Komatsu Hydraulic Excavator PC138USLC-11 Shop Manual SEN06589-CA PDF

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Komatsu Hydraulic Excavator PC138USLC-11 Shop Manual SEN06589-CA – PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC138USLC-11 Shop Manual SEN06589-CA – PDF DOWNLOAD

Language : English
Pages :3420
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu Hydraulic Excavator PC138USLC-11 Shop Manual SEN06589-CA – PDF DOWNLOAD

SERIAL NUMBERS C30001 and up

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC138USLC-11 Shop Manual SEN06589-CA – PDF DOWNLOAD

SERIAL NUMBERS C30001 and up

00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 22
FOREWORD, SAFETY, BASIC INFORMATION 28
HOW TO READ THE SHOP MANUAL 28
SAFETY NOTICE FOR OPERATION 30
PRECAUTIONS TO PREVENT FIRE 38
ACTIONS IF FIRE OCCURS 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 42
PRECAUTIONS FOR DEF 43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 43
PRECAUTIONS FOR ADDING 43
PRECAUTIONS FOR STORING 43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 43
THE OTHER PRECAUTIONS 43
STORE AdBlue/DEF 44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 58
PRACTICAL USE OF KOMTRAX 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 74
HOW TO READ ELECTRICAL WIRE CODE 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 79
STANDARD TIGHTENING TORQUE TABLE 82
CONVERSION TABLE 89
01 SPECIFICATIONS 95
CONTENTS 96
ABBREVIATION LIST 97
SPECIFICATIONS 103
SPECIFICATION DRAWING 103
SPECIFICATION DRAWING: PC138USLC-11 103
WORKING RANGE DRAWINGS 105
WORKING RANGE: PC138USLC-11 105
SPECIFICATIONS 106
SPECIFICATIONS: PC138USLC-11 106
WEIGHT TABLE 110
WEIGHT TABLE: PC138USLC-11 110
TABLE OF FUEL, COOLANT, AND LUBRICANTS 112
10 STRUCTURE AND FUNCTION 113
CONTENTS 114
ABBREVIATION LIST 117
UREA SCR SYSTEM 123
LAYOUT DRAWING OF UREA SCR SYSTEM 123
FUNCTION OF UREA SCR SYSTEM 0
INDUCEMENT STRATEGY 128
FUNCTION THAT CALLS FOR ATTENTION OF THE OPERATOR FOR UREA SCR SYSTEM TO STAY FUNCTIONAL 141
COMPONENT PARTS OF UREA SCR SYSTEM 148
AdBlue/DEF MIXING TUBE 148
SCR ASSEMBLY 149
AdBlue/DEF TANK 151
AdBlue/DEF HOSE 155
AdBlue/DEF TANK HEATING VALVE 156
BOOT-UP SYSTEM 157
LAYOUT DRAWING OF BOOT-UP SYSTEM 157
SYSTEM OPERATING LAMP SYSTEM 158
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 158
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 158
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 158
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 159
BATTERY DISCONNECT SWITCH 161
FUNCTION OF BATTERY DISCONNECT SWITCH 161
ENGINE SYSTEM 162
LAYOUT DRAWING OF ENGINE SYSTEM 162
ENGINE CONTROL SYSTEM 164
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 164
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 165
FUNCTION OF ENGINE CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 166
FUNCTION OF ENGINE CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 168
AUTO-DECELERATION SYSTEM 170
AUTO-DECELERATION SYSTEM DIAGRAM 170
FUNCTION OF AUTO-DECELERATION SYSTEM 170
OPERATION OF AUTO-DECELERATION SYSTEM 171
ENGINE AUTOMATIC WARM-UP SYSTEM 172
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 172
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 173
OVERHEAT PREVENTION SYSTEM 174
FUNCTION OF OVERHEAT PREVENTION SYSTEM 174
TURBOCHARGER PROTECTION SYSTEM 176
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 176
AUTOMATIC IDLE STOP SYSTEM 177
AUTOMATIC IDLE STOP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 177
AUTOMATIC IDLE STOP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 178
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 178
COMPONENT PARTS OF ENGINE SYSTEM 181
PTO 181
VARIABLE FLOW TURBOCHARGER 182
EGR SYSTEM 185
EGR VALVE 188
EGR COOLER 191
KCCV SYSTEM 193
KCCV VENTILATOR 196
EXHAUST THROTTLE VALVE 198
KDOC 199
COOLING SYSTEM 201
LAYOUT DRAWING OF COOLING SYSTEM 201
SPECIFICATIONS OF COOLING SYSTEM 202
CONTROL SYSTEM 203
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 203
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 205
MACHINE MONITOR SYSTEM 207
MACHINE MONITOR SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 207
MACHINE MONITOR SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 208
FUNCTION OF MACHINE MONITOR SYSTEM 209
KomVision SYSTEM 210
LAYOUT DRAWING OF KomVision SYSTEM 210
KomVision SYSTEM DIAGRAM 212
FUNCTION OF KomVision SYSTEM 212
KOMTRAX SYSTEM 0
FUNCTION OF KOMTRAX SYSTEM 215
COMPONENT PARTS OF CONTROL SYSTEM 216
MACHINE MONITOR 216
KomVision CONTROLLER 231
KomVision CAMERA 235
KOMTRAX TERMINAL 236
GATEWAY FUNCTION CONTROLLER 238
COMMUNICATION TERMINAL 241
PUMP CONTROLLER 243
RESISTOR FOR PC-EPC VALVE 248
CAN TERMINATING RESISTOR 249
ENGINE CONTROLLER 250
FUEL CONTROL DIAL 257
HYDRAULIC SYSTEM 259
LAYOUT DRAWING OF HYDRAULIC SYSTEM 259
ENGINE AND PUMP COMBINED CONTROL SYSTEM 264
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 264
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 265
COMPONENT PARTS OF HYDRAULIC SYSTEM 269
HYDRAULIC TANK 269
MAIN PUMP 271
CONTROL VALVE 298
WORK EQUIPMENT SYSTEM 358
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 358
STRUCTURE OF VALVE CONTROL 361
PPC LOCK SYSTEM 362
PPC LOCK SYSTEM DIAGRAM 362
FUNCTION OF PPC LOCK SYSTEM 362
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 363
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 363
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 363
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 364
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 365
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 365
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 366
TOOL CONTROL SYSTEM 367
TOOL CONTROL SYSTEM DIAGRAM 367
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 369
WORK EQUIPMENT AND SWING PPC VALVE 369
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 374
BLADE PPC VALVE 382
SOLENOID VALVE 384
VARIABLE BACK PRESSURE SOLENOID VALVE 389
MULTI-CONTROL VALVE 390
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE 393
PILOT CIRCUIT ACCUMULATOR 396
ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) 397
SWING SYSTEM 398
LAYOUT DRAWING OF SWING SYSTEM 398
SWING CONTROL SYSTEM DIAGRAM 400
FUNCTION OF SWING CONTROL SYSTEM 401
COMPONENT PARTS OF SWING SYSTEM 403
SWING MOTOR 403
SWING MACHINERY 413
SWING CIRCLE 415
TRAVEL SYSTEM 416
LAYOUT DRAWING OF TRAVEL SYSTEM 416
TRAVEL CONTROL SYSTEM DIAGRAM 418
FUNCTION OF TRAVEL CONTROL SYSTEM 419
COMPONENT PARTS OF TRAVEL SYSTEM 422
TRAVEL MOTOR 422
TRAVEL PPC VALVE 435
CENTER SWIVEL JOINT 439
UNDERCARRIAGE AND FRAME 441
LAYOUT DRAWING OF UNDERCARRIAGE 441
SPECIFICATIONS OF UNDERCARRIAGE 441
IDLER CUSHION 442
STRUCTURE OF IDLER CUSHION 442
SPECIFICATIONS OF IDLER CUSHION 442
WORK EQUIPMENT 443
STRUCTURE OF WORK EQUIPMENT 443
FUNCTION OF WORK EQUIPMENT 444
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 445
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 445
BUCKET CLEARANCE ADJUSTMENT SHIM 446
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 446
CAB AND ITS ATTACHMENTS 447
ROPS CAB 447
STRUCTURE OF ROPS CAB (MACHINE WITH KOMTRAX TERMINAL) 447
STRUCTURE OF ROPS CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 448
FUNCTION OF ROPS CAB 448
CAB MOUNT 449
STRUCTURE OF CAB MOUNT 449
FUNCTION OF CAB MOUNT 449
TAKE WIRING HARNESS OUT OF CAB 451
20 STANDARD VALUE TABLE 453
CONTENTS 454
ABBREVIATION LIST 455
STANDARD VALUE TABLE FOR ENGINE 461
STANDARD VALUE TABLE FOR ENGINE:PC138USLC-11 461
STANDARD VALUE TABLE FOR MACHINE 465
STANDARD VALUE TABLE FOR MACHINE:PC138USLC-11 465
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 479
30 TESTING AND ADJUSTING 483
CONTENTS 484
ABBREVIATION LIST 487
RELATED INFORMATION ON TESTING AND ADJUSTING 493
TOOLS FOR TESTING AND ADJUSTING 493
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 500
ENGINE AND COOLING SYSTEM 502
TEST ENGINE SPEED 502
METHOD FOR TESTING ENGINE SPEED 502
TEST EXHAUST GAS COLOR 505
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 505
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 506
TEST THE CLEARANCE OF THE EXHAUST THROTTLE VALVE 507
METHOD FOR MEASURING THE CLEARANCE OF THE EXHAUST THROTTLE VALVE 507
TEST AND ADJUST VALVE CLEARANCE 510
METHOD FOR TESTING VALVE CLEARANCE 510
METHOD FOR ADJUSTING VALVE CLEARANCE 511
TEST COMPRESSION PRESSURE 512
METHOD FOR TESTING COMPRESSION PRESSURE 512
TEST BLOWBY PRESSURE 515
METHOD FOR TESTING BLOWBY PRESSURE 515
TEST ENGINE OIL PRESSURE 517
METHOD FOR TESTING ENGINE OIL PRESSURE 517
VISUAL CHECK INSIDE OF EGR VALVE 519
VISUAL CHECK INSIDE OF EGR VALVE 519
CLEAN INSIDE OF EGR VALVE 521
CLEAN INSIDE OF EGR VALVE 521
TEST FUEL PRESSURE 524
METHOD FOR TESTING FUEL PRESSURE 524
TEST FUEL RETURN RATE AND LEAKAGE 526
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 527
BLEED AIR FROM FUEL SYSTEM 530
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 530
TEST FUEL CIRCUIT FOR LEAKAGE 532
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 532
HANDLE CYLINDER CUT-OUT MODE OPERATION 534
HANDLE NO-INJECTION CRANKING OPERATION 535
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 536
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 536
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 536
TEST ALTERNATOR BELT 538
METHOD FOR TESTING ALTERNATOR BELT 538
TEST AUTOMATIC TENSIONER 539
METHOD FOR TESTING AUTOMATIC TENSIONER 539
TEST COOLING FAN SPEED 541
METHOD FOR TESTING COOLING FAN SPEED 541
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 542
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 542
TEST SCR RELATED FUNCTIONS 548
TEST AdBlue/DEF PUMP RAISED PRESSURE 552
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 555
TEST AdBlue/DEF LINE HEATER RELAY 1 560
TEST AdBlue/DEF LINE HEATER RELAY 2 564
TEST AdBlue/DEF PUMP HEATER RELAY 567
TEST AdBlue/DEF TANK HEATER VALVE 571
TEST DENITRATION EFFICIENCY OF SCR 575
CLEAN AdBlue/DEF TANK 578
METHOD FOR CLEANING AdBlue/DEF TANK 578
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 583
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 583
CLEAN AdBlue/DEF PUMP 585
CLEAN AdBlue/DEF PUMP 585
POWER TRAIN 591
TEST SWING CIRCLE BEARING CLEARANCE 591
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 591
UNDERCARRIAGE AND FRAME 592
TEST AND ADJUST TRACK TENSION 592
METHOD FOR TESTING TRACK TENSION 592
METHOD FOR ADJUSTING TRACK TENSION 592
HYDRAULIC SYSTEM 594
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 594
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 594
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 594
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 596
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 596
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS 597
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS 597
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS 604
TEST OIL PRESSURE OF CONTROL CIRCUIT 606
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 606
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 608
METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 608
METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE 609
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 610
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 612
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 612
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE 614
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 615
METHOD FOR ADJUSTING LS VALVE 617
TEST OUTLET PRESSURE OF SOLENOID VALVE 618
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 618
OPERATING CONDITION OF SOLENOID VALVE 619
METHOD FOR TESTING OUTLET PRESSURE OF VARIABLE BACK PRESSURE SOLENOID VALVE 620
OPERATING CONDITION OF VARIABLE BACK PRESSURE SOLENOID VALVE 622
TEST PPC VALVE OUTLET PRESSURE 623
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 623
TEST ATTACHMENT CIRCUIT OIL PRESSURE 625
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 625
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 626
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 626
TEST AND ADJUST TRAVEL DEVIATION 627
METHOD FOR TESTING TRAVEL DEVIATION 627
METHOD FOR ADJUSTING TRAVEL DEVIATION 627
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 630
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 630
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 630
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 631
TEST OIL LEAKAGE 632
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 632
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 633
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 633
METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER 634
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 634
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 635
BLEED AIR FROM HYDRAULIC CIRCUIT 637
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 638
CAB AND ITS ATTACHMENTS 641
TEST CAB TIPPING STOPPER 641
METHOD FOR TESTING CAB TIPPING STOPPER 641
METHOD FOR ADJUSTING MIRRORS 642
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 642
PROCEDURE FOR ADJUSTING MACHINE REAR MIRROR (B) 642
ELECTRICAL SYSTEM 644
SET AND OPERATE MACHINE MONITOR 644
OPERATOR MODE 648
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 648
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 648
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 649
CHECKING FUNCTION OF SERVICE METER 649
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 649
SERVICE MODE 653
METHOD FOR OPERATING SERVICE MODE 653
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 655
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 661
ABNORMALITY RECORD MENU 673
METHOD FOR CONFIRMING MAINTENANCE RECORD 677
METHOD FOR OPERATING MAINTENANCE MODE SETTING 678
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 681
DEFAULT MENU 683
DIAGNOSTIC TESTS MENU 695
ADJUSTMENT MENU 704
METHOD FOR PERFORMING NO-INJECTION CRANKING 718
KOMTRAX SETTINGS MENU 720
METHOD FOR DISPLAYING SERVICE MESSAGE 724
START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 726
STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 731
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 733
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 739
ADJUST REARVIEW CAMERA ANGLE 741
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 741
ADJUST KomVision CAMERA ANGLE 744
METHOD FOR ADJUSTING KomVision CAMERA ANGLE 745
ADJUST KomVision RELATED ITEMS 747
SETTING OF KomVision (MAIN SETTING) 748
SETTING OF KomVision (CAMERA SETTING) 751
SETTING OF KomVision (CAMERA CALIBRATION) 753
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 766
BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL) 767
BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 768
TEST DIODES 769
METHOD FOR TESTING DIODE USING DIGITAL TESTER 769
METHOD FOR TESTING DIODE USING ANALOG TESTER 769
Pm CLINIC 770
Pm CLINIC SERVICE 770
Pm CLINIC CHECK SHEET:PC138USLC-11 771
40 TROUBLESHOOTING 781
CONTENTS 782
ABBREVIATION LIST 793
RELATED INFORMATION ON TROUBLESHOOTING 799
GENERAL TROUBLESHOOTING POINTS 799
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 800
SEQUENCE OF EVENTS IN TROUBLESHOOTING 812
CHECKS BEFORE TROUBLESHOOTING 814
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 816
WALK-AROUND CHECK 816
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 818
CHECK FUEL LEVEL AND TYPE 818
CHECK FUEL PREFILTER 819
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 819
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 820
CHECK MAIN FILTER 821
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 822
CHECK OIL LEVEL IN PTO GEAR CASE 823
CHECK COOLANT LEVEL (RESERVOIR TANK) 824
CHECK CLOGGING OF AIR CLEANER 825
OUTER ELEMENT – CLEAN 825
ELEMENTS – REPLACE 828
CHECK HYDRAULIC OIL LEVEL 829
CHECK HYDRAULIC OIL STRAINER 830
CHECK HYDRAULIC FILTER 831
CHECK OIL LEVEL IN SWING MACHINERY CASE 832
CHECK OIL LEVEL IN FINAL DRIVE CASE 833
BLEED AIR FROM FUEL SYSTEM 833
BLEED AIR FROM HYDRAULIC SYSTEM 833
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 833
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 839
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 839
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 839
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 840
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL 840
PREPARATION FOR TROUBLESHOOTING OF GATEWAY FUNCTION CONTROLLER 841
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 842
PROCEDURE FOR TESTING AND TROUBLESHOOTING 846
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 849
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 854
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 856
CONNECTOR/ELECTRICAL WIRING CONNECTION TABLE (MACHINE WITH KOMTRAX TERMINAL) 859
CONNECTOR LIST AND LAYOUT(MACHINE WITH GATEWAY FUNCTION CONTROLLER) 949
CONNECTOR CONTACT IDENTIFICATION 962
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE1002
FUSE LOCATION TABLE1008
PRECAUTIONS FOR REPLACING KDOC1010
FAILURE CODES TABLE1011
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1027
FAILURE CODE [879AKA]1027
FAILURE CODE [879AKB]1029
FAILURE CODE [879BKA]1031
FAILURE CODE [879BKB]1033
FAILURE CODE [879CKA]1035
FAILURE CODE [879CKB]1036
FAILURE CODE [879DKZ]1037
FAILURE CODE [879EMC]1040
FAILURE CODE [879FMC]1041
FAILURE CODE [879GKX]1042
FAILURE CODE [989L00]1044
FAILURE CODE [989M00]1045
FAILURE CODE [989N00]1046
FAILURE CODE [A1U0N3]1047
FAILURE CODE [A1U0N4]1050
FAILURE CODE [A900FR]1053
FAILURE CODE [A900N6]1054
FAILURE CODE [A900NY]1055
FAILURE CODE [AA10NX]1056
FAILURE CODE [AB00KE]1058
FAILURE CODE [AQ10MB]1061
FAILURE CODE [AQ10N3]1063
FAILURE CODE [AS00R2]1065
FAILURE CODE [AS00R3]1066
FAILURE CODE [AS00R4]1067
FAILURE CODE [AS00R5]1068
FAILURE CODE [AS00R6]1069
FAILURE CODE [AS00ZK]1070
FAILURE CODE [AS10KM]1072
FAILURE CODE [AS10NR]1073
FAILURE CODE [AS10NT]1075
FAILURE CODE [AU10QA]1076
FAILURE CODE [B@BAZG]1077
FAILURE CODE [B@BAZK]1078
FAILURE CODE [B@BCNS]1080
FAILURE CODE [B@HANS]1081
FAILURE CODE [CA115]1083
FAILURE CODE [CA122]1085
FAILURE CODE [CA123]1089
FAILURE CODE [CA131]1093
FAILURE CODE [CA132]1096
FAILURE CODE [CA144]1099
FAILURE CODE [CA145]1103
FAILURE CODE [CA153]1106
FAILURE CODE [CA154]1110
FAILURE CODE [CA187]1114
FAILURE CODE [CA221]1116
FAILURE CODE [CA222]1120
FAILURE CODE [CA227]1123
FAILURE CODE [CA234]1124
FAILURE CODE [CA238]1126
FAILURE CODE [CA239]1128
FAILURE CODE [CA249]1130
FAILURE CODE [CA256]1133
FAILURE CODE [CA271]1136
FAILURE CODE [CA272]1139
FAILURE CODE [CA322]1141
FAILURE CODE [CA324]1145
FAILURE CODE [CA331]1149
FAILURE CODE [CA332]1153
FAILURE CODE [CA343]1157
FAILURE CODE [CA351]1158
FAILURE CODE [CA352]1159
FAILURE CODE [CA356]1162
FAILURE CODE [CA357]1165
FAILURE CODE [CA386]1169
FAILURE CODE [CA435]1170
FAILURE CODE [CA441]1172
FAILURE CODE [CA442]1175
FAILURE CODE [CA449]1176
FAILURE CODE [CA451]1177
FAILURE CODE [CA452]1180
FAILURE CODE [CA515]1183
FAILURE CODE [CA516]1185
FAILURE CODE [CA553]1188
FAILURE CODE [CA555]1190
FAILURE CODE [CA556]1192
FAILURE CODE [CA559]1194
FAILURE CODE [CA689]1200
FAILURE CODE [CA691]1205
FAILURE CODE [CA692]1208
FAILURE CODE [CA697]1211
FAILURE CODE [CA698]1212
FAILURE CODE [CA731]1213
FAILURE CODE [CA778]1216
FAILURE CODE [CA1117]1223
FAILURE CODE [CA1664]1225
FAILURE CODE [CA1669]1228
FAILURE CODE [CA1673]1230
FAILURE CODE [CA1677]1232
FAILURE CODE [CA1678]1234
FAILURE CODE [CA1682]1236
FAILURE CODE [CA1683]1245
FAILURE CODE [CA1684]1248
FAILURE CODE [CA1686]1251
FAILURE CODE [CA1691]1253
FAILURE CODE [CA1694]1257
FAILURE CODE [CA1695]1262
FAILURE CODE [CA1696]1263
FAILURE CODE [CA1712]1266
FAILURE CODE [CA1713]1270
FAILURE CODE [CA1714]1273
FAILURE CODE [CA1715]1275
FAILURE CODE [CA1776]1277
FAILURE CODE [CA1777]1280
FAILURE CODE [CA1843]1284
FAILURE CODE [CA1844]1287
FAILURE CODE [CA1885]1291
FAILURE CODE [CA1887]1294
FAILURE CODE [CA1896]1297
FAILURE CODE [CA1938]1299
FAILURE CODE [CA1942]1302
FAILURE CODE [CA1961]1304
FAILURE CODE [CA2185]1305
FAILURE CODE [CA2186]1307
FAILURE CODE [CA2249]1309
FAILURE CODE [CA2272]1310
FAILURE CODE [CA2311]1314
FAILURE CODE [CA2349]1315
FAILURE CODE [CA2353]1318
FAILURE CODE [CA2357]1321
FAILURE CODE [CA2636]1323
FAILURE CODE [CA2637]1327
FAILURE CODE [CA2765]1330
FAILURE CODE [CA2771]1331
FAILURE CODE [CA2976]1339
FAILURE CODE [CA3142]1343
FAILURE CODE [CA3143]1344
FAILURE CODE [CA3144]1345
FAILURE CODE [CA3146]1349
FAILURE CODE [CA3147]1350
FAILURE CODE [CA3148]1351
FAILURE CODE [CA3151]1355
FAILURE CODE [CA3165]1363
FAILURE CODE [CA3229]1367
FAILURE CODE [CA3231]1371
FAILURE CODE [CA3232]1375
FAILURE CODE [CA3235]1380
FAILURE CODE [CA3239]1384
FAILURE CODE [CA3241]1388
FAILURE CODE [CA3242]1392
FAILURE CODE [CA3251]1396
FAILURE CODE [CA3313]1400
FAILURE CODE [CA3314]1402
FAILURE CODE [CA3315]1403
FAILURE CODE [CA3419]1407
FAILURE CODE [CA3421]1409
FAILURE CODE [CA3497]1411
FAILURE CODE [CA3498]1413
FAILURE CODE [CA3543]1415
FAILURE CODE [CA3545]1423
FAILURE CODE [CA3547]1426
FAILURE CODE [CA3558]1428
FAILURE CODE [CA3559]1431
FAILURE CODE [CA3562]1434
FAILURE CODE [CA3563]1437
FAILURE CODE [CA3567]1442
FAILURE CODE [CA3568]1446
FAILURE CODE [CA3571]1454
FAILURE CODE [CA3572]1457
FAILURE CODE [CA3574]1460
FAILURE CODE [CA3575]1466
FAILURE CODE [CA3577]1469
FAILURE CODE [CA3578]1472
FAILURE CODE [CA3582]1475
FAILURE CODE [CA3583]1487
FAILURE CODE [CA3596]1490
FAILURE CODE [CA3649]1497
FAILURE CODE [CA3681]1500
FAILURE CODE [CA3682]1507
FAILURE CODE [CA3713]1514
FAILURE CODE [CA3717]1518
FAILURE CODE [CA3718]1520
FAILURE CODE [CA3724]1522
FAILURE CODE [CA3725]1523
FAILURE CODE [CA3748]1526
FAILURE CODE [CA3755]1530
FAILURE CODE [CA3866]1534
FAILURE CODE [CA3867]1539
FAILURE CODE [CA3868]1543
FAILURE CODE [CA3899]1548
FAILURE CODE [CA3911]1551
FAILURE CODE [CA3912]1556
FAILURE CODE [CA3918]1559
FAILURE CODE [CA3921]1562
FAILURE CODE [CA3928]1564
FAILURE CODE [CA3932]1565
FAILURE CODE [CA3933]1568
FAILURE CODE [CA3934]1571
FAILURE CODE [CA3935]1575
FAILURE CODE [CA3936]1578
FAILURE CODE [CA4152]1580
FAILURE CODE [CA4155]1585
FAILURE CODE [CA4156]1588
FAILURE CODE [CA4157]1592
FAILURE CODE [CA4159]1595
FAILURE CODE [CA4164]1597
FAILURE CODE [CA4165]1600
FAILURE CODE [CA4166]1603
FAILURE CODE [CA4168]1605
FAILURE CODE [CA4169]1608
FAILURE CODE [CA4171]1611
FAILURE CODE [CA4249]1615
FAILURE CODE [CA4251]1618
FAILURE CODE [CA4261]1621
FAILURE CODE [CA4277]1625
FAILURE CODE [CA4281]1630
FAILURE CODE [CA4459]1636
FAILURE CODE [CA4461]1639
FAILURE CODE [CA4533]1644
FAILURE CODE [CA4534]1645
FAILURE CODE [CA4731]1647
FAILURE CODE [CA4732]1649
FAILURE CODE [CA4739]1651
FAILURE CODE [CA4768]1653
FAILURE CODE [CA4769]1656
FAILURE CODE [CA4842]1659
FAILURE CODE [CA4952](MACHINE WITH KOMTRAX TERMINAL)1664
FAILURE CODE [CA4952](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1666
FAILURE CODE [CA5115]1668
FAILURE CODE [CA5179]1672
FAILURE CODE [CA5181]1675
FAILURE CODE [CA5271]1678
FAILURE CODE [CA5272]1681
FAILURE CODE [CA5273]1684
FAILURE CODE [CA5274]1687
FAILURE CODE [CA5275]1689
FAILURE CODE [CA5276]1692
FAILURE CODE [CA5277]1695
FAILURE CODE [CA5387]1697
FAILURE CODE [CA5388]1701
FAILURE CODE [CA5389]1704
FAILURE CODE [CA5391]1709
FAILURE CODE [CA5392]1715
FAILURE CODE [CA5393]1717
FAILURE CODE [CA5394]1720
FAILURE CODE [CA5395]1723
FAILURE CODE [CA5396]1726
FAILURE CODE [CA5631]1728
FAILURE CODE [CA5938]1730
FAILURE CODE [D110KB]1732
FAILURE CODE [D19JKZ]1734
FAILURE CODE [D811MC](MACHINE WITH KOMTRAX TERMINAL)1737
FAILURE CODE [D811MC](MACHINE WITH GATEWAY FUNCTION CONTROLLER )1738
FAILURE CODE [D862KA](MACHINE WITH KOMTRAX TERMINAL)1739
FAILURE CODE [D862KA](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1740
FAILURE CODE [D8ALKA](MACHINE WITH KOMTRAX TERMINAL)1742
FAILURE CODE [D8ALKA](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1745
FAILURE CODE [D8ALKB](MACHINE WITH KOMTRAX TERMINAL)1748
FAILURE CODE [D8ALKB](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1750
FAILURE CODE [D8AQKR](MACHINE WITH KOMTRAX TERMINAL)1752
FAILURE CODE [D8AQKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1757
FAILURE CODE [D8G1KT]1762
FAILURE CODE [D8G6KT]1763
FAILURE CODE [DA20MC]1764
FAILURE CODE [DA22KK]1765
FAILURE CODE [DA25KP]1769
FAILURE CODE [DA26KP]1774
FAILURE CODE [DA29KQ]1776
FAILURE CODE [DA2LKA](MACHINE WITH KOMTRAX TERMINAL)1779
FAILURE CODE [DA2LKA](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1782
FAILURE CODE [DA2LKB](MACHINE WITH KOMTRAX TERMINAL)1785
FAILURE CODE [DA2LKB](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1787
FAILURE CODE [DA2QKR](MACHINE WITH KOMTRAX TERMINAL)1789
FAILURE CODE [DA2QKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1796
FAILURE CODE [DA2RKR](MACHINE WITH KOMTRAX TERMINAL)1803
FAILURE CODE [DA2RKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1810
FAILURE CODE [DAF0KM]1817
FAILURE CODE [DAF0MB]1818
FAILURE CODE [DAF0MC]1819
FAILURE CODE [DAF8KB]1820
FAILURE CODE [DAF9KQ]1822
FAILURE CODE [DAFGMC]1824
FAILURE CODE [DAFLKA](MACHINE WITH KOMTRAX TERMINAL)1825
FAILURE CODE [DAFLKA](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1828
FAILURE CODE [DAFLKB](MACHINE WITH KOMTRAX TERMINAL)1831
FAILURE CODE [DAFLKB](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1833
FAILURE CODE [DAFQKR](MACHINE WITH KOMTRAX TERMINAL)1835
FAILURE CODE [DAFQKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1841
FAILURE CODE [DAZ9KQ]1847
FAILURE CODE [DAZQKR](MACHINE WITH KOMTRAX TERMINAL)1849
FAILURE CODE [DAZQKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1854
FAILURE CODE [DB2QKR](MACHINE WITH KOMTRAX TERMINAL)1859
FAILURE CODE [DB2QKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1866
FAILURE CODE [DB2RKR](MACHINE WITH KOMTRAX TERMINAL)1873
FAILURE CODE [DB2RKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1881
FAILURE CODE [DB90MC]1889
FAILURE CODE [DBP0KM]1890
FAILURE CODE [DBP0KT]1891
FAILURE CODE [DBP5KB]1892
FAILURE CODE [DBP5KY]1895
FAILURE CODE [DBPQKR](MACHINE WITH KOMTRAX TERMINAL)1898
FAILURE CODE [DBPQKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER)1904
FAILURE CODE [DDNRKA]1910
FAILURE CODE [DDNRKY]1913
FAILURE CODE [DDNS00]1916
FAILURE CODE [DFB1KZ]1918
FAILURE CODE [DFB2KZ]1921
FAILURE CODE [DFB3L8]1924
FAILURE CODE [DFB4L8]1926
FAILURE CODE [DFB5KZ]1928
FAILURE CODE [DFB6KZ]1931
FAILURE CODE [DGH2KA]1934
FAILURE CODE [DGH2KB]1936
FAILURE CODE [DHA4KA]1938
FAILURE CODE [DHPAMA]1940
FAILURE CODE [DHS3MA]1943
FAILURE CODE [DHS4MA]1946
FAILURE CODE [DHS8MA]1949
FAILURE CODE [DHS9MA]1952
FAILURE CODE [DHSAMA]1955
FAILURE CODE [DHSBMA]1958
FAILURE CODE [DHSCMA]1961
FAILURE CODE [DHSDMA]1964
FAILURE CODE [DHSFMA]1967
FAILURE CODE [DHSGMA]1970
FAILURE CODE [DHSHMA]1973
FAILURE CODE [DHSJMA]1976
FAILURE CODE [DHSKMA]1979
FAILURE CODE [DHSLMA]1981
FAILURE CODE [DKULKA]1983
FAILURE CODE [DKULKB]1985
FAILURE CODE [DKULKY]1987
FAILURE CODE [DLM5KA]1989
FAILURE CODE [DLM5MB]1993
FAILURE CODE [DR10KA]1995
FAILURE CODE [DR12KA]1999
FAILURE CODE [DR20KA]2001
FAILURE CODE [DR21KX]2003
FAILURE CODE [DR40KA]2006
FAILURE CODE [DUMBKA](MACHINE WITH KOMTRAX TERMINAL)2008
FAILURE CODE [DUMBKA](MACHINE WITH GATEWAY FUNCTION CONTROLLER)2011
FAILURE CODE [DUMBKB](MACHINE WITH KOMTRAX TERMINAL)2014
FAILURE CODE [DUMBKB](MACHINE WITH GATEWAY FUNCTION CONTROLLER)2016
FAILURE CODE [DV20KB]2018
FAILURE CODE [DW43KA]2020
FAILURE CODE [DW43KB]2022
FAILURE CODE [DW43KY]2024
FAILURE CODE [DW45KA]2026
FAILURE CODE [DW45KB]2030
FAILURE CODE [DW45KY]2034
FAILURE CODE [DW4CKY]2036
FAILURE CODE [DW91KA]2038
FAILURE CODE [DW91KB]2041
FAILURE CODE [DW91KY]2043
FAILURE CODE [DWA2KA]2045
FAILURE CODE [DWA2KB]2048
FAILURE CODE [DWA2KY]2050
FAILURE CODE [DWJ0KA]2052
FAILURE CODE [DWJ0KB]2055
FAILURE CODE [DWJ0KY]2058
FAILURE CODE [DWK2KA]2060
FAILURE CODE [DWK2KB]2063
FAILURE CODE [DWK2KY]2065
FAILURE CODE [DWN5KA]2067
FAILURE CODE [DWN5KB]2070
FAILURE CODE [DWN5KY]2073
FAILURE CODE [DWNSKA]2075
FAILURE CODE [DWNSKB]2077
FAILURE CODE [DWNSKY]2079
FAILURE CODE [DXA8KA]2081
FAILURE CODE [DXA8KB]2085
FAILURE CODE [DXE4KA]2087
FAILURE CODE [DXE4KB]2090
FAILURE CODE [DXE4KY]2092
FAILURE CODE [DXEKKA]2094
FAILURE CODE [DXEKKB]2097
FAILURE CODE [DXEKKY]2099
FAILURE CODE [DY20KA]2101
FAILURE CODE [DY20MA]2104
FAILURE CODE [DY2CKB]2107
FAILURE CODE [DY2DKB]2111
FAILURE CODE [DY2EKB]2114
FAILURE CODE [F313KA]2117
FAILURE CODE [F313KB]2119
FAILURE CODE [F318KB]2121
FAILURE CODE [F318KY]2123
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)2125
ENGINE DOES NOT START (ENGINE DOES NOT CRANK)2125
MANUAL PREHEATING SYSTEM DOES NOT WORK2131
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP2134
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING2136
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING2139
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING2140
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING2141
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2142
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2143
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2144
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2145
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2146
FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM2147
DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL2149
ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM2150
DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE2151
AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY2152
HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM2155
DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE2157
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED2158
FUNCTION SWITCH DOES NOT OPERATE2159
AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)2160
WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF2161
AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER2162
WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED2164
WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED2165
WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE2166
WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE2167
ALARM BUZZER CANNOT BE CANCELED2168
SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION2169
SERVICE MODE CANNOT BE SELECTED2170
ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE2171
ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK2174
WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING2176
WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE2178
WORK EQUIPMENT DOES NOT OPERATE WHILE LOCK LEVER AUTOMATIC RELEASE SWITCH IS IN RELEASE POSITION2180
ALARM DOES NOT SOUND DURING TRAVEL2182
ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED2184
HORN DOES NOT SOUND2185
HORN DOES NOT STOP SOUNDING2187
WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF2188
WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE2189
WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE2191
BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2192
BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2193
ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2194
ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2195
BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2196
BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2197
SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2198
TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2199
SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2200
BLADE RAISE ON IS NOT DISPLAYED CORRECTLY WITH MONITORING2203
BLADE LOWER ON IS NOT DISPLAYED CORRECTLY WITH MONITORING2204
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY2205
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)2206
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)2206
FAILURE MODE AND CAUSE TABLE2207
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK2216
ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER2217
FINE CONTROL PERFORMANCE OR RESPONSE IS POOR2219
UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP2220
ENGINE SPEED DROPS LARGELY OR ENGINE STOPS2221
SPEED OR POWER OF BOOM IS LOW2223
ARM SPEED OR POWER IS LOW2226
BUCKET SPEED OR POWER IS LOW2229
BLADE SPEED OR POWER IS LOW2232
WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION2234
HYDRAULIC DRIFT OF BOOM IS LARGE2235
HYDRAULIC DRIFT OF ARM IS LARGE2236
HYDRAULIC DRIFT OF BUCKET IS LARGE2237
HYDRAULIC DRIFT OF BLADE IS LARGE2238
WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES2240
TIME LAG OF WORK EQUIPMENT IS LARGE2241
ATTACHMENT CIRCUIT CANNOT BE CHANGED2242
OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED2243
IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER2244
IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY2245
IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW2246
MACHINE DOES NOT TRAVEL STRAIGHT2247
MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW2250
TRAVEL SPEED IS LOW2252
ONE OF TRACKS DOES NOT RUN2254
TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST2256
UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT2257
SWINGS ONLY IN ONE DIRECTION2258
SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)2259
SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION2260
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)2261
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)2262
SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING2263
LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING2264
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)2265
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)2266
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)2267
UNUSUAL NOISE IS HEARD FROM AROUND FAN2268
TROUBLESHOOTING OF ENGINE (S-MODE)2269
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2269
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2270
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2271
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2272
ENGINE STARTABILITY IS POOR2273
ENGINE DOES NOT PICK UP SMOOTHLY2275
ENGINE STOPS DURING OPERATION2277
ENGINE RUNS ROUGH OR IS UNSTABLE2279
ENGINE LACKS POWER2280
EXHAUST SMOKE IS BLACK2282
ENGINE OIL CONSUMPTION IS EXCESSIVE2284
OIL BECOMES CONTAMINATED QUICKLY2285
FUEL CONSUMPTION IS EXCESSIVE2286
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2287
OIL PRESSURE DROPS2288
FUEL MIXES INTO ENGINE OIL2289
WATER MIXES INTO ENGINE OIL (MILKY)2290
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2291
UNUSUAL NOISE IS HEARD2292
VIBRATION IS EXCESSIVE2294
AIR CANNOT BE BLED FROM FUEL CIRCUIT2295
ACTIVE REGENERATION IS EXECUTED FREQUENTLY2296
ACTIVE REGENERATION TAKES TIME2297
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2298
AdBlue/DEF CONSUMPTION IS EXCESSIVE2299
THERE IS UNUSUAL SMELL (IRRITATING ODOR)2301
FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2302
50 DISASSEMBLY AND ASSEMBLY2303
CONTENTS2304
ABBREVIATION LIST2309
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2315
HOW TO READ THIS MANUAL2315
COATING MATERIALS LIST2317
SPECIAL TOOLS LIST2321
SKETCHES OF SPECIAL TOOLS2334
ENGINE AND COOLING SYSTEM2337
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS NOT REMOVED)2337
REMOVE SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS NOT REMOVED)2338
INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS NOT REMOVED)2344
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS REMOVED)2351
REMOVE SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS REMOVED)2351
INSTALL SUPPLY PUMP ASSEMBLY (WHEN COUNTERWEIGHT ASSEMBLY IS REMOVED)2354
REMOVE AND INSTALL INJECTOR ASSEMBLY2358
METHOD FOR REMOVING INJECTOR ASSEMBLY2359
METHOD FOR INSTALLING INJECTOR ASSEMBLY2366
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2379
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2380
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2396
REMOVE AND INSTALL EGR VALVE ASSEMBLY2420
METHOD FOR REMOVING EGR VALVE ASSEMBLY2420
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2422
REMOVE AND INSTALL EGR COOLER ASSEMBLY2425
METHOD FOR REMOVING EGR COOLER ASSEMBLY2425
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2428
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2432
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY2432
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY2437
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT2442
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT2442
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT2443
REMOVE AND INSTALL ALTERNATOR BELT2445
METHOD FOR REMOVING ALTERNATOR BELT2445
METHOD FOR INSTALLING ALTERNATOR BELT2447
REMOVE AND INSTALL AUTOMATIC TENSIONER2449
METHOD FOR REMOVING AUTOMATIC TENSIONER2449
METHOD FOR INSTALLING AUTOMATIC TENSIONER2449
REMOVE AND INSTALL RADIATOR ASSEMBLY2451
METHOD FOR REMOVING RADIATOR ASSEMBLY2451
METHOD FOR INSTALLING RADIATOR ASSEMBLY2454
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2458
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2458
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2464
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2469
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2469
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2471
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY2473
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY2474
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY2480
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY2489
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY2491
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY2502
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2518
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2518
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2519
REMOVE AND INSTALL ENGINE REAR OIL SEAL2521
METHOD FOR REMOVING ENGINE REAR OIL SEAL2521
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2522
REMOVE AND INSTALL FUEL COOLER ASSEMBLY2526
METHOD FOR REMOVING FUEL COOLER ASSEMBLY2526
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY2528
REMOVE AND INSTALL KDOC ASSEMBLY2530
METHOD FOR REMOVING KDOC ASSEMBLY2530
METHOD FOR INSTALLING KDOC ASSEMBLY2535
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY2539
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY2540
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY2547
REMOVE AND INSTALL FUEL TANK ASSEMBLY2555
METHOD FOR REMOVING FUEL TANK ASSEMBLY2556
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2563
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2572
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2573
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2578
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2585
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2586
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2591
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2598
REMOVE AdBlue/DEF TANK SENSOR2598
INSTALL AdBlue/DEF TANK SENSOR2599
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2606
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2606
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2606
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER2608
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER2608
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER2610
REMOVE AND INSTALL SCR ASSEMBLY2613
METHOD FOR REMOVING SCR ASSEMBLY2613
METHOD FOR INSTALLING SCR ASSEMBLY2618
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY BRACKET2623
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY BRACKET2623
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY BRACKET2627
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY2632
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY2633
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY2635
REMOVE AND INSTALL KCCV ASSEMBLY2639
METHOD FOR REMOVING KCCV ASSEMBLY2640
METHOD FOR INSTALLING KCCV ASSEMBLY2641
REMOVE AND INSTALL EXHAUST THROTTLE VALVE2643
METHOD FOR REMOVING EXHAUST THROTTLE VALVE2644
METHOD FOR INSTALLING EXHAUST THROTTLE VALVE2650
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2657
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2658
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2663
REMOVE AND INSTALL AdBlue/DEF INJECTOR2667
METHOD FOR REMOVING AdBlue/DEF INJECTOR2668
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2672
REMOVE AND INSTALL AdBlue/DEF PUMP2677
METHOD FOR REMOVING AdBlue/DEF PUMP2678
METHOD FOR INSTALLING AdBlue/DEF PUMP2681
REMOVE AND INSTALL AdBlue/DEF HOSE2685
METHOD FOR REMOVING AdBlue/DEF HOSE2685
METHOD FOR INSTALLING AdBlue/DEF HOSE2696
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2706
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2706
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2708
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2712
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2712
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2715
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2718
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2718
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2720
POWER TRAIN2722
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2722
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2723
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2725
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE MACHINE:50001～54383)2729
METHOD FOR DISASSEMBLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE MACHINE:50001～54383)2740
METHOD FOR ASSEMBLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE MACHINE:50001～54383)2757
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE MACHINE:54384～)2774
DISASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE MACHINE:54834～)2786
ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY (APPLICABLE MACHINE:54384～)2804
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY2825
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY2826
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY2829
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY2832
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY2833
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY2836
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY2842
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY2842
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY2843
UNDERCARRIAGE AND FRAME2844
SEPARATION AND CONNECTION OF TRACK ASSEMBLY2844
METHOD FOR SEPARATING TRACK ASSEMBLY2845
METHOD FOR INSTALLING TRACK ASSEMBLY2847
REMOVE AND INSTALL SPROCKET2850
METHOD FOR REMOVING SPROCKET2850
METHOD FOR INSTALLING SPROCKET2851
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY2852
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY2852
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY2853
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2854
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2855
METHOD FOR ASSEMBLING IDLER ASSEMBLY2856
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY2860
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY2860
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY2862
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2865
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2865
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2867
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY2870
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY2871
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY2874
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2877
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2878
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2883
HYDRAULIC SYSTEM2890
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY2890
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY2891
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY2894
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2899
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2900
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2901
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2902
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2903
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2908
REMOVE AND INSTALL MAIN PUMP ASSEMBLY2914
METHOD FOR REMOVING MAIN PUMP ASSEMBLY2915
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY2920
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2927
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2928
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2938
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY2950
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY2950
METHOD FOR REPLACING PRESSURE REDUCING VALVE CARTRIDGE ASSEMBLY2953
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2956
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2956
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2957
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2959
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY2959
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY2959
WORK EQUIPMENT2962
REMOVE AND INSTALL BLADE ASSEMBLY2962
METHOD FOR REMOVING BLADE ASSEMBLY2962
METHOD FOR INSTALLING BLADE ASSEMBLY2963
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2966
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2967
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2973
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2979
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2980
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2982
CAB AND ITS ATTACHMENTS2989
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2989
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2989
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2993
REMOVE AND INSTALL OPERATOR’S CAB DOOR2998
METHOD FOR INSTALLING OPERATOR’S CAB DOOR2999
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)3003
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)3004
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)3005
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY3014
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY3014
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY3017
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY3018
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY3019
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY3029
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY3040
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY3041
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY3046
REMOVE AND INSTALL OPERATOR’S SEAT3053
METHOD FOR REMOVING OPERATOR’S SEAT3053
METHOD FOR INSTALLING OPERATOR’S SEAT3054
REMOVE AND INSTALL SEAT BELT3055
METHOD FOR REMOVING SEAT BELT3055
METHOD FOR INSTALLING SEAT BELT3056
REMOVE AND INSTALL FRONT WIPER ASSEMBLY3057
METHOD FOR REMOVING FRONT WIPER ASSEMBLY3057
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY3062
ELECTRICAL SYSTEM3070
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY3070
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY3070
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY3072
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY3073
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY3073
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY3076
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY3079
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY3079
METHOD FOR INSTALLING KomVision CONTROLLER ASSEMBLY3081
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY3083
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY3083
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY3086
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR3089
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR3089
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR3090
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR3092
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR3092
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR3094
REMOVE AND INSTALL SCR TEMPERATURE SENSOR3097
METHOD FOR REMOVING SCR TEMPERATURE SENSOR3097
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR3098
REMOVE AND INSTALL REARVIEW CAMERA3100
METHOD FOR REMOVING REARVIEW CAMERA3100
METHOD FOR INSTALLING REARVIEW CAMERA3102
REMOVE AND INSTALL KomVision CAMERA3104
METHOD FOR REMOVING KomVision CAMERA3105
METHOD FOR INSTALLING KomVision CAMERA3107
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY3109
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY3109
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY3111
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY3113
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY3113
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY3115
REMOVE AND INSTALL COMMUNICATION TERMINAL3117
REMOVE COMMUNICATION TERMINAL3117
INSTALL COMMUNICATION TERMINAL3118
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS3120
REMOVE COMMUNICATION TERMINAL WIRING HARNESS3121
INSTALL COMMUNICATION TERMINAL WIRING HARNESS3124
60 MAINTENANCE STANDARD3129
CONTENTS3130
ABBREVIATION LIST3131
ENGINE AND COOLING SYSTEM3137
MAINTENANCE STANDARD OF ENGINE MOUNT3137
MAINTENANCE STANDARD FOR PTO3138
MAINTENANCE STANDARD OF COOLING SYSTEM3139
POWER TRAIN3140
MAINTENANCE STANDARD OF SWING CIRCLE3140
MAINTENANCE STANDARD OF SWING MACHINERY3141
MAINTENANCE STANDARD OF SPROCKET3143
UNDERCARRIAGE AND FRAME3144
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION3144
MAINTENANCE STANDARD OF IDLER3146
MAINTENANCE STANDARD OF TRACK ROLLER3147
MAINTENANCE STANDARD OF CARRIER ROLLER3148
MAINTENANCE STANDARD OF TRACK SHOE3149
MAINTENANCE STANDARD OF TRIPLE SHOE3152
MAINTENANCE STANDARD OF ROAD LINER3153
HYDRAULIC SYSTEM3154
MAINTENANCE STANDARD OF HYDRAULIC TANK3154
MAINTENANCE STANDARD OF MAIN PUMP3155
MAINTENANCE STANDARD OF PC-EPC VALVE3159
MAINTENANCE STANDARD OF SWING MOTOR3160
MAINTENANCE STANDARD OF TRAVEL MOTOR (APPLICABLE MACHINE:50001～54383)3163
MAINTENANCE STANDARD OF TRAVEL MOTOR (APPLICABLE MACHINE:54384～)3164
MAINTENANCE STANDARD OF CONTROL VALVE3165
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE3176
MAINTENANCE STANDARD OF BLADE PPC VALVE3179
MAINTENANCE STANDARD OF TRAVEL PPC VALVE3181
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)3184
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE3186
MAINTENANCE STANDARD OF SOLENOID VALVE3187
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE SOLENOID VALVE3190
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)3191
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)3192
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT)3193
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT3194
WORK EQUIPMENT3195
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE3195
DIMENSION OF ARM3200
DIMENSIONS OF BUCKET3202
MAINTENANCE STANDARD OF BOOM CYLINDER3204
MAINTENANCE STANDARD OF ARM CYLINDER3205
MAINTENANCE STANDARD OF BUCKET CYLINDER3206
MAINTENANCE STANDARD OF BLADE CYLINDER3207
CAB AND ITS ATTACHMENTS3208
MAINTENANCE STANDARD OF CAB MOUNT3208
80 APPENDIX3209
CONTENTS3210
ABBREVIATION LIST3212
AIR CONDITIONER SYSTEM3218
PRECAUTIONS FOR REFRIGERANT3218
AIR CONDITIONER COMPONENT3219
SPECIFICATIONS OF AIR CONDITIONER3221
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE3222
OUTLINE OF REFRIGERATION CYCLE3223
COMPONENT PARTS OF AIR CONDITIONER SYSTEM3225
AIR CONDITIONER UNIT3225
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT3225
FUNCTION OF AIR CONDITIONER UNIT3227
COMPONENT PARTS OF AIR CONDITIONER UNIT3228
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT3228
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT3228
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT3228
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT3229
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3230
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3230
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3230
FUNCTION OF DUAL PRESSURE SWITCH3231
AIR CONDITIONER CONTROLLER3232
STRUCTURE OF AIR CONDITIONER CONTROLLER3232
COMPRESSOR3233
STRUCTURE OF COMPRESSOR3233
SPECIFICATIONS OF COMPRESSOR3233
FUNCTION OF COMPRESSOR3233
CONDENSER3234
STRUCTURE OF CONDENSER3234
SPECIFICATIONS OF CONDENSER3234
FUNCTION OF CONDENSER3234
SENSORS FOR AIR CONDITIONER SYSTEM3236
STRUCTURE OF SUNLIGHT SENSOR3236
FUNCTION OF SUNLIGHT SENSOR3236
STRUCTURE OF AMBIENT TEMPERATURE SENSOR3236
FUNCTION OF AMBIENT TEMPERATURE SENSOR3236
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER3238
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER3240
AIR CONDITIONER SYSTEM DIAGRAM3242
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER3243
FUNCTION OF AIR CONDITIONER CONTROLLER3244
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS3245
TESTING AIR LEAKAGE (DUCT)3254
METHOD FOR TESTING AIR LEAKAGE (DUCT)3254
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION3256
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR3257
TEST VENT (MODE) CHANGEOVER3258
METHOD FOR TESTING VENT (MODE) CHANGEOVER3258
TESTING FRESH/RECIRC AIR CHANGEOVER3259
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER3259
TEST SUNLIGHT SENSOR3260
METHOD FOR TESTING SUNLIGHT SENSOR3260
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT3261
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT3261
TEST RELAYS3263
METHOD FOR TESTING RELAYS3263
AIR CONDITIONER TROUBLESHOOTING CHART 13264
AIR CONDITIONER TROUBLESHOOTING CHART 23265
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE3268
FAILURE CODE [879AKA]3270
FAILURE CODE [879AKB]3272
FAILURE CODE [879BKA]3274
FAILURE CODE [879BKB]3276
FAILURE CODE [879CKA]3278
FAILURE CODE [879CKB]3279
FAILURE CODE [879DKZ]3280
FAILURE CODE [879EMC]3283
FAILURE CODE [879FMC]3284
FAILURE CODE [879GKX]3285
TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)3287
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)3289
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)3292
TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER3294
TROUBLESHOOTING USING GAUGE PRESSURE3296
CONNECTION OF SERVICE TOOL3298
METHOD FOR CONNECTING SERVICE TOOL3298
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS3300
HANDLE COMPRESSOR OIL3302
METHOD FOR REPLACING DESICCANT3304
90 CIRCUIT DIAGRAMS3307
CONTENTS3308
ABBREVIATION LIST3309
HYDRAULIC CIRCUIT DIAGRAM3315
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM3315
HYDRAULIC CIRCUIT DIAGRAM (BLADE LESS SPECIFICATION, MACHINE WITH 1ST-LINE ATTACHMENT IS INSTALLABLE)3319
HYDRAULIC CIRCUIT DIAGRAM (BLADE SPECIFICATION, MACHINE WITH 1ST-LINE ATTACHMENT IS INSTALLABLE)3321
HYDRAULIC CIRCUIT DIAGRAM (BLADE SPECIFICATION, MACHINE WITH 1ST-LINE ATTACHMENT IS INSTALLABLE AND ARM CRANE SPECIFICATION)3323
HYDRAULIC CIRCUIT DIAGRAM (MACHINE WITH MULTI-CONTROL VALVE)3325
HYDRAULIC CIRCUIT DIAGRAM (MACHINE WITH TOOL CONTROL SYSTEM)3327
ELECTRICAL CIRCUIT DIAGRAM3329
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM3329
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (1/9)3333
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (2/9)3335
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (3/9)3337
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (4/9)3339
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (5/9)3341
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (6/9)3343
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (7/9)3345
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (8/9)3347
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (9/9)3349
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/10)3351
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/10)3353
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/10)3355
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/10)3357
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/10)3359
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/10)3361
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/10)3363
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/10)3365
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/10)3367
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (10/10)3369
WIRING HARNESS DIAGRAM3371
WIRING HARNESS DIAGRAM (1/14)3373
WIRING HARNESS DIAGRAM (2/14)3375
WIRING HARNESS DIAGRAM (3/14)3377
WIRING HARNESS DIAGRAM (4/14)3379
WIRING HARNESS DIAGRAM (5/14)3381
WIRING HARNESS DIAGRAM (6/14)3383
WIRING HARNESS DIAGRAM (7/14)3385
WIRING HARNESS DIAGRAM (8/14)3387
WIRING HARNESS DIAGRAM (9/14)3389
WIRING HARNESS DIAGRAM (10/14)3391
WIRING HARNESS DIAGRAM (11/14)3393
WIRING HARNESS DIAGRAM (12/14)3395
WIRING HARNESS DIAGRAM (13/14)3397
WIRING HARNESS DIAGRAM (14/14)3399
INDEX3401

S.M 29/12/24