Komatsu Hydraulic Excavator PC130-11 Shop Manual SEN06804-05 PDF
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Komatsu Hydraulic Excavator PC130-11 Shop Manual SEN06804-05 – PDF DOWNLOAD
SERIAL NUMBERS 90001 and up
Description
Komatsu Hydraulic Excavator PC130-11 Shop Manual SEN06804-05 – PDF DOWNLOAD
FILE DETAILS:
Komatsu Hydraulic Excavator PC130-11 Shop Manual SEN06804-05 – PDF DOWNLOAD
Language : English
Pages :2900
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
Komatsu Hydraulic Excavator PC130-11 Shop Manual SEN06804-05 – PDF DOWNLOAD
SERIAL NUMBERS 90001 and up
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.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the
same as the terminology in the 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 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effectively.
TABLE OF CONTENTS:
Komatsu Hydraulic Excavator PC130-11 Shop Manual SEN06804-05 – PDF DOWNLOAD
SERIAL NUMBERS 90001 and up
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: PC130-11 93
WORKING RANGE DRAWINGS 95
WORKING RANGE DRAWINGS: PC130-11 95
SPECIFICATIONS 96
SPECIFICATIONS: PC130-11 96
WEIGHT TABLE 99
WEIGHT TABLE: PC130-11 99
FUEL, COOLANT, LUBRICANT 101
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 101
10 STRUCTURE AND FUNCTION 103
CONTENTS 104
UREA SCR SYSTEM 107
LAYOUT DRAWING OF UREA SCR SYSTEM 107
UREA SCR SYSTEM DIAGRAM 110
FUNCTION OF UREA SCR SYSTEM 111
FUNCTION OF AdBlue/DEF SYSTEM (SERIAL NO: 90001 TO 92188) 111
FUNCTION OF AdBlue/DEF SYSTEM (SERIAL NO: 92189 AND UP) 113
INDUCEMENT STRATEGY 115
FUNCTION THAT CALLS FOR ATTENTION OF THE OPERATOR FOR UREA SCR SYSTEM TO STAY FUNCTIONAL 115
COMPONENT PARTS OF UREA SCR SYSTEM 123
AdBlue/DEF MIXING TUBE 123
SCR ASSEMBLY 123
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 (SERIAL NO: 90001 TO 92188) 132
LAYOUT DRAWING OF BOOT-UP SYSTEM (SERIAL NO: 92189 AND UP) 133
SYSTEM OPERATING LAMP SYSTEM 134
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 134
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (SERIAL NO: 90001 TO 92188) 134
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (SERIAL NO: 92189 AND UP) 135
BATTERY DISCONNECT SWITCH 136
FUNCTION OF BATTERY DISCONNECT SWITCH (SERIAL NO: 90001 TO 92188) 136
FUNCTION OF BATTERY DISCONNECT SWITCH (SERIAL NO: 92189 AND UP) 136
ENGINE SYSTEM 138
LAYOUT DRAWING OF ENGINE SYSTEM 138
ENGINE CONTROL SYSTEM 140
ENGINE CONTROL SYSTEM DIAGRAM 140
FUNCTION OF ENGINE CONTROL SYSTEM 141
AUTO-DECELERATION SYSTEM 143
SYSTEM DIAGRAM OF AUTO-DECELERATION SYSTEM 143
FUNCTION OF AUTO-DECELERATION SYSTEM 143
OPERATION OF AUTO-DECELERATION SYSTEM 144
ENGINE AUTOMATIC WARM-UP SYSTEM 145
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 145
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 145
OVERHEAT PREVENTION SYSTEM 147
FUNCTION OF OVERHEAT PREVENTION SYSTEM 147
TURBOCHARGER PROTECTION SYSTEM 149
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 149
AUTOMATIC IDLE STOP SYSTEM 150
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 150
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 150
COMPONENT PARTS OF ENGINE SYSTEM 153
PTO 153
VARIABLE FLOW TURBOCHARGER 153
EGR SYSTEM 157
EGR VALVE 159
EGR COOLER 160
KCCV SYSTEM 162
KCCV VENTILATOR 164
EXHAUST THROTTLE VALVE 166
KDOC 166
COOLING SYSTEM 170
LAYOUT DRAWING OF COOLING SYSTEM 170
SPECIFICATIONS OF COOLING SYSTEM 171
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 172
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 172
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 173
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 174
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 174
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 174
COMPONENT PARTS OF COOLING SYSTEM 176
FAN CLUTCH 176
CONTROL SYSTEM 177
LAYOUT DRAWING OF CONTROL SYSTEM 177
MACHINE MONITOR SYSTEM 179
MACHINE MONITOR SYSTEM DIAGRAM 179
FUNCTION OF MACHINE MONITOR SYSTEM 179
KomVision SYSTEM 181
LAYOUT DRAWING OF KomVision SYSTEM 181
SYSTEM DIAGRAM OF KomVision SYSTEM 182
FUNCTION OF KomVision SYSTEM 182
KOMTRAX SYSTEM 184
SYSTEM DIAGRAM OF KOMTRAX SYSTEM 184
FUNCTION OF KOMTRAX SYSTEM 184
COMPONENT PARTS OF CONTROL SYSTEM 185
MACHINE MONITOR 185
KomVision CONTROLLER 198
KomVision CAMERA 202
GATEWAY FUNCTION CONTROLLER 203
COMMUNICATION TERMINAL 206
PUMP CONTROLLER 207
RESISTOR FOR PC-EPC VALVE 211
CAN TERMINATING RESISTOR 211
ENGINE CONTROLLER 213
FUEL CONTROL DIAL 219
HYDRAULIC SYSTEM 221
LAYOUT DRAWING OF HYDRAULIC SYSTEM 221
CLSS 223
STRUCTURE OF CLSS 223
FUNCTION OF CLSS 224
ENGINE AND PUMP COMBINED CONTROL SYSTEM 226
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 226
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 227
COMPONENT PARTS OF HYDRAULIC SYSTEM 231
HYDRAULIC TANK 231
MAIN PUMP 233
CONTROL VALVE 257
WORK EQUIPMENT SYSTEM 318
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 318
STRUCTURE OF VALVE CONTROL 320
PPC LOCK SYSTEM 321
SYSTEM DIAGRAM OF PPC LOCK SYSTEM 321
FUNCTION OF PPC LOCK SYSTEM 321
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 322
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 322
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 322
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 323
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 324
WORK EQUIPMENT AND SWING PPC VALVE 324
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 328
SOLENOID VALVE 335
VARIABLE BACK PRESSURE SOLENOID VALVE 339
MULTI-CONTROL VALVE 340
ARM DUMP QUICK RETURN VALVE 341
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE 342
PILOT CIRCUIT ACCUMULATOR 345
ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) 346
SWING SYSTEM 348
LAYOUT DRAWING OF SWING SYSTEM 348
SWING CONTROL SYSTEM DIAGRAM 350
FUNCTION OF SWING CONTROL SYSTEM 350
COMPONENT PARTS OF SWING SYSTEM 353
SWING MOTOR 353
SWING MACHINERY 361
SWING CIRCLE 362
TRAVEL SYSTEM 364
LAYOUT DRAWING OF TRAVEL SYSTEM 364
SYSTEM DIAGRAM OF TRAVEL CONTROL SYSTEM 366
FUNCTION OF TRAVEL CONTROL SYSTEM 366
COMPONENT PARTS OF TRAVEL SYSTEM 370
TRAVEL MOTOR 370
TRAVEL PPC VALVE 380
CENTER SWIVEL JOINT 384
UNDERCARRIAGE AND FRAME 386
LAYOUT DRAWING OF UNDERCARRIAGE 386
SPECIFICATIONS OF UNDERCARRIAGE 386
IDLER CUSHION 387
STRUCTURE OF IDLER CUSHION 387
SPECIFICATIONS OF IDLER CUSHION 387
WORK EQUIPMENT 388
STRUCTURE OF WORK EQUIPMENT 388
FUNCTION OF WORK EQUIPMENT 389
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 390
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 390
BUCKET CLEARANCE ADJUSTMENT SHIM 391
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 391
CAB AND ITS ATTACHMENTS 392
ROPS CAB 392
STRUCTURE OF ROPS CAB 392
FUNCTION OF ROPS CAB 392
CAB MOUNT 393
STRUCTURE OF CAB MOUNT 393
FUNCTION OF CAB MOUNT 393
CAB TIPPING STOPPER 394
STRUCTURE OF CAB TIPPING STOPPER 394
FUNCTION OF CAB TIPPING STOPPER 394
20 STANDARD VALUE TABLE 395
CONTENTS 396
STANDARD VALUE TABLE FOR ENGINE 397
STANDARD VALUE TABLE FOR ENGINE: PC130-11 397
STANDARD VALUE TABLE FOR MACHINE 400
STANDARD VALUE TABLE FOR MACHINE: PC130-11 400
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE 414
30 TESTING AND ADJUSTING 419
CONTENTS 420
RELATED INFORMATION ON TESTING AND ADJUSTING 423
TOOLS FOR TESTING AND ADJUSTING 423
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 430
ENGINE AND COOLING SYSTEM 432
TEST ENGINE SPEED 432
TEST ENGINE SPEED 432
TEST EXHAUST GAS COLOR 435
TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 435
TEST EXHAUST GAS COLOR BY SMOKE METER 436
TEST THE CLEARANCE OF THE EXHAUST THROTTLE VALVE 437
MEASURE CLEARANCE OF THE EXHAUST THROTTLE VALVE 437
TEST AND ADJUST VALVE CLEARANCE 439
TEST VALVE CLEARANCE 439
METHOD FOR ADJUSTING VALVE CLEARANCE 440
TEST COMPRESSION PRESSURE 441
TEST COMPRESSION PRESSURE 441
TEST BLOWBY PRESSURE 444
TEST BLOWBY PRESSURE 444
TEST ENGINE OIL PRESSURE 446
TEST ENGINE OIL PRESSURE 446
VISUAL CHECK INSIDE OF EGR VALVE 447
VISUAL CHECK INSIDE OF EGR VALVE 447
CLEAN INSIDE OF EGR VALVE 449
CLEAN INSIDE OF EGR VALVE 449
TEST FUEL PRESSURE 452
TEST FUEL PRESSURE 452
TEST FUEL RETURN RATE AND LEAKAGE 454
TEST FUEL RETURN RATE AND LEAKAGE 455
BLEED AIR FROM FUEL SYSTEM 458
BLEED AIR FROM FUEL SYSTEM 458
TEST FUEL CIRCUIT FOR LEAKAGE 460
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 460
HANDLE CYLINDER CUT-OUT MODE OPERATION 462
HANDLE NO-INJECTION CRANKING OPERATION 463
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 464
CHECK AIR CONDITIONER COMPRESSOR BELT 464
ADJUST AIR CONDITIONER COMPRESSOR BELT 464
TEST ALTERNATOR BELT 466
TEST ALTERNATOR BELT TENSION 466
TEST AUTOMATIC TENSIONER 467
TEST AUTOMATIC TENSIONER 467
TEST COOLING FAN SPEED 469
METHOD FOR TESTING COOLING FAN SPEED 469
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 470
WRITE INJECTOR COMPENSATION VALUE 470
TEST SCR RELATED FUNCTIONS 476
TEST AdBlue/DEF PUMP RAISED PRESSURE 480
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 483
TEST AdBlue/DEF LINE HEATER RELAY 1 488
TEST AdBlue/DEF LINE HEATER RELAY 2 492
TEST AdBlue/DEF PUMP HEATER RELAY 496
TEST AdBlue/DEF TANK HEATER VALVE 500
TEST DENITRATION EFFICIENCY OF SCR 504
CLEAN AdBlue/DEF TANK 507
CLEAN AdBlue/DEF TANK 507
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 512
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 512
CLEAN AdBlue/DEF PUMP 514
CLEAN AdBlue/DEF PUMP 514
POWER TRAIN 520
TEST SWING CIRCLE BEARING CLEARANCE 520
TEST SWING CIRCLE BEARING CLEARANCE 520
UNDERCARRIAGE AND FRAME 521
TEST AND ADJUST TRACK TENSION 521
METHOD FOR TESTING TRACK TENSION 521
METHOD FOR ADJUSTING TRACK TENSION 521
HYDRAULIC SYSTEM 523
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 523
RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK 523
RELEASE REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 523
RELEASE REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 523
RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 524
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 525
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 525
ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 531
TEST OIL PRESSURE OF CONTROL CIRCUIT 533
TEST OIL PRESSURE OF CONTROL CIRCUIT 533
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 535
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 535
TEST PC-EPC VALVE OUTLET PRESSURE 536
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 537
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 539
TEST LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 539
TEST LS DIFFERENTIAL PRESSURE BY TESTING TOOL 541
TEST LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 542
METHOD FOR ADJUSTING LS VALVE 544
TEST OUTLET PRESSURE OF SOLENOID VALVE 545
METHOD FOR OUTLET PRESSURE OF SOLENOID VALVE 545
OPERATING CONDITION OF SOLENOID VALVE 546
VARIABLE BACK PRESSURE SOLENOID VALVE OUTLET PRESSURE 548
OPERATING CONDITION OF VARIABLE BACK PRESSURE SOLENOID VALVE 549
TEST OUTLET PRESSURE IN PPC VALVE 550
TEST OUTLET PRESSURE IN PPC VALVE 550
TEST ATTACHMENT CIRCUIT OIL PRESSURE 552
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 552
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 553
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 553
TEST AND ADJUST TRAVEL DEVIATION 554
TEST TRAVEL DEVIATION 554
METHOD FOR ADJUSTING TRAVEL DEVIATION 554
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 557
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 557
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 557
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 558
TEST OIL LEAKAGE 559
TEST OIL LEAKAGE FROM BOOM CYLINDER 559
TEST OIL LEAKAGE FROM ARM CYLINDER 559
TEST OIL LEAKAGE FROM BUCKET CYLINDER 560
TEST OIL LEAKAGE FROM SWING MOTOR 561
TEST OIL LEAKAGE FROM TRAVEL MOTOR 561
BLEED AIR FROM HYDRAULIC CIRCUIT 563
BLEED AIR FROM HYDRAULIC CIRCUIT 564
CAB RELATED PARTS 567
TEST CAB TIPPING STOPPER 567
METHOD FOR TESTING CAB TIPPING STOPPER 567
ADJUST MIRRORS 568
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 568
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 569
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 570
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 571
ADJUST MACHINE RIGHT SIDE MIRROR (C) 572
ELECTRICAL SYSTEM 573
SET AND OPERATE MACHINE MONITOR 573
OPERATOR MODE 577
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 577
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 577
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 578
CHECKING FUNCTION OF SERVICE METER 578
SET USAGE LIMITATION AND CHANGE MAINTENANCE PASSWORD 578
SERVICE MODE 581
SERVICE MODE 581
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 583
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 589
ABNORMALITY RECORD MENU 600
CHECK MAINTENANCE RECORD 604
METHOD FOR OPERATING MAINTENANCE MODE SETTING 605
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 609
DEFAULT MENU 611
DIAGNOSTIC TESTS MENU 618
ADJUSTMENT MENU 627
METHOD FOR PERFORMING NO-INJECTION CRANKING 639
KOMTRAX SETTINGS MENU 641
METHOD FOR DISPLAYING SERVICE MESSAGE 643
START UP KOMTRAX SYSTEM 645
STOP USING OF KOMTRAX SYSTEM 651
ADJUST REARVIEW CAMERA ANGLE 653
ADJUST REARVIEW CAMERA ANGLE 653
ADJUST KomVision CAMERA ANGLE 656
Angle adjustment method for KomVision camera 657
ADJUST KomVision RELATED FUNCTION 659
SETTING OF KomVision (MAIN SETTING) 659
SETTING OF KomVision (CAMERA SETTING) 662
SETTING OF KomVision (CAMERA CALIBRATION) 663
SET REGION OF Bluetooth(R) COMPATIBLE RADIO 677
SET REGION OF Bluetooth(R) COMPATIBLE RADIO 677
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 679
HANDLE BATTERY DISCONNECT SWITCH 680
TEST DIODES 681
METHOD FOR TESTING DIODE USING DIGITAL TESTER 681
METHOD FOR TESTING DIODE USING ANALOG TESTER 681
Pm-CLINIC 682
Pm CLINIC SERVICE 682
Pm CLINIC CHECK SHEET: PC130-11 684
40 TROUBLESHOOTING 693
CONTENTS 694
RELATED INFORMATION ON TROUBLESHOOTING 704
GENERAL TROUBLESHOOTING POINTS 704
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 705
SEQUENCE OF EVENTS IN TROUBLESHOOTING 717
CHECKS BEFORE TROUBLESHOOTING 719
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 721
WALK-AROUND CHECK 721
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 723
CHECK OF FUEL LEVEL AND TYPE 723
CHECK FUEL PREFILTER 724
CHECK WATER SEPARATOR, DRAIN WATER AND SEDIMENT 724
REPLACE FUEL PREFILTER CARTRIDGE 724
CHECK FUEL MAIN FILTER 726
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 727
CHECK OIL LEVEL IN PTO GEAR CASE 728
CHECK COOLANT LEVEL (RESERVOIR TANK) 729
CHECK CLOGGING OF AIR CLEANER 730
CLEAN OUTER ELEMENT 730
REPLACE ELEMENT 733
CHECK HYDRAULIC OIL LEVEL 734
CHECK HYDRAULIC OIL STRAINER 736
CHECK HYDRAULIC OIL FILTER 737
CHECK OF OIL LEVEL IN SWING MACHINERY CASE 738
CHECK OIL LEVEL IN FINAL DRIVE CASE 739
BLEED AIR FROM FUEL SYSTEM 739
BLEED AIR FROM HYDRAULIC SYSTEM 739
CHECK ELECTRIC EQUIPMENT 740
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 745
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 745
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 745
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 746
PREPARATION FOR TROUBLESHOOTING OF GATEWAY FUNCTION CONTROLLER 746
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 746
PROCEDURE FOR TESTING AND TROUBLESHOOTING 751
SYMPTOM AND TROUBLESHOOTING NUMBERS 754
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 758
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 760
CONNECTOR LIST AND LAYOUT 763
CONNECTOR CONTACT IDENTIFICATION 776
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 818
FUSE LOCATION TABLE 824
PRECAUTIONS FOR REPLACING KDOC 827
FAILURE CODE TABLE 828
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 844
FAILURE CODE [879AKA] 844
FAILURE CODE [879AKB] 845
FAILURE CODE [879BKA] 846
FAILURE CODE [879BKB] 848
FAILURE CODE [879CKA] 850
FAILURE CODE [879CKB] 851
FAILURE CODE [879DKZ] 852
FAILURE CODE [879EMC] 854
FAILURE CODE [879FMC] 855
FAILURE CODE [879GKX] 856
FAILURE CODE [989L00] 858
FAILURE CODE [989M00] 859
FAILURE CODE [989N00] 860
FAILURE CODE [A1U0N3] 861
FAILURE CODE [A1U0N4] 863
FAILURE CODE [A900FR] 865
FAILURE CODE [A900N6] 866
FAILURE CODE [A900NY] 867
FAILURE CODE [AA10NX] 868
FAILURE CODE [AB00KE] 870
FAILURE CODE [AQ10MB] 872
FAILURE CODE [AQ10N3] 874
FAILURE CODE [AS00R2] 875
FAILURE CODE [AS00R3] 876
FAILURE CODE [AS00R4] 877
FAILURE CODE [AS00R5] 878
FAILURE CODE [AS00R6] 879
FAILURE CODE [AS00ZK] 880
FAILURE CODE [AS10KM] 881
FAILURE CODE [AS10NR] 882
FAILURE CODE [AS10NT] 883
FAILURE CODE [AU10QA] 884
FAILURE CODE [B@BAZG] 885
FAILURE CODE [B@BAZK] 886
FAILURE CODE [B@BCNS] 888
FAILURE CODE [B@BCZK] 889
FAILURE CODE [B@HANS] 891
FAILURE CODE [CA115] 893
FAILURE CODE [CA122] 894
FAILURE CODE [CA123] 896
FAILURE CODE [CA131] 898
FAILURE CODE [CA132] 900
FAILURE CODE [CA144] 902
FAILURE CODE [CA145] 904
FAILURE CODE [CA153] 906
FAILURE CODE [CA154] 909
FAILURE CODE [CA187] 912
FAILURE CODE [CA221] 914
FAILURE CODE [CA222] 916
FAILURE CODE [CA227] 918
FAILURE CODE [CA234] 919
FAILURE CODE [CA238] 920
FAILURE CODE [CA239] 922
FAILURE CODE [CA249] 924
FAILURE CODE [CA256] 926
FAILURE CODE [CA271] 928
FAILURE CODE [CA272] 930
FAILURE CODE [CA322] 932
FAILURE CODE [CA324] 934
FAILURE CODE [CA331] 936
FAILURE CODE [CA332] 938
FAILURE CODE [CA343] 940
FAILURE CODE [CA351] 941
FAILURE CODE [CA352] 942
FAILURE CODE [CA356] 945
FAILURE CODE [CA357] 947
FAILURE CODE [CA386] 949
FAILURE CODE [CA435] 950
FAILURE CODE [CA441] 952
FAILURE CODE [CA442] 955
FAILURE CODE [CA449] 956
FAILURE CODE [CA451] 957
FAILURE CODE [CA452] 959
FAILURE CODE [CA515] 961
FAILURE CODE [CA516] 963
FAILURE CODE [CA553] 965
FAILURE CODE [CA555] 966
FAILURE CODE [CA556] 967
FAILURE CODE [CA559] 968
FAILURE CODE [CA689] 972
FAILURE CODE [CA691] 975
FAILURE CODE [CA692] 977
FAILURE CODE [CA697] 979
FAILURE CODE [CA698] 980
FAILURE CODE [CA731] 981
FAILURE CODE [CA778] 983
FAILURE CODE [CA1117] 988
FAILURE CODE [CA1664] 989
FAILURE CODE [CA1669] 991
FAILURE CODE [CA1673] 992
FAILURE CODE [CA1677] 993
FAILURE CODE [CA1678] 994
FAILURE CODE [CA1682] 995
FAILURE CODE [CA1683]1000
FAILURE CODE [CA1684]1002
FAILURE CODE [CA1686]1004
FAILURE CODE [CA1691]1005
FAILURE CODE [CA1694]1007
FAILURE CODE [CA1695]1009
FAILURE CODE [CA1696]1010
FAILURE CODE [CA1712]1012
FAILURE CODE [CA1713]1015
FAILURE CODE [CA1714]1018
FAILURE CODE [CA1715]1019
FAILURE CODE [CA1776]1020
FAILURE CODE [CA1777]1023
FAILURE CODE [CA1843]1026
FAILURE CODE [CA1844]1028
FAILURE CODE [CA1885]1031
FAILURE CODE [CA1887]1033
FAILURE CODE [CA1896]1035
FAILURE CODE [CA1938]1039
FAILURE CODE [CA1942]1041
FAILURE CODE [CA1961]1042
FAILURE CODE [CA2185]1043
FAILURE CODE [CA2186]1045
FAILURE CODE [CA2249]1047
FAILURE CODE [CA2272]1048
FAILURE CODE [CA2311]1051
FAILURE CODE [CA2349]1052
FAILURE CODE [CA2353]1054
FAILURE CODE [CA2357]1056
FAILURE CODE [CA2636]1057
FAILURE CODE [CA2637]1060
FAILURE CODE [CA2765]1062
FAILURE CODE [CA2771]1063
FAILURE CODE [CA2976]1069
FAILURE CODE [CA3142]1071
FAILURE CODE [CA3143]1072
FAILURE CODE [CA3144]1073
FAILURE CODE [CA3146]1075
FAILURE CODE [CA3147]1076
FAILURE CODE [CA3148]1077
FAILURE CODE [CA3151]1079
FAILURE CODE [CA3165]1085
FAILURE CODE [CA3229]1087
FAILURE CODE [CA3231]1089
FAILURE CODE [CA3232]1091
FAILURE CODE [CA3235]1095
FAILURE CODE [CA3239]1097
FAILURE CODE [CA3241]1100
FAILURE CODE [CA3242]1103
FAILURE CODE [CA3251]1106
FAILURE CODE [CA3313]1108
FAILURE CODE [CA3314]1109
FAILURE CODE [CA3315]1110
FAILURE CODE [CA3419]1112
FAILURE CODE [CA3421]1114
FAILURE CODE [CA3497]1116
FAILURE CODE [CA3498]1117
FAILURE CODE [CA3543]1118
FAILURE CODE [CA3545]1124
FAILURE CODE [CA3547]1126
FAILURE CODE [CA3558]1127
FAILURE CODE [CA3559]1129
FAILURE CODE [CA3562]1131
FAILURE CODE [CA3563]1133
FAILURE CODE [CA3567]1136
FAILURE CODE [CA3568]1140
FAILURE CODE [CA3571]1146
FAILURE CODE [CA3572]1148
FAILURE CODE [CA3574]1150
FAILURE CODE [CA3575]1153
FAILURE CODE [CA3577]1155
FAILURE CODE [CA3578]1157
FAILURE CODE [CA3582]1159
FAILURE CODE [CA3583]1167
FAILURE CODE [CA3596]1169
FAILURE CODE [CA3649]1173
FAILURE CODE [CA3681]1175
FAILURE CODE [CA3682]1180
FAILURE CODE [CA3713]1185
FAILURE CODE [CA3717]1188
FAILURE CODE [CA3718]1189
FAILURE CODE [CA3724]1190
FAILURE CODE [CA3725]1191
FAILURE CODE [CA3748]1194
FAILURE CODE [CA3755]1197
FAILURE CODE [CA3866]1200
FAILURE CODE [CA3867]1204
FAILURE CODE [CA3868]1207
FAILURE CODE [CA3899]1211
FAILURE CODE [CA3911]1213
FAILURE CODE [CA3912]1217
FAILURE CODE [CA3918]1219
FAILURE CODE [CA3921]1221
FAILURE CODE [CA3928]1222
FAILURE CODE [CA3932]1223
FAILURE CODE [CA3933]1225
FAILURE CODE [CA3934]1227
FAILURE CODE [CA3935]1230
FAILURE CODE [CA3936]1232
FAILURE CODE [CA4152]1234
FAILURE CODE [CA4155]1238
FAILURE CODE [CA4156]1241
FAILURE CODE [CA4157]1244
FAILURE CODE [CA4159]1246
FAILURE CODE [CA4164]1247
FAILURE CODE [CA4165]1249
FAILURE CODE [CA4166]1251
FAILURE CODE [CA4168]1253
FAILURE CODE [CA4169]1256
FAILURE CODE [CA4171]1258
FAILURE CODE [CA4249]1261
FAILURE CODE [CA4251]1263
FAILURE CODE [CA4261]1265
FAILURE CODE [CA4277]1268
FAILURE CODE [CA4281]1272
FAILURE CODE [CA4459]1276
FAILURE CODE [CA4461]1279
FAILURE CODE [CA4533]1282
FAILURE CODE [CA4534]1283
FAILURE CODE [CA4731]1284
FAILURE CODE [CA4732]1285
FAILURE CODE [CA4739]1286
FAILURE CODE [CA4768]1287
FAILURE CODE [CA4769]1289
FAILURE CODE [CA4842]1292
FAILURE CODE [CA4952] (APPLICABLE MACHINE: 90001 to 92188)1296
FAILURE CODE [CA4952] (APPLICABLE MACHINE: 92189 and up)1298
FAILURE CODE [CA5115]1300
FAILURE CODE [CA5179]1303
FAILURE CODE [CA5181]1305
FAILURE CODE [CA5271]1307
FAILURE CODE [CA5272]1309
FAILURE CODE [CA5273]1311
FAILURE CODE [CA5274]1313
FAILURE CODE [CA5275]1315
FAILURE CODE [CA5276]1317
FAILURE CODE [CA5277]1319
FAILURE CODE [CA5387]1320
FAILURE CODE [CA5388]1322
FAILURE CODE [CA5389]1324
FAILURE CODE [CA5391]1326
FAILURE CODE [CA5392]1330
FAILURE CODE [CA5393]1331
FAILURE CODE [CA5394]1334
FAILURE CODE [CA5395]1337
FAILURE CODE [CA5396]1340
FAILURE CODE [CA5631]1342
FAILURE CODE [CA5938]1344
FAILURE CODE [D110KB]1346
FAILURE CODE [D19JKZ]1348
FAILURE CODE [D811MC]1350
FAILURE CODE [D862KA]1351
FAILURE CODE [D8ALKA] (APPLICABLE MACHINE: 90001 to 92188)1352
FAILURE CODE [D8ALKA] (APPLICABLE MACHINE: 92189 and up)1354
FAILURE CODE [D8ALKB] (APPLICABLE MACHINE: 90001 to 92188)1356
FAILURE CODE [D8ALKB] (APPLICABLE MACHINE: 92189 and up)1358
FAILURE CODE [D8AQKR]1360
FAILURE CODE [D8G1KT]1364
FAILURE CODE [D8G6KT]1365
FAILURE CODE [DA20MC]1366
FAILURE CODE [DA22KK]1367
FAILURE CODE [DA25KP]1370
FAILURE CODE [DA26KP]1374
FAILURE CODE [DA29KQ]1376
FAILURE CODE [DA2LKA] (APPLICABLE MACHINE: 90001 to 92188)1378
FAILURE CODE [DA2LKA] (APPLICABLE MACHINE: 92189 and up)1380
FAILURE CODE [DA2LKB] (APPLICABLE MACHINE: 90001 to 92188)1382
FAILURE CODE [DA2LKB] (APPLICABLE MACHINE: 92189 and up)1384
FAILURE CODE [DA2QKR]1386
FAILURE CODE [DA2RKR]1391
FAILURE CODE [DAF0KM]1396
FAILURE CODE [DAF0MB]1397
FAILURE CODE [DAF0MC]1398
FAILURE CODE [DAF8KB]1399
FAILURE CODE [DAF9KQ]1403
FAILURE CODE [DAFGMC]1404
FAILURE CODE [DAFLKA] (APPLICABLE MACHINE: 90001 to 92188)1405
FAILURE CODE [DAFLKA] (APPLICABLE MACHINE: 92189 and up)1407
FAILURE CODE [DAFLKB] (APPLICABLE MACHINE: 90001 to 92188)1409
FAILURE CODE [DAFLKB] (APPLICABLE MACHINE: 92189 and up)1411
FAILURE CODE [DAFQKR]1413
FAILURE CODE [DAZ9KQ]1417
FAILURE CODE [DAZQKR]1418
FAILURE CODE [DB2QKR]1422
FAILURE CODE [DB2RKR]1428
FAILURE CODE [DBP0KM]1434
FAILURE CODE [DBP0KT]1435
FAILURE CODE [DBP5KB]1436
FAILURE CODE [DBP5KY]1439
FAILURE CODE [DBPQKR]1441
FAILURE CODE [DDNRKA]1446
FAILURE CODE [DDNRKY]1449
FAILURE CODE [DDNS00]1451
FAILURE CODE [DFB1KZ]1453
FAILURE CODE [DFB2KZ]1455
FAILURE CODE [DFB3L8]1457
FAILURE CODE [DFB4L8]1459
FAILURE CODE [DFB5KZ]1461
FAILURE CODE [DFB6KZ]1463
FAILURE CODE [DGH2KA]1465
FAILURE CODE [DGH2KB]1467
FAILURE CODE [DHA4KA]1469
FAILURE CODE [DHPAMA]1471
FAILURE CODE [DHS3MA]1473
FAILURE CODE [DHS4MA]1475
FAILURE CODE [DHS8MA]1477
FAILURE CODE [DHS9MA]1479
FAILURE CODE [DHSAMA]1481
FAILURE CODE [DHSBMA]1483
FAILURE CODE [DHSCMA]1485
FAILURE CODE [DHSDMA]1487
FAILURE CODE [DHSFMA]1489
FAILURE CODE [DHSGMA]1491
FAILURE CODE [DHSHMA]1493
FAILURE CODE [DHSJMA]1495
FAILURE CODE [DKULKA]1497
FAILURE CODE [DKULKB]1499
FAILURE CODE [DKULKY]1501
FAILURE CODE [DLM5KA]1503
FAILURE CODE [DLM5MB]1505
FAILURE CODE [DR10KA]1506
FAILURE CODE [DR12KA]1509
FAILURE CODE [DR20KA]1511
FAILURE CODE [DR21KX]1513
FAILURE CODE [DR31KX]1515
FAILURE CODE [DR40KA]1517
FAILURE CODE [DUMBKA] (APPLICABLE MACHINE: 90001 to 92188)1519
FAILURE CODE [DUMBKA] (APPLICABLE MACHINE: 92189 and up)1521
FAILURE CODE [DUMBKB] (APPLICABLE MACHINE: 90001 to 92188)1523
FAILURE CODE [DUMBKB] (APPLICABLE MACHINE: 92189 and up)1525
FAILURE CODE [DV20KB]1527
FAILURE CODE [DW43KA]1529
FAILURE CODE [DW43KB]1531
FAILURE CODE [DW43KY]1533
FAILURE CODE [DW45KA]1534
FAILURE CODE [DW45KB]1537
FAILURE CODE [DW45KY]1540
FAILURE CODE [DW4CKY]1542
FAILURE CODE [DW4WKA]1544
FAILURE CODE [DW4WKB]1546
FAILURE CODE [DW4WKY]1548
FAILURE CODE [DW91KA]1549
FAILURE CODE [DW91KB]1551
FAILURE CODE [DW91KY]1553
FAILURE CODE [DWA2KA]1555
FAILURE CODE [DWA2KB]1557
FAILURE CODE [DWA2KY]1559
FAILURE CODE [DWJ0KA]1561
FAILURE CODE [DWJ0KB]1563
FAILURE CODE [DWJ0KY]1565
FAILURE CODE [DWK0KA]1567
FAILURE CODE [DWK0KB]1569
FAILURE CODE [DWK0KY]1571
FAILURE CODE [DWK2KA]1573
FAILURE CODE [DWK2KB]1575
FAILURE CODE [DWK2KY]1577
FAILURE CODE [DWN5KA]1579
FAILURE CODE [DWN5KB]1581
FAILURE CODE [DWN5KY]1583
FAILURE CODE [DWNSKA]1585
FAILURE CODE [DWNSKB]1587
FAILURE CODE [DWNSKY]1589
FAILURE CODE [DXA8KA]1590
FAILURE CODE [DXA8KB]1592
FAILURE CODE [DXE4KA]1594
FAILURE CODE [DXE4KB]1596
FAILURE CODE [DXE4KY]1598
FAILURE CODE [DXEKKA]1600
FAILURE CODE [DXEKKB]1602
FAILURE CODE [DXEKKY]1604
FAILURE CODE [DY20KA]1606
FAILURE CODE [DY20MA]1608
FAILURE CODE [DY2CKB]1610
FAILURE CODE [DY2DKB]1612
FAILURE CODE [DY2EKB]1614
FAILURE CODE [F313KA]1616
FAILURE CODE [F313KB]1618
FAILURE CODE [F318KB]1619
FAILURE CODE [F318KY]1621
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1622
ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1622
MANUAL PREHEATING SYSTEM DOES NOT WORK1628
WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP1631
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR SHOWS NOTHING1633
WHILE ENGINE IS IN OPERATION, ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE1636
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS IN OPERATION1637
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS IN OPERATION1638
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1639
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1640
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1641
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1642
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1643
FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM1644
FUEL GAUGE DOES NOT SHOW CORRECT FUEL LEVEL1646
COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM1647
COOLANT TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE1648
AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY1649
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM1652
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE1654
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT SHOWN1655
FUNCTION SWITCH DOES NOT OPERATE1656
AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER)1657
AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED1658
AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION1659
WORK MODE SELECTOR SCREEN IS NOT SHOWN WHILE WORK MODE SWITCH IS OPERATED1660
ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED1661
TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED1662
TRAVEL SPEED DOES NOT CHANGE EVEN WHEN YOU OPERATE THE OPERATION TO CHANGE TRAVEL SPEED1663
ALARM BUZZER CANNOT BE STOPPED1664
SERVICE METER IS NOT SHOWN WHILE STARTING SWITCH IS IN OFF POSITION1665
MACHINE DOES NOT CHANGE TO SERVICE MODE1666
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE1667
ALL WORK EQUIPMENT, SWING OR TRAVEL CANNOT BE LOCKED1670
MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED1672
WHILE SWING PARKING BRAKE RELEASE SWITCH IS TURNED ON, SWING BRAKE IS NOT OPERATED1674
WHEN LOCK LEVER AUTOMATIC CANCEL SWITCH IS OPERATED, WORK EQUIPMENT CANNOT BE OPERATED1676
TRAVEL ALARM DOES NOT OPERATE DURING TRAVEL1678
TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS1680
HORN DOES NOT MAKE SOUND1681
HORN DOES NOT STOP1683
WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED1684
WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED1685
WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED1687
“BOOM RAISE” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION1688
“BOOM LOWER” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION1689
“ARM DUMP” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION1690
“ARM IN” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION1691
“BUCKET DUMP” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION1692
“BUCKET CURL” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION1693
“SWING” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION1694
“TRAVEL” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION1695
SERVICE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION1696
KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY1698
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1699
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)1699
FAILURE MODE AND CAUSE TABLE1700
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK1709
All WORK EQUIPMENT, SWING, AND TRAVEL SPEED IS LOW OR POWER IS LOW1710
FINE CONTROL PERFORMANCE OR RESPONSE IS UNSATISFACTORY1712
THERE IS UNUSUAL NOISE FROM AROUND HYDRAULIC PUMP1713
ENGINE SPEED FALLS LARGELY OR ENGINE STOPS1714
BOOM SPEED OR POWER IS LOW1716
ARM SPEED IS LOW OR POWER IS LOW1719
BUCKET SPEED OR POWER IS LOW1722
WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION1725
HYDRAULIC DRIFT OF BOOM IS LARGE1726
HYDRAULIC DRIFT OF ARM IS LARGE1727
HYDRAULIC DRIFT OF BUCKET IS LARGE1728
WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES1729
TIME LAG OF WORK EQUIPMENT IS LARGE1730
ATTACHMENT CIRCUIT CANNOT BE CHANGED1731
OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED1732
IN COMBINED OPERATION OF WORK EQUIPMENT, WORK EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER1733
IN COMBINATION OPERATION OF SWING AND TRAVEL, TRAVEL SPEED FALLS LARGELY1734
IN COMBINATION OPERATION OF SWING AND BOOM RAISE, BOOM RAISE SPEED IS LOW1735
MACHINE DOES NOT TRAVEL STRAIGHT1736
MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW1739
TRAVEL SPEED IS SLOW1742
ONE OF TRACKS DOES NOT RUN1744
TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST1746
MACHINE DOES NOT SWING TO RIGHT OR LEFT1747
SWINGS ONLY IN ONE DIRECTION1748
SWING ACCELERATION OR SWING SPEED IS LOW IN TWO DIRECTIONS OF RIGHT AND LEFT1749
SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION1750
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (RIGHT AND LEFT)1751
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (ONLY ONE DIRECTION)1752
SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWING OPERATION1753
THERE IS A LARGE UNUSUAL NOISE WHEN UPPER STRUCTURE STOPS SWING OPERATION1754
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)1755
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)1756
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT ROTATE)1757
THERE IS UNUSUAL NOISE FROM AROUND FAN1758
TROUBLESHOOTING OF ENGINE (S-MODE)1759
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)1759
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION1760
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT1761
FUEL IS INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)1762
ENGINE STARTABILITY IS UNSATISFACTORY1763
ENGINE DOES NOT PICK UP SMOOTHLY1765
ENGINE STOPS DURING OPERATION1767
ENGINE RUNS ROUGH OR IS NOT STABLE1769
ENGINE LACKS POWER1770
EXHAUST IS BLACK1772
ENGINE OIL CONSUMPTION IS EXCESSIVE1774
OIL BECOMES CONTAMINATED QUICKLY1775
FUEL CONSUMPTION IS EXCESSIVE1776
OIL MIXES INTO COOLANT (OR COOLANT SPURTS BACK AND COOLANT LEVEL DOES DOWN)1777
ENGINE OIL PRESSURE FALLS1778
FUEL MIXES INTO ENGINE OIL1779
WATER MIXES INTO ENGINE OIL (MILKY)1780
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEAT)1781
THERE IS AN UNUSUAL NOISE1782
VIBRATION IS EXCESSIVE1784
AIR CANNOT BE BLED FROM FUEL CIRCUIT1785
ACTIVE REGENERATION IS DONE FREQUENTLY1786
ACTIVE REGENERATION TAKES LONG1787
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION1788
AdBlue/DEF CONSUMPTION IS EXCESSIVE1789
THERE IS AN UNUSUAL SMELL (IRRITATING ODOR)1791
FOREIGN MATERIAL MIXES INTO ADBLUE/DEF (ADBLUE/DEF LEVEL INCREASES)1792
50 DISASSEMBLY AND ASSEMBLY1793
CONTENTS1794
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY1799
HOW TO READ THIS MANUAL1799
COATING MATERIALS LIST1801
SPECIAL TOOLS LIST1805
SKETCHES OF SPECIAL TOOLS1824
ENGINE AND COOLING SYSTEM1827
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY1827
REMOVE SUPPLY PUMP ASSEMBLY1827
INSTALL SUPPLY PUMP ASSEMBLY1831
REMOVE AND INSTALL INJECTOR ASSEMBLY1838
REMOVE INJECTOR ASSEMBLY1838
INSTALL INJECTOR ASSEMBLY1847
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY1860
REMOVE CYLINDER HEAD ASSEMBLY1860
INSTALL CYLINDER HEAD ASSEMBLY1878
REMOVE AND INSTALL EGR VALVE ASSEMBLY1901
REMOVE EGR VALVE ASSEMBLY1901
INSTALL EGR VALVE ASSEMBLY1902
REMOVE AND INSTALL EGR COOLER ASSEMBLY1904
REMOVE EGR COOLER ASSEMBLY1904
INSTALL EGR COOLER ASSEMBLY1908
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY1913
REMOVE STARTING MOTOR ASSEMBLY1913
INSTALL STARTING MOTOR ASSEMBLY1916
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT1919
REMOVE AIR CONDITIONER COMPRESSOR BELT1919
INSTALL AIR CONDITIONER COMPRESSOR BELT1920
REMOVE AND INSTALL ALTERNATOR BELT1921
REMOVE ALTERNATOR BELT1921
INSTALL ALTERNATOR BELT1924
REMOVE AND INSTALL AUTOMATIC TENSIONER1926
METHOD FOR REMOVING AUTOMATIC TENSIONER1926
METHOD FOR INSTALLING AUTOMATIC TENSIONER1926
REMOVE AND INSTALL RADIATOR ASSEMBLY1927
REMOVE RADIATOR ASSEMBLY1927
INSTALL RADIATOR ASSEMBLY1930
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY1935
REMOVE HYDRAULIC OIL COOLER ASSEMBLY1935
INSTALL HYDRAULIC OIL COOLER ASSEMBLY1940
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY1945
REMOVE AFTERCOOLER ASSEMBLY1945
INSTALL AFTERCOOLER ASSEMBLY1947
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY1952
REMOVE FAN CLUTCH ASSEMBLY1952
INSTALL FAN CLUTCH ASSEMBLY1956
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY1961
REMOVE ENGINE AND MAIN PUMP ASSEMBLY1962
INSTALL ENGINE AND MAIN PUMP ASSEMBLY1974
REMOVE AND INSTALL ENGINE FRONT OIL SEAL1987
METHOD FOR REMOVING ENGINE FRONT OIL SEAL1987
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL1988
REMOVE AND INSTALL ENGINE REAR OIL SEAL1990
METHOD FOR REMOVING ENGINE REAR OIL SEAL1990
METHOD FOR INSTALLING ENGINE REAR OIL SEAL1991
REMOVE AND INSTALL FUEL COOLER ASSEMBLY1995
REMOVE FUEL COOLER ASSEMBLY1995
INSTALL FUEL COOLER ASSEMBLY1996
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY1997
REMOVE ENGINE HOOD ASSEMBLY1997
INSTALL ENGINE HOOD ASSEMBLY1999
REMOVE AND INSTALL KDOC ASSEMBLY2003
REMOVE KDOC ASSEMBLY2004
INSTALL KDOC ASSEMBLY2011
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY2023
REMOVE KDOC AND SCR ASSEMBLY2024
INSTALL KDOC AND SCR ASSEMBLY2030
REMOVE AND INSTALL FUEL TANK ASSEMBLY2039
REMOVE FUEL TANK ASSEMBLY2039
INSTALL FUEL TANK ASSEMBLY2049
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2059
REMOVE AdBlue/DEF TANK ASSEMBLY2060
INSTALL AdBlue/DEF TANK ASSEMBLY2072
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2083
REMOVE AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2083
INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2093
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2102
REMOVE AdBlue/DEF TANK SENSOR2102
INSTALL AdBlue/DEF TANK SENSOR2103
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2110
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2110
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2110
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER2111
REMOVE AdBlue/DEF TANK FILLER PORT FILTER2111
INSTALL AdBlue/DEF TANK FILLER PORT FILTER2113
REMOVE AND INSTALL SCR ASSEMBLY2116
REMOVE SCR ASSEMBLY2116
INSTALL SCR ASSEMBLY2125
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY BRACKET2138
REMOVE KDOC AND SCR ASSEMBLY BRACKET2139
INSTALL KDOC AND SCR ASSEMBLY BRACKET2152
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY2167
REMOVE BELLOWS PIPE ASSEMBLY2167
INSTALL BELLOWS PIPE ASSEMBLY2170
REMOVE AND INSTALL KCCV ASSEMBLY2173
REMOVE KCCV ASSEMBLY2173
INSTALL KCCV ASSEMBLY2174
REMOVE AND INSTALL EXHAUST THROTTLE VALVE2176
REMOVE EXHAUST THROTTLE VALVE2176
INSTALL EXHAUST THROTTLE VALVE2183
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2191
REMOVE AdBlue/DEF MIXING TUBE2191
INSTALL AdBlue/DEF MIXING TUBE2195
REMOVE AND INSTALL AdBlue/DEF INJECTOR2200
REMOVE AdBlue/DEF INJECTOR2200
INSTALL AdBlue/DEF INJECTOR2203
REMOVE AND INSTALL AdBlue/DEF PUMP2207
REMOVE AdBlue/DEF PUMP2207
INSTALL AdBlue/DEF PUMP2214
REMOVE AND INSTALL AdBlue/DEF HOSE2220
REMOVE AdBlue/DEF HOSE2220
INSTALL AdBlue/DEF HOSE2229
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2238
REMOVE AIR CLEANER ASSEMBLY2238
INSTALL AIR CLEANER ASSEMBLY2242
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2249
REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY2249
INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2251
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2254
REMOVE AIR CONDITIONER CONDENSER ASSEMBLY2254
INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2255
POWER TRAIN2258
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2258
REMOVE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2258
INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2260
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2262
DISASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2274
ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2292
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY2313
REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY2313
INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY2315
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY2318
DISASSEMBLE SWING MACHINERY ASSEMBLY2319
ASSEMBLE SWING MACHINERY ASSEMBLY2322
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY2328
REMOVE SWING CIRCLE ASSEMBLY2328
INSTALL SWING CIRCLE ASSEMBLY2329
UNDERCARRIAGE AND FRAME2330
SEPARATION AND CONNECTION OF TRACK ASSEMBLY2330
METHOD FOR SEPARATING TRACK ASSEMBLY2330
METHOD FOR INSTALLING TRACK ASSEMBLY2332
REMOVE AND INSTALL SPROCKET2335
REMOVE SPROCKET2335
INSTALL SPROCKET2336
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY2337
REMOVE IDLER AND IDLER CUSHION ASSEMBLY2337
INSTALL IDLER AND IDLER CUSHION ASSEMBLY2337
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2339
DISASSEMBLE IDLER CUSHION ASSEMBLY2339
ASSEMBLE IDLER ASSEMBLY2340
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY2343
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY2343
ASSEMBLE IDLER CUSHION ASSEMBLY2345
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2347
DISASSEMBLE TRACK ROLLER ASSEMBLY2347
ASSEMBLE TRACK ROLLER ASSEMBLY2349
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY2351
REMOVE REVOLVING FRAME ASSEMBLY2351
INSTALL REVOLVING FRAME ASSEMBLY2354
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2356
REMOVE COUNTERWEIGHT ASSEMBLY2356
INSTALL COUNTERWEIGHT ASSEMBLY2358
HYDRAULIC SYSTEM2361
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY2361
REMOVE CENTER SWIVEL JOINT ASSEMBLY2361
INSTALL CENTER SWIVEL JOINT ASSEMBLY2365
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2368
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2368
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2369
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2370
REMOVE HYDRAULIC TANK ASSEMBLY2370
INSTALL HYDRAULIC TANK ASSEMBLY2384
REMOVE AND INSTALL MAIN PUMP ASSEMBLY2396
REMOVE MAIN PUMP ASSEMBLY2396
INSTALL MAIN PUMP ASSEMBLY2399
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2403
REMOVE CONTROL VALVE ASSEMBLY2403
INSTALL CONTROL VALVE ASSEMBLY2411
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY2420
ASSEMBLE CONTROL VALVE ASSEMBLY2420
REPLACE PRESSURE REDUCING VALVE CARTRIDGE ASSEMBLY2422
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2425
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2425
ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2425
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2427
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY2427
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY2428
WORK EQUIPMENT2430
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2430
REMOVE WORK EQUIPMENT ASSEMBLY2431
INSTALL WORK EQUIPMENT ASSEMBLY2436
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2442
DISASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2443
ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2445
CAB AND ITS ATTACHMENTS2452
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY2452
REMOVE OPERATOR CAB ASSEMBLY2452
INSTALL OPERATOR CAB ASSEMBLY2460
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)2467
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)2469
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)2469
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY2479
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY2479
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY2482
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY2488
REMOVE FLOOR FRAME ASSEMBLY2488
INSTALL FLOOR FRAME ASSEMBLY2494
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2501
REMOVE AIR CONDITIONER UNIT ASSEMBLY2501
INSTALL AIR CONDITIONER UNIT ASSEMBLY2507
REMOVE AND INSTALL OPERATOR’S SEAT2514
REMOVE OPERATOR’S SEAT2514
METHOD FOR INSTALLING OPERATOR’S SEAT2515
REMOVE AND INSTALL SEAT BELT2518
METHOD FOR REMOVING SEAT BELT2518
METHOD FOR INSTALLING SEAT BELT2518
REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY2520
REMOVE WORK EQUIPMENT CONTROL LEVER ASSEMBLY2520
INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY2526
REMOVE AND INSTALL FRONT WIPER ASSEMBLY2535
REMOVE FRONT WIPER ASSEMBLY2535
INSTALL FRONT WIPER ASSEMBLY2540
ELECTRICAL SYSTEM2549
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2549
REMOVE ENGINE CONTROLLER ASSEMBLY2549
INSTALL ENGINE CONTROLLER ASSEMBLY2551
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY2552
REMOVE PUMP CONTROLLER ASSEMBLY2552
INSTALL PUMP CONTROLLER ASSEMBLY2555
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY2557
REMOVE KomVision CONTROLLER ASSEMBLY2557
INSTALL KomVision CONTROLLER ASSEMBLY2558
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2560
REMOVE MACHINE MONITOR ASSEMBLY2560
INSTALL MACHINE MONITOR ASSEMBLY2562
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2566
REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR2566
INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2568
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2570
REMOVE KCCV CRANKCASE PRESSURE SENSOR2570
INSTALL KCCV CRANKCASE PRESSURE SENSOR2572
REMOVE AND INSTALL SCR TEMPERATURE SENSOR2574
REMOVE SCR TEMPERATURE SENSOR2574
INSTALL SCR TEMPERATURE SENSOR2575
REMOVE AND INSTALL REARVIEW CAMERA2577
REMOVE REARVIEW CAMERA2577
INSTALL REARVIEW CAMERA2579
REMOVE AND INSTALL KomVision CAMERA2581
REMOVE KomVision CAMERA2581
INSTALL KomVision CAMERA2585
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY2589
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY2589
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY2593
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS2599
REMOVE COMMUNICATION TERMINAL WIRING HARNESS2599
INSTALL COMMUNICATION TERMINAL WIRING HARNESS2606
REMOVE AND INSTALL COMMUNICATION TERMINAL2615
REMOVE COMMUNICATION TERMINAL2615
INSTALL COMMUNICATION TERMINAL2616
60 MAINTENANCE STANDARD2619
CONTENTS2620
ENGINE AND COOLING SYSTEM2621
MAINTENANCE STANDARD OF ENGINE MOUNT2621
MAINTENANCE STANDARD OF PTO2622
MAINTENANCE STANDARD OF COOLING SYSTEM2623
POWER TRAIN2624
MAINTENANCE STANDARD OF SWING CIRCLE2624
MAINTENANCE STANDARD OF SWING MACHINERY2625
MAINTENANCE STANDARD OF SPROCKET2627
UNDERCARRIAGE AND FRAME2628
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION2628
MAINTENANCE STANDARD OF IDLER2630
MAINTENANCE STANDARD OF TRACK ROLLER2631
MAINTENANCE STANDARD OF CARRIER ROLLER2632
MAINTENANCE STANDARD OF TRACK SHOE2633
MAINTENANCE STANDARD OF TRIPLE SHOE2636
MAINTENANCE STANDARD OF ROAD LINER2637
HYDRAULIC SYSTEM2638
MAINTENANCE STANDARD OF HYDRAULIC TANK2638
MAINTENANCE STANDARD OF MAIN PUMP2639
MAINTENANCE STANDARD OF PC-EPC VALVE2643
MAINTENANCE STANDARD OF SWING MOTOR2644
MAINTENANCE STANDARD OF TRAVEL MOTOR2647
MAINTENANCE STANDARD OF CONTROL VALVE2648
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE2660
MAINTENANCE STANDARD OF TRAVEL PPC VALVE2663
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)2666
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE2668
MAINTENANCE STANDARD OF SOLENOID VALVE2669
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE SOLENOID VALVE2673
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)2674
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT)2675
MAINTENANCE STANDARD OF ARM OUT QUICK RETURN VALVE2676
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT2677
WORK EQUIPMENT2679
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE2679
DIMENSIONS OF ARM2684
DIMENSIONS OF BUCKET2686
MAINTENANCE STANDARD OF BOOM CYLINDER2688
MAINTENANCE STANDARD OF ARM CYLINDER2689
MAINTENANCE STANDARD OF BUCKET CYLINDER2690
CAB AND ITS ATTACHMENTS2691
MAINTENANCE STANDARD OF CAB MOUNT2691
80 APPENDIX2693
CONTENTS2694
AIR CONDITIONER SYSTEM2696
PRECAUTIONS FOR REFRIGERANT2696
AIR CONDITIONER2697
SPECIFICATIONS OF AIR CONDITIONER2699
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2700
OUTLINE OF REFRIGERATION CYCLE2701
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2703
AIR CONDITIONER UNIT2703
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2703
FUNCTION OF AIR CONDITIONER UNIT2705
COMPONENT PARTS OF AIR CONDITIONER UNIT2707
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2708
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2708
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT2708
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT2708
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2709
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2709
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2709
FUNCTION OF DUAL PRESSURE SWITCH2710
AIR CONDITIONER CONTROLLER2711
STRUCTURE OF AIR CONDITIONER CONTROLLER2711
COMPRESSOR2712
STRUCTURE OF COMPRESSOR2712
SPECIFICATIONS OF COMPRESSOR2712
FUNCTION OF COMPRESSOR2712
CONDENSER2713
STRUCTURE OF CONDENSER2713
SPECIFICATIONS OF CONDENSER2713
FUNCTION OF CONDENSER2713
SENSORS FOR AIR CONDITIONER SYSTEM2715
STRUCTURE OF SUNLIGHT SENSOR2715
FUNCTION OF SUNLIGHT SENSOR2715
STRUCTURE OF AMBIENT TEMPERATURE SENSOR2715
FUNCTION OF AMBIENT TEMPERATURE SENSOR2715
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2717
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER2719
AIR CONDITIONER SYSTEM DIAGRAM2721
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER2722
FUNCTION OF AIR CONDITIONER CONTROLLER2723
LOCATIONS OF AIR CONDITIONER PARTS AND LAYOUT OF CONNECTORS2724
TESTING AIR LEAKAGE (DUCT)2728
METHOD FOR TESTING AIR LEAKAGE (DUCT)2728
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION2730
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR2731
TEST VENT (MODE) CHANGEOVER2732
METHOD FOR TESTING VENT (MODE) CHANGEOVER2732
TESTING FRESH/RECIRC AIR CHANGEOVER2734
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER2734
TEST SUNLIGHT SENSOR2735
METHOD FOR TESTING SUNLIGHT SENSOR2735
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT2736
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT2736
TEST RELAYS2737
METHOD FOR TESTING RELAYS2737
AIR CONDITIONER TROUBLESHOOTING CHART 12738
AIR CONDITIONER TROUBLESHOOTING CHART 22739
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2742
FAILURE CODE [879AKA]2744
FAILURE CODE [879AKB]2745
FAILURE CODE [879BKA]2746
FAILURE CODE [879BKB]2748
FAILURE CODE [879CKA]2750
FAILURE CODE [879CKB]2751
FAILURE CODE [879DKZ]2752
FAILURE CODE [879EMC]2754
FAILURE CODE [879FMC]2755
FAILURE CODE [879GKX]2756
TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)2758
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)2760
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)2763
TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER2765
TROUBLESHOOTING USING GAUGE PRESSURE2767
CONNECTION OF SERVICE TOOL2770
METHOD FOR CONNECTING SERVICE TOOL2770
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS2772
COMPRESSOR OIL2774
METHOD FOR REPLACING DESICCANT2776
90 CIRCUIT DIAGRAMS2779
CONTENTS2780
HOW TO READ THE CODES FOR ELECTRIC CABLE2782
HYDRAULIC CIRCUIT DIAGRAM2786
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2786
HYDRAULIC CIRCUIT DIAGRAM (1/3)2791
HYDRAULIC CIRCUIT DIAGRAM (2/3)2793
HYDRAULIC CIRCUIT DIAGRAM (3/3)2795
ELECTRICAL CIRCUIT DIAGRAM2797
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM2797
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 90001 TO 92188) (1/10)2801
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 90001 TO 92188) (2/10)2803
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 90001 TO 92188) (3/10)2805
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 90001 TO 92188) (4/10)2807
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 90001 TO 92188) (5/10)2809
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 90001 TO 92188) (1/10)2811
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 90001 TO 92188) (7/10)2813
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 90001 TO 92188) (8/10)2815
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 90001 TO 92188) (9/10)2817
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 90001 TO 92188) (10/10)2819
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 92189 AND UP) (1/10)2821
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 92189 AND UP) (2/10)2823
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 92189 AND UP) (3/10)2825
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 92189 AND UP) (4/10)2827
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 92189 AND UP) (5/10)2829
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 92189 AND UP) (6/10)2831
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 92189 AND UP) (7/10)2833
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 92189 AND UP) (8/10)2835
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 92189 AND UP) (9/10)2837
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO: 92189 AND UP) (10/10)2839
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 90001 TO 92188) (1/10)2841
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 90001 TO 92188) (2/10)2843
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 90001 TO 92188) (3/10)2845
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 90001 TO 92188) (4/10)2847
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 90001 TO 92188) (5/10)2849
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 90001 TO 92188) (6/10)2851
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 90001 TO 92188) (7/10)2853
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 90001 TO 92188) (8/10)2855
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 90001 TO 92188) (9/10)2857
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 90001 TO 92188) (10/10)2859
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 92189 AND UP) (1/10)2861
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 92189 AND UP) (2/10)2863
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 92189 AND UP) (3/10)2865
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 92189 AND UP) (4/10)2867
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 92189 AND UP) (5/10)2869
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 92189 AND UP) (6/10)2871
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 92189 AND UP) (7/10)2873
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 92189 AND UP) (8/10)2875
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 92189 AND UP) (9/10)2877
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO: 92189 AND UP) (10/10)2879
INDEX2881
S.M 28/12/24
