAILURE CODE [DWJ0KY] 1849
FAILURE CODE [DWK2KA] 1851
FAILURE CODE [DWK2KB] 1853
FAILURE CODE [DWK2KY] 1855
FAILURE CODE [DWN5KA] 1857
FAILURE CODE [DWN5KB] 1860
FAILURE CODE [DWN5KY] 1862
FAILURE CODE [DWNSKA] 1864
FAILURE CODE [DWNSKB] 1866
FAILURE CODE [DWNSKY] 1868
FAILURE CODE [DXA8KA] 1870
FAILURE CODE [DXA8KB] 1874
FAILURE CODE [DXE4KA] 1877
FAILURE CODE [DXE4KB] 1879
FAILURE CODE [DXE4KY] 1881
FAILURE CODE [DXE7KA] 1883
FAILURE CODE [DXE7KB] 1885
FAILURE CODE [DXE7KY] 1887
FAILURE CODE [DXE8KA] 1889
FAILURE CODE [DXE8KB] 1891
FAILURE CODE [DXE8KY] 1893
FAILURE CODE [DXE9KA] 1895
FAILURE CODE [DXE9KB] 1897
FAILURE CODE [DXE9KY] 1899
FAILURE CODE [DXEAKA] 1901
FAILURE CODE [DXEAKB] 1903
FAILURE CODE [DXEAKY] 1905
FAILURE CODE [DXEKKA] 1907
FAILURE CODE [DXEKKB] 1909
FAILURE CODE [DXEKKY] 1911
FAILURE CODE [DXELKA] 1913
FAILURE CODE [DXELKB] 1915
FAILURE CODE [DXELKY] 1917
FAILURE CODE [DY20KA] 1919
FAILURE CODE [DY20MA] 1922
FAILURE CODE [DY2CKB] 1925
FAILURE CODE [DY2DKB] 1929
FAILURE CODE [DY2EKB] 1932
FAILURE CODE [F313KA] 1935
FAILURE CODE [F313KB] 1937
FAILURE CODE [F318KB] 1939
FAILURE CODE [F318KY] 1941
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1943
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1943
MANUAL PREHEATING SYSTEM DOES NOT WORK 1949
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1952
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1954
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1957
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1958
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1959
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1960
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1961
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1962
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1963
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1964
FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1965
DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 1967
ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1968
DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1969
AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 1970
HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1973
DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 1975
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 1976
FUNCTION SWITCH DOES NOT OPERATE 1977
AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 1978
WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1979
AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1980
WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 1982
WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1983
WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 1984
WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1985
ALARM BUZZER CANNOT BE CANCELED 1986
SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 1987
SERVICE MODE CANNOT BE SELECTED 1988
ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1989
ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 1992
WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 1994
WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 1996
WORK EQUIPMENT DOES NOT OPERATE WHILE LOCK LEVER AUTOMATIC RELEASE SWITCH IS IN RELEASE POSITION 1998
ALARM DOES NOT SOUND DURING TRAVEL 2000
ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 2002
HORN DOES NOT SOUND 2003
HORN DOES NOT STOP SOUNDING 2005
WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 2006
WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 2007
WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 2009
BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2010
BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2011
ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2012
ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2013
BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2014
BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2015
SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2016
TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2017
SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2018
BLADE RAISE ON IS NOT DISPLAYED CORRECTLY WITH MONITORING 2021
BLADE LOWER ON IS NOT DISPLAYED CORRECTLY WITH MONITORING 2022
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2023
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2024
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2024
FAILURE MODE AND CAUSE TABLE 2025
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 2034
ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 2035
FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2037
UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 2038
ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2039
SPEED OR POWER OF BOOM IS LOW 2041
ARM SPEED OR POWER IS LOW 2044
BUCKET SPEED OR POWER IS LOW 2047
BLADE SPEED OR POWER IS LOW 2050
WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2052
HYDRAULIC DRIFT OF BOOM IS LARGE 2053
HYDRAULIC DRIFT OF ARM IS LARGE 2054
HYDRAULIC DRIFT OF BUCKET IS LARGE 2055
HYDRAULIC DRIFT OF BLADE IS LARGE 2056
WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2058
TIME LAG OF WORK EQUIPMENT IS LARGE 2059
ATTACHMENT CIRCUIT CANNOT BE CHANGED 2060
OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 2061
IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2062
IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 2063
IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 2064
MACHINE DOES NOT TRAVEL STRAIGHT 2065
MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 2068
TRAVEL SPEED IS LOW 2070
ONE OF TRACKS DOES NOT RUN 2072
TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2074
UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2075
SWINGS ONLY IN ONE DIRECTION 2076
SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 2077
SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2078
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2079
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2080
SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 2081
LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 2082
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 2083
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2084
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2085
UNUSUAL NOISE IS HEARD FROM AROUND FAN 2086
TROUBLESHOOTING OF ENGINE (S-MODE) 2087
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2087
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2088
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2089
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2090
ENGINE STARTABILITY IS POOR 2091
ENGINE DOES NOT PICK UP SMOOTHLY 2093
ENGINE STOPS DURING OPERATION 2095
ENGINE RUNS ROUGH OR IS UNSTABLE 2097
OUTPUT IS NOT SUFFICIENT (POWER IS LOW) 2098
EXHAUST IS BLACK (KDPF GETS CLOGGED IN A SHORT TIME) 2101
ENGINE OIL CONSUMPTION IS EXCESSIVE 2103
ENGINE OIL BECOMES CONTAMINATED QUICKLY 2104
FUEL CONSUMPTION IS EXCESSIVE 2105
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2106
OIL PRESSURE DROPS 2107
FUEL MIXES INTO ENGINE OIL 2108
WATER MIXES INTO ENGINE OIL (MILKY) 2109
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2110
THERE IS AN UNUSUAL NOISE 2111
VIBRATION IS EXCESSIVE 2113
AIR CANNOT BE BLED FROM FUEL CIRCUIT 2114
ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2115
ACTIVE REGENERATION TAKES LONG 2116
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2117
AdBlue/DEF CONSUMPTION IS EXCESSIVE 2118
THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2120
FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2121
50 DISASSEMBLY AND ASSEMBLY 2123
CONTENTS 2124
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2130
HOW TO READ THIS MANUAL 2130
COATING MATERIALS LIST 2132
SPECIAL TOOLS LIST 2136
SKETCHES OF SPECIAL TOOLS 2155
PREPARATION 2158
DRAIN AND ADD COOLANT 2158
DRAIN COOLANT 2159
ADD COOLANT 2160
DRAIN AND ADD HYDRAULIC OIL 2162
DRAIN HYDRAULIC OIL 2163
ADD HYDRAULIC OIL 2164
DRAIN AND ADD FUEL 2167
DRAIN FUEL 2167
ADD FUEL 2168
COLLECT AND REFILL REFRIGERANT 2170
COLLECT REFRIGERANT 2171
REFILL REFRIGERANT 2171
ENGINE AND COOLING SYSTEM 2173
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS NOT REMOVED) 2173
REMOVE SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS NOT REMOVED) 2174
INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS NOT REMOVED) 2181
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS REMOVED) 2189
REMOVE SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS REMOVED) 2190
INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS REMOVED) 2193
REMOVE AND INSTALL INJECTOR ASSEMBLY 2197
REMOVE INJECTOR ASSEMBLY 2198
INSTALL INJECTOR ASSEMBLY 2212
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2228
REMOVE CYLINDER HEAD ASSEMBLY 2230
INSTALL CYLINDER HEAD ASSEMBLY 2258
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2292
REMOVE EGR VALVE ASSEMBLY 2292
INSTALL EGR VALVE ASSEMBLY 2295
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2300
REMOVE EGR COOLER ASSEMBLY 2301
INSTALL EGR COOLER ASSEMBLY 2305
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2310
REMOVE STARTING MOTOR ASSEMBLY 2311
INSTALL STARTING MOTOR ASSEMBLY 2318
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT 2326
REMOVE AIR CONDITIONER COMPRESSOR BELT 2327
INSTALL AIR CONDITIONER COMPRESSOR BELT 2328
REMOVE AND INSTALL ALTERNATOR BELT 2330
METHOD FOR REMOVING ALTERNATOR BELT 2330
METHOD FOR INSTALLING ALTERNATOR BELT 2332
REMOVE AND INSTALL AUTOMATIC TENSIONER 2334
METHOD FOR REMOVING AUTOMATIC TENSIONER 2334
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2334
REMOVE AND INSTALL RADIATOR ASSEMBLY 2335
REMOVE RADIATOR ASSEMBLY 2336
INSTALL RADIATOR ASSEMBLY 2339
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2344
REMOVE HYDRAULIC OIL COOLER ASSEMBLY 2344
INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2347
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2350
REMOVE AFTERCOOLER ASSEMBLY 2350
INSTALL AFTERCOOLER ASSEMBLY 2352
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2354
REMOVE FAN CLUTCH ASSEMBLY 2355
INSTALL FAN CLUTCH ASSEMBLY 2363
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2375
REMOVE ENGINE AND MAIN PUMP ASSEMBLY 2377
INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2410
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2445
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2445
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2446
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2448
REMOVE ENGINE REAR OIL SEAL 2449
INSTALL ENGINE REAR OIL SEAL 2450
REMOVE AND INSTALL FUEL COOLER ASSEMBLY 2454
REMOVE FUEL COOLER ASSEMBLY 2455
INSTALL FUEL COOLER ASSEMBLY 2456
REMOVE AND INSTALL KDPF ASSEMBLY 2457
REMOVE KDPF ASSEMBLY 2458
INSTALL KDPF ASSEMBLY 2460
DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY 2464
DISASSEMBLE KDPF ASSEMBLY 2466
ASSEMBLE KDPF ASSEMBLY 2471
REMOVE AND INSTALL KDPF AND SCR ASSEMBLY 2478
REMOVE KDPF AND SCR ASSEMBLY 2479
INSTALL KDPF AND SCR ASSEMBLY 2492
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2506
REMOVE FUEL TANK ASSEMBLY 2507
INSTALL FUEL TANK ASSEMBLY 2524
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2541
REMOVE AdBlue/DEF TANK ASSEMBLY 2542
INSTALL AdBlue/DEF TANK ASSEMBLY 2550
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2557
REMOVE AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2558
INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2565
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2573
REMOVE AdBlue/DEF TANK SENSOR 2573
INSTALL AdBlue/DEF TANK SENSOR 2574
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2581
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2581
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2581
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2582
REMOVE AdBlue/DEF TANK FILLER PORT FILTER 2583
INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2584
REMOVE AND INSTALL SCR ASSEMBLY 2587
REMOVE SCR ASSEMBLY 2588
INSTALL SCR ASSEMBLY 2593
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 2599
REMOVE BELLOWS PIPE ASSEMBLY 2600
INSTALL BELLOWS PIPE ASSEMBLY 2604
REMOVE AND INSTALL KCCV ASSEMBLY 2609
REMOVE KCCV ASSEMBLY 2610
INSTALL KCCV ASSEMBLY 2612
REMOVE AND INSTALL EXHAUST THROTTLE VALVE 2616
REMOVE EXHAUST THROTTLE VALVE 2617
INSTALL EXHAUST THROTTLE VALVE 2626
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2636
REMOVE AdBlue/DEF MIXING TUBE 2637
INSTALL AdBlue/DEF MIXING TUBE 2646
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2656
REMOVE AdBlue/DEF INJECTOR 2657
INSTALL AdBlue/DEF INJECTOR 2661
REMOVE AND INSTALL AdBlue/DEF PUMP 2666
REMOVE AdBlue/DEF PUMP 2667
INSTALL AdBlue/DEF PUMP 2672
REMOVE AND INSTALL AdBlue/DEF HOSE 2677
REMOVE AdBlue/DEF HOSE 2678
INSTALL AdBlue/DEF HOSE 2689
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2699
REMOVE AIR CLEANER ASSEMBLY 2700
INSTALL AIR CLEANER ASSEMBLY 2703
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2708
REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY 2708
INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2710
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2712
REMOVE AIR CONDITIONER CONDENSER ASSEMBLY 2712
INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2714
POWER TRAIN 2717
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2717
REMOVE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2718
INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2721
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2724
DISASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2735
ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2753
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2773
REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY 2774
INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2777
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2780
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 2780
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2783
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2790
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 2790
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 2791
UNDERCARRIAGE AND FRAME 2792
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2792
METHOD FOR SEPARATING TRACK ASSEMBLY 2792
METHOD FOR INSTALLING TRACK ASSEMBLY 2794
REMOVE AND INSTALL SPROCKET 2797
METHOD FOR REMOVING SPROCKET 2797
METHOD FOR INSTALLING SPROCKET 2797
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2799
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2799
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2799
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2801
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2801
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2802
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2806
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 2806
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2808
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2811
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2811
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2813
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2816
REMOVE REVOLVING FRAME ASSEMBLY 2817
INSTALL REVOLVING FRAME ASSEMBLY 2820
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2823
REMOVE COUNTERWEIGHT ASSEMBLY 2824
INSTALL COUNTERWEIGHT ASSEMBLY 2835
HYDRAULIC SYSTEM 2849
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2849
REMOVE CENTER SWIVEL JOINT ASSEMBLY 2850
INSTALL CENTER SWIVEL JOINT ASSEMBLY 2855
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2861
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2861
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2862
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2863
REMOVE HYDRAULIC TANK ASSEMBLY 2865
INSTALL HYDRAULIC TANK ASSEMBLY 2873
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 2883
REMOVE MAIN PUMP ASSEMBLY 2884
INSTALL MAIN PUMP ASSEMBLY 2892
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2900
REMOVE CONTROL VALVE ASSEMBLY 2902
INSTALL CONTROL VALVE ASSEMBLY 2922
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 2941
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2941
METHOD FOR REPLACING PRESSURE REDUCING VALVE CARTRIDGE ASSEMBLY 2944
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2947
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2947
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2948
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2950
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2950
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2950
WORK EQUIPMENT 2952
REMOVE AND INSTALL BLADE ASSEMBLY 2952
METHOD FOR REMOVING BLADE ASSEMBLY 2952
METHOD FOR INSTALLING BLADE ASSEMBLY 2953
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2955
REMOVE WORK EQUIPMENT ASSEMBLY 2957
INSTALL WORK EQUIPMENT ASSEMBLY 2965
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2975
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2976
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2978
CAB AND ITS ATTACHMENTS 2985
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2985
REMOVE OPERATOR CAB ASSEMBLY 2985
INSTALL OPERATOR CAB ASSEMBLY 2990
REMOVE AND INSTALL OPERATOR’S CAB DOOR 2995
METHOD FOR INSTALLING OPERATOR’S CAB DOOR 2995
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 2999
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 3000
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 3001
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 3010
REMOVE FRONT WINDOW ASSEMBLY 3010
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 3013
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 3014
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 3014
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 3024
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 3035
REMOVE AIR CONDITIONER UNIT ASSEMBLY 3036
INSTALL AIR CONDITIONER UNIT ASSEMBLY 3045
REMOVE AND INSTALL OPERATOR’S SEAT 3055
REMOVE OPERATOR’S SEAT 3055
INSTALL OPERATOR’S SEAT 3058
REMOVE AND INSTALL SEATBELT 3061
REMOVE SEATBELT 3062
INSTALL SEATBELT 3063
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 3064
REMOVE FRONT WIPER ASSEMBLY 3064
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 3069
ELECTRICAL SYSTEM 3077
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3077
REMOVE ENGINE CONTROLLER ASSEMBLY 3078
INSTALL ENGINE CONTROLLER ASSEMBLY 3080
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 3082
REMOVE PUMP CONTROLLER ASSEMBLY 3082
INSTALL PUMP CONTROLLER ASSEMBLY 3085
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 3089
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY 3089
METHOD FOR INSTALLING KomVision CONTROLLER ASSEMBLY 3091
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3093
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 3093
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 3096
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3100
REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR 3101
INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3102
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3103
REMOVE KCCV CRANKCASE PRESSURE SENSOR 3104
INSTALL KCCV CRANKCASE PRESSURE SENSOR 3106
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR 3109
REMOVE KDPF TEMPERATURE SENSOR 3111
INSTALL KDPF TEMPERATURE SENSOR 3114
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR 3118
REMOVE KDPF DIFFERENTIAL PRESSURE SENSOR 3120
INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR 3122
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 3126
REMOVE SCR TEMPERATURE SENSOR 3127
INSTALL SCR TEMPERATURE SENSOR 3131
REMOVE AND INSTALL TURBOCHARGER OUTLET NOx SENSOR 3135
REMOVE TURBOCHARGER OUTLET NOx SENSOR 3136
INSTALL TURBOCHARGER OUTLET NOx SENSOR 3139
REMOVE AND INSTALL SCR OUTLET NOx SENSOR 3142
REMOVE SCR OUTLET NOx SENSOR 3143
INSTALL SCR OUTLET NOx SENSOR 3146
REMOVE AND INSTALL AMMONIA SENSOR 3149
REMOVE AMMONIA SENSOR 3150
INSTALL AMMONIA SENSOR 3152
REMOVE AND INSTALL KomVision CAMERA 3154
REMOVE KomVision CAMERA 3155
INSTALL KomVision CAMERA 3160
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 3167
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 3167
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 3170
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 3173
REMOVE COMMUNICATION TERMINAL WIRING HARNESS 3173
INSTALL COMMUNICATION TERMINAL WIRING HARNESS 3177
REMOVE AND INSTALL COMMUNICATION TERMINAL 3183
REMOVE COMMUNICATION TERMINAL 3183
INSTALL COMMUNICATION TERMINAL 3184
60 MAINTENANCE STANDARD 3187
CONTENTS 3188
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 3189
ENGINE AND COOLING SYSTEM 3191
MAINTENANCE STANDARD OF ENGINE MOUNT 3191
MAINTENANCE STANDARD FOR PTO 3192
MAINTENANCE STANDARD OF COOLING SYSTEM 3193
POWER TRAIN 3194
MAINTENANCE STANDARD OF SWING CIRCLE 3194
MAINTENANCE STANDARD OF SWING MACHINERY 3195
MAINTENANCE STANDARD OF SPROCKET 3197
UNDERCARRIAGE AND FRAME 3198
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 3198
MAINTENANCE STANDARD OF IDLER 3200
MAINTENANCE STANDARD OF TRACK ROLLER 3201
MAINTENANCE STANDARD OF CARRIER ROLLER 3202
MAINTENANCE STANDARD OF TRACK SHOE 3203
MAINTENANCE STANDARD OF TRIPLE SHOE 3206
MAINTENANCE STANDARD OF ROAD LINER 3207
HYDRAULIC SYSTEM 3208
MAINTENANCE STANDARD OF HYDRAULIC TANK 3208
MAINTENANCE STANDARD OF MAIN PUMP 3209
MAINTENANCE STANDARD OF PC-EPC VALVE 3213
MAINTENANCE STANDARD OF SWING MOTOR 3214
MAINTENANCE STANDARD OF TRAVEL MOTOR 3217
MAINTENANCE STANDARD OF CONTROL VALVE 3218
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 3229
MAINTENANCE STANDARD OF BLADE PPC VALVE 3232
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 3234
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 3237
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 3239
MAINTENANCE STANDARD OF SOLENOID VALVE 3240
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE SOLENOID VALVE 3242
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 3243
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) 3244
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 3245
WORK EQUIPMENT 3246
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 3246
DIMENSION OF ARM 3251
DIMENSIONS OF BUCKET 3253
MAINTENANCE STANDARD OF BOOM CYLINDER 3255
MAINTENANCE STANDARD OF ARM CYLINDER 3256
MAINTENANCE STANDARD OF BUCKET CYLINDER 3257
MAINTENANCE STANDARD OF BLADE CYLINDER 3258
CAB AND ITS ATTACHMENTS 3259
MAINTENANCE STANDARD OF CAB MOUNT 3259
80 APPENDIX 3261
CONTENTS 3262
AIR CONDITIONER SYSTEM 3264
PRECAUTIONS FOR REFRIGERANT 3264
AIR CONDITIONER COMPONENT 3265
SPECIFICATIONS OF AIR CONDITIONER 3267
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3268
OUTLINE OF REFRIGERATION CYCLE 3269
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3271
AIR CONDITIONER UNIT 3271
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3271
FUNCTION OF AIR CONDITIONER UNIT 3273
COMPONENT PARTS OF AIR CONDITIONER UNIT 3274
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3274
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3274
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3274
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3275
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3276
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3276
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3276
FUNCTION OF DUAL PRESSURE SWITCH 3277
AIR CONDITIONER CONTROLLER 3278
STRUCTURE OF AIR CONDITIONER CONTROLLER 3278
COMPRESSOR 3279
STRUCTURE OF COMPRESSOR 3279
SPECIFICATIONS OF COMPRESSOR 3279
FUNCTION OF COMPRESSOR 3279
CONDENSER 3280
STRUCTURE OF CONDENSER 3280
SPECIFICATIONS OF CONDENSER 3280
FUNCTION OF CONDENSER 3280
SENSORS FOR AIR CONDITIONER SYSTEM 3282
STRUCTURE OF SUNLIGHT SENSOR 3282
FUNCTION OF SUNLIGHT SENSOR 3282
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 3282
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3282
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3284
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3286
AIR CONDITIONER SYSTEM DIAGRAM 3288
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3289
FUNCTION OF AIR CONDITIONER CONTROLLER 3290
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3291
TESTING AIR LEAKAGE (DUCT) 3300
METHOD FOR TESTING AIR LEAKAGE (DUCT) 3300
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3302
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3303
TEST VENT (MODE) CHANGEOVER 3304
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3304
TESTING FRESH/RECIRC AIR CHANGEOVER 3305
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3305
TEST SUNLIGHT SENSOR 3306
METHOD FOR TESTING SUNLIGHT SENSOR 3306
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3307
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3307
TEST RELAYS 3309
METHOD FOR TESTING RELAYS 3309
AIR CONDITIONER TROUBLESHOOTING CHART 1 3310
AIR CONDITIONER TROUBLESHOOTING CHART 2 3311
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3314
FAILURE CODE [879AKA] 3316
FAILURE CODE [879AKB] 3318
FAILURE CODE [879BKA] 3320
FAILURE CODE [879BKB] 3322
FAILURE CODE [879CKA] 3324
FAILURE CODE [879CKB] 3325
FAILURE CODE [879DKZ] 3326
FAILURE CODE [879EMC] 3329
FAILURE CODE [879FMC] 3330
FAILURE CODE [879GKX] 3331
TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3333
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3335
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3338
TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3340
TROUBLESHOOTING USING GAUGE PRESSURE 3342
CONNECTION OF SERVICE TOOL 3344
METHOD FOR CONNECTING SERVICE TOOL 3344
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3346
HANDLE COMPRESSOR OIL 3348
METHOD FOR REPLACING DESICCANT 3350
90 CIRCUIT DIAGRAMS 3353
CONTENTS 3354
HOW TO READ THE CODES FOR ELECTRIC CABLE 3355
HYDRAULIC CIRCUIT DIAGRAM 3359
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3359
HYDRAULIC CIRCUIT DIAGRAM (BLADE LESS SPECIFICATION, MACHINE WITH 2ND-LINE ATTACHMENT IS INSTALLABLE) 3363
HYDRAULIC CIRCUIT DIAGRAM (BLADE SPECIFICATION, MACHINE WITH 2ND-LINE ATTACHMENT IS INSTALLABLE) 3365
HYDRAULIC CIRCUIT DIAGRAM (2-PIECE BOOM SPECIFICATION, MACHINE WITH 2ND-LINE ATTACHMENT IS INSTALLABLE) 3367
HYDRAULIC CIRCUIT DIAGRAM (MACHINE WITH TOOL CONTROL SYSTEM) 3369
ELECTRICAL CIRCUIT DIAGRAM 3371
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3371
ELECTRICAL CIRCUIT DIAGRAM (1/11) 3375
ELECTRICAL CIRCUIT DIAGRAM (2/11) 3377
ELECTRICAL CIRCUIT DIAGRAM (3/11) 3379
ELECTRICAL CIRCUIT DIAGRAM (4/11) 3381
ELECTRICAL CIRCUIT DIAGRAM (5/11) 3383
ELECTRICAL CIRCUIT DIAGRAM (6/11) 3385
ELECTRICAL CIRCUIT DIAGRAM (7/11) 3387
ELECTRICAL CIRCUIT DIAGRAM (8/11) 3389
ELECTRICAL CIRCUIT DIAGRAM (9/11) 3391
ELECTRICAL CIRCUIT DIAGRAM (10/11) 3393
ELECTRICAL CIRCUIT DIAGRAM (11/11) 3395
INDEX 3397
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