Komatsu HYDRAULIC EXCAVATOR PC700LC -11 Shop Manual UENBM00432 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC700LC -11 Shop Manual UENBM00432 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC700LC -11 Shop Manual UENBM00432 – PDF DOWNLOAD

Language : English
Pages :2736
Downloadable : Yes
File Type : PDF

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Komatsu HYDRAULIC EXCAVATOR PC700LC -11 Shop Manual UENBM00432 – PDF DOWNLOAD

SERIAL NUMBERS 80013 and up
K70001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
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 THE OTHER INFORMATION
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.

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC700LC -11 Shop Manual UENBM00432 – PDF DOWNLOAD

SERIAL NUMBERS 80013 and up
K70001 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: PC700LC-11 103
SPECIFICATION DRAWING: PC700LCSE-11 104
WORKING RANGE DRAWINGS 106
WORKING RANGE: PC700LC-11 106
WORKING RANGE: PC700LCSE-11 107
SPECIFICATIONS 108
SPECIFICATIONS: PC700LC-11 108
SPECIFICATIONS: PC700LCSE-11 110
WEIGHT TABLE 114
WEIGHT TABLE: PC700LC-11 114
WEIGHT TABLE: PC700LCSE-11 115
TABLE OF FUEL, COOLANT, AND LUBRICANTS 117
10 STRUCTURE AND FUNCTION 119
CONTENTS 120
ABBREVIATION LIST 123
UREA SCR SYSTEM 129
LAYOUT DRAWING OF UREA SCR SYSTEM 129
UREA SCR SYSTEM DIAGRAM 134
FUNCTION OF UREA SCR SYSTEM 135
FUNCTION OF AdBlue/DEF SYSTEM 135
INDUCEMENT STRATEGY 137
COMPONENT PARTS OF UREA SCR SYSTEM 145
AdBlue/DEF MIXING TUBE 145
SCR ASSEMBLY 145
AdBlue/DEF TANK 148
AdBlue/DEF PUMP 150
AdBlue/DEF INJECTOR 151
AdBlue/DEF HOSE 152
AdBlue/DEF TANK HEATING VALVE 153
BOOT-UP SYSTEM 154
LAYOUT DRAWING OF BOOT-UP SYSTEM 154
SYSTEM OPERATING LAMP SYSTEM 155
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 155
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 155
BATTERY DISCONNECT SWITCH 157
FUNCTION OF BATTERY DISCONNECT SWITCH 157
ENGINE SYSTEM 158
LAYOUT DRAWING OF ENGINE SYSTEM 158
FUNCTION OF ENGINE SYSTEM 159
ENGINE CONTROL SYSTEM 160
ENGINE CONTROL SYSTEM DIAGRAM 160
FUNCTION OF ENGINE CONTROL SYSTEM 160
AUTO-DECELERATION SYSTEM 163
AUTO-DECELERATION SYSTEM DIAGRAM 163
FUNCTION OF AUTO-DECELERATION SYSTEM 163
OPERATION OF AUTO-DECELERATION SYSTEM 164
AUTOMATIC LOW IDLE SYSTEM 165
AUTOMATIC LOW IDLE SYSTEM DIAGRAM 165
FUNCTION OF AUTOMATIC LOW IDLE SYSTEM 165
OPERATION OF AUTOMATIC LOW IDLE SYSTEM 166
ENGINE AUTOMATIC WARM-UP SYSTEM 167
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 167
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 168
OVERHEAT PREVENTION SYSTEM 170
OVERHEAT PREVENTION SYSTEM DIAGRAM 170
FUNCTION OF OVERHEAT PREVENTION SYSTEM 171
TURBOCHARGER PROTECTION SYSTEM 172
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 172
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 173
AUTOMATIC IDLE STOP SYSTEM 174
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 174
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 174
COMPONENT PARTS OF ENGINE SYSTEM 177
PTO 177
VGT 178
EGR SYSTEM 181
EGR VALVE 183
EGR COOLER 185
KCCV SYSTEM 186
KCCV VENTILATOR 188
KDPF 190
COOLING SYSTEM 195
LAYOUT DRAWING OF COOLING SYSTEM 195
SPECIFICATIONS OF COOLING SYSTEM 196
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 197
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 197
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 198
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 199
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 199
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 199
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 201
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN 201
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 201
COMPONENT PARTS OF COOLING SYSTEM 202
COOLING FAN PUMP 202
COOLING FAN MOTOR 210
CONTROL SYSTEM 217
LAYOUT DRAWING OF CONTROL SYSTEM 217
MACHINE MONITOR SYSTEM 219
MACHINE MONITOR SYSTEM DIAGRAM 219
FUNCTION OF MACHINE MONITOR SYSTEM 219
KomVision SYSTEM 221
LAYOUT DRAWING OF KOMVISION SYSTEM 221
KomVision SYSTEM DIAGRAM 223
FUNCTION OF KomVision SYSTEM 223
KOMTRAX SYSTEM 225
KOMTRAX SYSTEM DIAGRAM 225
FUNCTION OF KOMTRAX SYSTEM 225
COMPONENT PARTS OF CONTROL SYSTEM 226
MACHINE MONITOR 226
KomVision CONTROLLER 239
KomVision CAMERA 243
KOMTRAX TERMINAL 243
PUMP CONTROLLER 246
RESISTOR FOR TVC VALVE 250
CAN TERMINATING RESISTOR 250
ENGINE CONTROLLER 252
FUEL CONTROL DIAL 258
FUEL FEED PUMP 260
FUEL FEED PUMP SWITCH 261
HYDRAULIC SYSTEM 262
LAYOUT DRAWING OF HYDRAULIC SYSTEM 262
OLSS 265
STRUCTURE OF OLSS 265
FUNCTION OF OLSS 265
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 266
ENGINE AND PUMP COMBINED CONTROL SYSTEM 277
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 277
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 279
COMPONENT PARTS OF HYDRAULIC SYSTEM 282
HYDRAULIC TANK 282
MAIN PUMP 284
CONTROL VALVE 311
VARIABLE BACK PRESSURE VALVE 331
WORK EQUIPMENT SYSTEM 334
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 334
ONE-TOUCH POWER MAXIMIZING SYSTEM 340
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 340
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 341
MACHINE PUSH-UP SYSTEM 342
MACHINE PUSH-UP SYSTEM DIAGRAM 342
FUNCTION OF MACHINE PUSH-UP SYSTEM 343
PPC LOCK SYSTEM 344
PPC LOCK SYSTEM DIAGRAM 344
FUNCTION OF PPC LOCK SYSTEM 344
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 345
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 345
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 345
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 346
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 347
WORK EQUIPMENT AND SWING PPC VALVE 347
1ST-LINE ATTACHMENT PPC VALVE 351
PPC SHUTTLE VALVE 353
SOLENOID VALVE 354
ANTI-DROP VALVE FOR BOOM 356
ANTI-DROP VALVE FOR ARM 360
PILOT CIRCUIT ACCUMULATOR 365
SWING SYSTEM 366
LAYOUT DRAWING OF SWING SYSTEM 366
SWING CONTROL SYSTEM DIAGRAM 369
FUNCTION OF SWING CONTROL SYSTEM 370
COMPONENT PARTS OF SWING SYSTEM 373
SWING MOTOR 373
SWING MACHINERY 384
SWING CIRCLE 385
TRAVEL SYSTEM 387
LAYOUT DRAWING OF TRAVEL SYSTEM 387
TRAVEL CONTROL SYSTEM DIAGRAM 391
FUNCTION OF TRAVEL CONTROL SYSTEM 392
COMPONENT PARTS OF TRAVEL SYSTEM 394
TRAVEL MOTOR 394
FINAL DRIVE 404
TRAVEL PPC VALVE 405
CENTER SWIVEL JOINT 410
UNDERCARRIAGE AND FRAME 412
LAYOUT DRAWING OF UNDERCARRIAGE 412
SPECIFICATIONS OF UNDERCARRIAGE 412
WORK EQUIPMENT 413
STRUCTURE OF WORK EQUIPMENT 413
FUNCTION OF WORK EQUIPMENT 414
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 415
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 415
BUCKET CLEARANCE ADJUSTMENT SHIM 416
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 416
CAB AND ITS ATTACHMENTS 417
ROPS CAB 417
STRUCTURE OF ROPS CAB 417
FUNCTION OF ROPS CAB 417
CAB MOUNT 418
STRUCTURE OF CAB MOUNT 418
FUNCTION OF CAB MOUNT 418
CAB TIPPING STOPPER 419
STRUCTURE OF CAB TIPPING STOPPER 419
FUNCTION OF CAB TIPPING STOPPER 419
20 STANDARD VALUE TABLE 421
CONTENTS 422
ABBREVIATION LIST 423
STANDARD VALUE TABLE FOR ENGINE 429
STANDARD VALUE TABLE FOR ENGINE: PC700LC-11 429
STANDARD VALUE TABLE FOR MACHINE 434
STANDARD VALUE TABLE FOR MACHINE: PC700LC-11 434
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 451
30 TESTING AND ADJUSTING 455
CONTENTS 456
ABBREVIATION LIST 459
RELATED INFORMATION ON TESTING AND ADJUSTING 465
TOOLS FOR TESTING AND ADJUSTING 465
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 474
ENGINE AND COOLING SYSTEM 476
TEST ENGINE SPEED 476
METHOD FOR TESTING ENGINE SPEED 476
TEST BOOST PRESSURE 479
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 479
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL 480
TEST EXHAUST GAS TEMPERATURE 481
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 481
TEST EXHAUST GAS COLOR 483
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 483
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 484
TEST AND ADJUST VALVE CLEARANCE 486
METHOD FOR TESTING VALVE CLEARANCE 486
METHOD FOR ADJUSTING VALVE CLEARANCE 487
TEST COMPRESSION PRESSURE 489
METHOD FOR TESTING COMPRESSION PRESSURE 489
TEST BLOWBY PRESSURE 492
METHOD FOR TESTING BLOWBY PRESSURE 492
TEST ENGINE OIL PRESSURE 494
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 494
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 494
TEST EGR VALVE AND VGT OIL PRESSURE 496
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 496
TEST FUEL PRESSURE 498
METHOD FOR TESTING FUEL PRESSURE 498
TEST FUEL RETURN RATE AND LEAKAGE 500
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 500
BLEED AIR FROM FUEL SYSTEM 503
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 503
TEST FUEL CIRCUIT FOR LEAKAGE 505
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 505
HANDLE CYLINDER CUT-OUT MODE OPERATION 507
HANDLE NO-INJECTION CRANKING OPERATION 508
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 509
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 509
CLEAN FUEL DOSER 510
METHOD FOR CLEANING FUEL DOSER 510
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 512
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 512
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 518
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 518
TEST SCR RELATED FUNCTIONS 519
TEST AdBlue/DEF PUMP RAISED PRESSURE 522
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 525
TEST AdBlue/DEF LINE HEATER RELAY 1 529
TEST AdBlue/DEF LINE HEATER RELAY 2 532
TEST AdBlue/DEF PUMP HEATER RELAY 535
TEST AdBlue/DEF TANK HEATER VALVE 538
TEST DENITRATION EFFICIENCY OF SCR 541
CLEAN AdBlue/DEF TANK 545
METHOD FOR CLEANING AdBlue/DEF TANK 545
POWER TRAIN 549
TEST SWING CIRCLE BEARING CLEARANCE 549
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 549
UNDERCARRIAGE AND FRAME 550
TEST AND ADJUST TRACK TENSION 550
METHOD FOR TESTING TRACK TENSION 550
METHOD FOR ADJUSTING TRACK TENSION 550
HYDRAULIC SYSTEM 552
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 552
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 552
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 561
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 561
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 562
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 565
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 573
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 577
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 577
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 578
TEST AND ADJUST PISTON PUMP CONTROL OIL PRESSURE 579
METHOD FOR TESTING TVC VALVE OUTLET PRESSURE 579
METHOD FOR TESTING CO AND NC VALVE OUTLET PRESSURE 580
METHOD FOR TESTING JET SENSOR OUTLET PRESSURE 581
METHOD FOR ADJUSTING TVC VALVE 583
METHOD FOR ADJUSTING CO AND NC VALVE 584
METHOD FOR ADJUSTING JET SENSOR 585
TEST SERVO PISTON STROKE 586
METHOD FOR TESTING SERVO PISTON STROKE 586
TEST OUTLET PRESSURE OF SOLENOID VALVE 588
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 588
OPERATING CONDITION OF SOLENOID VALVE 589
TEST PPC VALVE OUTLET PRESSURE 592
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 592
TEST PPC SHUTTLE VALVE OUTLET PRESSURE 594
METHOD FOR TESTING PPC SHUTTLE VALVE OUTLET PRESSURE 594
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 598
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 598
TEST AND ADJUST TRAVEL DEVIATION 599
METHOD FOR TESTING TRAVEL DEVIATION 599
METHOD FOR ADJUSTING TRAVEL DEVIATION 599
TEST COOLING FAN SPEED 601
METHOD FOR TESTING COOLING FAN SPEED 601
TEST OIL PRESSURE IN FAN PUMP CIRCUIT 602
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT 602
TEST FAN PUMP EPC ELECTRIC CURRENT 603
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 603
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 604
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 604
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 605
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 605
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 605
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 606
TEST OIL LEAKAGE 607
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 607
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 608
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 608
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 609
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 609
METHOD FOR TESTING OIL LEAKAGE OF SWIVEL JOINT 610
BLEED AIR FROM HYDRAULIC CIRCUIT 612
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 613
CAB AND ITS ATTACHMENTS 616
TEST CAB TIPPING STOPPER 616
METHOD FOR TESTING CAB TIPPING STOPPER 616
METHOD FOR ADJUSTING MIRRORS 617
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 617
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 618
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 619
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 620
ELECTRICAL SYSTEM 622
SET AND OPERATE MACHINE MONITOR 622
OPERATOR MODE 625
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 625
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 625
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 626
CHECKING FUNCTION OF SERVICE METER 627
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 627
SERVICE MODE 629
METHOD FOR OPERATING SERVICE MODE 629
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 632
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 638
ABNORMALITY RECORD MENU 649
METHOD FOR CONFIRMING MAINTENANCE RECORD 654
METHOD FOR OPERATING MAINTENANCE MODE SETTING 655
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 659
DEFAULT MENU 660
DIAGNOSTIC TESTS MENU 666
ADJUSTMENT MENU 676
METHOD FOR PERFORMING NO-INJECTION CRANKING 680
KOMTRAX SETTINGS MENU 681
METHOD FOR DISPLAYING SERVICE MESSAGE 683
METHOD FOR STARTING UP KOMTRAX TERMINAL 685
ADJUST REARVIEW CAMERA ANGLE 690
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 690
ADJUST KomVision CAMERA ANGLE 692
METHOD FOR ADJUSTING KomVision CAMERA ANGLE 693
ADJUST KomVision RELATED ITEMS 695
SETTING OF KomVision (MAIN SETTING) 695
SETTING OF KomVision (CAMERA SETTING) 697
SETTING OF KomVision (CAMERA CALIBRATION) 697
KomVision screen – Check 12 m visibility 711
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 714
HANDLE BATTERY DISCONNECT SWITCH 715
TEST DIODES 716
METHOD FOR TESTING DIODE USING DIGITAL TESTER 716
METHOD FOR TESTING DIODE USING ANALOG TESTER 716
Pm CLINIC 717
Pm CLINIC SERVICE 717
Pm CLINIC CHECK SHEET: PC700LC-11 720
40 TROUBLESHOOTING 737
CONTENTS 738
ABBREVIATION LIST 749
RELATED INFORMATION ON TROUBLESHOOTING 755
GENERAL TROUBLESHOOTING POINTS 755
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 756
SEQUENCE OF EVENTS IN TROUBLESHOOTING 768
CHECKS BEFORE TROUBLESHOOTING 770
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 772
WALK-AROUND CHECK 772
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 774
CHECK FUEL LEVEL AND TYPE 774
CHECK IMPURE INGREDIENT IN FUEL 775
CHECK FUEL PREFILTER 775
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 775
FUEL PREFILTER CARTRIDGE – REPLACE 776
CHECK MAIN FILTER 777
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 778
CHECK COOLANT LEVEL (RESERVOIR TANK) 780
CHECK CLOGGING OF AIR CLEANER 780
OUTER ELEMENT – CLEAN 780
ELEMENTS – REPLACE 783
CHECK HYDRAULIC OIL LEVEL 783
CHECK HYDRAULIC OIL STRAINER 785
CHECK HYDRAULIC FILTER 785
CHECK OIL LEVEL IN SWING MACHINERY CASE 786
CHECK OIL LEVEL IN PTO CASE 787
CHECK PTO LUBRICATION FILTER STRAINER 787
CHECK OIL LEVEL IN FINAL DRIVE CASE 788
BLEED AIR FROM FUEL SYSTEM 789
BLEED AIR FROM HYDRAULIC SYSTEM 789
ELECTRICAL EQUIPMENT – CHECK METHOD 789
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 795
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 795
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 795
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 795
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL 796
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER 796
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 796
PROCEDURE FOR TESTING AND TROUBLESHOOTING 800
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 803
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 807
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 809
CONNECTOR LIST AND LAYOUT 812
CONNECTOR CONTACT IDENTIFICATION 826
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 866
FUSE LOCATION TABLE 872
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 875
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 879
FAILURE CODES TABLE 881
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 898
FAILURE CODE [879AKA] 898
FAILURE CODE [879AKB] 899
FAILURE CODE [879BKA] 900
FAILURE CODE [879BKB] 902
FAILURE CODE [879CKA] 904
FAILURE CODE [879CKB] 905
FAILURE CODE [879DKZ] 906
FAILURE CODE [879EMC] 908
FAILURE CODE [879FMC] 909
FAILURE CODE [879GKX] 910
FAILURE CODE [989L00] 912
FAILURE CODE [989M00] 913
FAILURE CODE [989N00] 914
FAILURE CODE [A1U0N3] 915
FAILURE CODE [A1U0N4] 917
FAILURE CODE [A900FR] 919
FAILURE CODE [A900N6] 920
FAILURE CODE [A900NY] 921
FAILURE CODE [AA10NX] 922
FAILURE CODE [AB00KE] 924
FAILURE CODE [AQ10N3] 926
FAILURE CODE [AS00N3] 928
FAILURE CODE [AS00R2] 930
FAILURE CODE [AS00R3] 931
FAILURE CODE [AS00R4] 932
FAILURE CODE [AS00R5] 933
FAILURE CODE [AS00R6] 934
FAILURE CODE [AS00ZK] 935
FAILURE CODE [AS10KM] 936
FAILURE CODE [AS10NR] 937
FAILURE CODE [AS10NT] 938
FAILURE CODE [B@BAZG] 939
FAILURE CODE [B@BAZK] 940
FAILURE CODE [B@BCNS] 942
FAILURE CODE [B@BCZK] 943
FAILURE CODE [B@HANS] 945
FAILURE CODE [CA115] 946
FAILURE CODE [CA122] 947
FAILURE CODE [CA123] 949
FAILURE CODE [CA131] 951
FAILURE CODE [CA132] 953
FAILURE CODE [CA135] 955
FAILURE CODE [CA141] 957
FAILURE CODE [CA144] 959
FAILURE CODE [CA145] 961
FAILURE CODE [CA153] 963
FAILURE CODE [CA154] 966
FAILURE CODE [CA187] 969
FAILURE CODE [CA221] 971
FAILURE CODE [CA222] 973
FAILURE CODE [CA227] 975
FAILURE CODE [CA234] 976
FAILURE CODE [CA238] 977
FAILURE CODE [CA239] 979
FAILURE CODE [CA249] 981
FAILURE CODE [CA256] 983
FAILURE CODE [CA271] 985
FAILURE CODE [CA272] 987
FAILURE CODE [CA273] 988
FAILURE CODE [CA274] 990
FAILURE CODE [CA322] 991
FAILURE CODE [CA323] 993
FAILURE CODE [CA324] 995
FAILURE CODE [CA325] 997
FAILURE CODE [CA331] 999
FAILURE CODE [CA332]1001
FAILURE CODE [CA343]1003
FAILURE CODE [CA351]1004
FAILURE CODE [CA352]1005
FAILURE CODE [CA356]1008
FAILURE CODE [CA357]1010
FAILURE CODE [CA386]1012
FAILURE CODE [CA441]1013
FAILURE CODE [CA442]1015
FAILURE CODE [CA449]1016
FAILURE CODE [CA451]1017
FAILURE CODE [CA452]1019
FAILURE CODE [CA515]1021
FAILURE CODE [CA516]1023
FAILURE CODE [CA553]1025
FAILURE CODE [CA555]1026
FAILURE CODE [CA556]1027
FAILURE CODE [CA559]1028
FAILURE CODE [CA595]1033
FAILURE CODE [CA687]1034
FAILURE CODE [CA689]1036
FAILURE CODE [CA691]1038
FAILURE CODE [CA692]1040
FAILURE CODE [CA697]1042
FAILURE CODE [CA698]1043
FAILURE CODE [CA731]1044
FAILURE CODE [CA778]1045
FAILURE CODE [CA1117]1048
FAILURE CODE [CA1664]1049
FAILURE CODE [CA1669]1053
FAILURE CODE [CA1673]1054
FAILURE CODE [CA1677]1055
FAILURE CODE [CA1678]1056
FAILURE CODE [CA1682]1057
FAILURE CODE [CA1683]1059
FAILURE CODE [CA1684]1061
FAILURE CODE [CA1686]1063
FAILURE CODE [CA1691]1064
FAILURE CODE [CA1694]1067
FAILURE CODE [CA1695]1069
FAILURE CODE [CA1696]1070
FAILURE CODE [CA1712]1072
FAILURE CODE [CA1713]1075
FAILURE CODE [CA1714]1078
FAILURE CODE [CA1715]1079
FAILURE CODE [CA1776]1080
FAILURE CODE [CA1777]1083
FAILURE CODE [CA1843]1086
FAILURE CODE [CA1844]1088
FAILURE CODE [CA1879]1091
FAILURE CODE [CA1881]1094
FAILURE CODE [CA1883]1096
FAILURE CODE [CA1885]1100
FAILURE CODE [CA1887]1102
FAILURE CODE [CA1921]1104
FAILURE CODE [CA1922]1107
FAILURE CODE [CA1923]1112
FAILURE CODE [CA1924]1114
FAILURE CODE [CA1925]1116
FAILURE CODE [CA1927]1118
FAILURE CODE [CA1928]1120
FAILURE CODE [CA1942]1122
FAILURE CODE [CA1963]1123
FAILURE CODE [CA1977]1127
FAILURE CODE [CA1993]1130
FAILURE CODE [CA2185]1133
FAILURE CODE [CA2186]1135
FAILURE CODE [CA2249]1137
FAILURE CODE [CA2265]1138
FAILURE CODE [CA2266]1140
FAILURE CODE [CA2271]1142
FAILURE CODE [CA2272]1144
FAILURE CODE [CA2349]1146
FAILURE CODE [CA2353]1148
FAILURE CODE [CA2357]1150
FAILURE CODE [CA2381]1151
FAILURE CODE [CA2382]1153
FAILURE CODE [CA2383]1155
FAILURE CODE [CA2386]1157
FAILURE CODE [CA2387]1159
FAILURE CODE [CA2555]1160
FAILURE CODE [CA2556]1162
FAILURE CODE [CA2637]1164
FAILURE CODE [CA2639]1166
FAILURE CODE [CA2732]1168
FAILURE CODE [CA2733]1170
FAILURE CODE [CA2741]1172
FAILURE CODE [CA2765]1173
FAILURE CODE [CA2771]1174
FAILURE CODE [CA2777]1180
FAILURE CODE [CA2878]1183
FAILURE CODE [CA2881]1186
FAILURE CODE [CA2976]1189
FAILURE CODE [CA3133]1191
FAILURE CODE [CA3134]1193
FAILURE CODE [CA3135]1195
FAILURE CODE [CA3142]1198
FAILURE CODE [CA3143]1199
FAILURE CODE [CA3144]1200
FAILURE CODE [CA3146]1202
FAILURE CODE [CA3147]1203
FAILURE CODE [CA3148]1204
FAILURE CODE [CA3151]1206
FAILURE CODE [CA3165]1211
FAILURE CODE [CA3167]1214
FAILURE CODE [CA3229]1218
FAILURE CODE [CA3231]1221
FAILURE CODE [CA3232]1224
FAILURE CODE [CA3235]1229
FAILURE CODE [CA3239]1231
FAILURE CODE [CA3241]1234
FAILURE CODE [CA3242]1237
FAILURE CODE [CA3251]1240
FAILURE CODE [CA3253]1244
FAILURE CODE [CA3254]1250
FAILURE CODE [CA3255]1254
FAILURE CODE [CA3256]1257
FAILURE CODE [CA3311]1260
FAILURE CODE [CA3312]1263
FAILURE CODE [CA3313]1266
FAILURE CODE [CA3314]1267
FAILURE CODE [CA3315]1268
FAILURE CODE [CA3316]1271
FAILURE CODE [CA3317]1272
FAILURE CODE [CA3318]1273
FAILURE CODE [CA3319]1276
FAILURE CODE [CA3321]1277
FAILURE CODE [CA3322]1278
FAILURE CODE [CA3419]1281
FAILURE CODE [CA3421]1283
FAILURE CODE [CA3497]1285
FAILURE CODE [CA3498]1286
FAILURE CODE [CA3543]1287
FAILURE CODE [CA3545]1292
FAILURE CODE [CA3547]1294
FAILURE CODE [CA3558]1295
FAILURE CODE [CA3559]1297
FAILURE CODE [CA3562]1299
FAILURE CODE [CA3563]1301
FAILURE CODE [CA3567]1304
FAILURE CODE [CA3568]1307
FAILURE CODE [CA3571]1311
FAILURE CODE [CA3572]1313
FAILURE CODE [CA3574]1315
FAILURE CODE [CA3575]1318
FAILURE CODE [CA3577]1320
FAILURE CODE [CA3578]1322
FAILURE CODE [CA3582]1324
FAILURE CODE [CA3583]1329
FAILURE CODE [CA3596]1331
FAILURE CODE [CA3649]1335
FAILURE CODE [CA3681]1338
FAILURE CODE [CA3682]1343
FAILURE CODE [CA3713]1349
FAILURE CODE [CA3717]1352
FAILURE CODE [CA3718]1353
FAILURE CODE [CA3725]1354
FAILURE CODE [CA3748]1357
FAILURE CODE [CA3751]1359
FAILURE CODE [CA3755]1361
FAILURE CODE [CA3866]1363
FAILURE CODE [CA3867]1367
FAILURE CODE [CA3868]1370
FAILURE CODE [CA3899]1374
FAILURE CODE [CA3911]1377
FAILURE CODE [CA3912]1381
FAILURE CODE [CA3932]1383
FAILURE CODE [CA3933]1385
FAILURE CODE [CA3934]1387
FAILURE CODE [CA3935]1390
FAILURE CODE [CA3936]1392
FAILURE CODE [CA4151]1394
FAILURE CODE [CA4152]1398
FAILURE CODE [CA4155]1402
FAILURE CODE [CA4156]1404
FAILURE CODE [CA4157]1407
FAILURE CODE [CA4158]1409
FAILURE CODE [CA4159]1411
FAILURE CODE [CA4161]1413
FAILURE CODE [CA4162]1416
FAILURE CODE [CA4163]1419
FAILURE CODE [CA4164]1421
FAILURE CODE [CA4165]1424
FAILURE CODE [CA4166]1427
FAILURE CODE [CA4168]1430
FAILURE CODE [CA4169]1435
FAILURE CODE [CA4171]1440
FAILURE CODE [CA4249]1445
FAILURE CODE [CA4251]1449
FAILURE CODE [CA4259]1453
FAILURE CODE [CA4261]1456
FAILURE CODE [CA4277]1459
FAILURE CODE [CA4281]1463
FAILURE CODE [CA4459]1466
FAILURE CODE [CA4461]1469
FAILURE CODE [CA4658]1472
FAILURE CODE [CA4731]1476
FAILURE CODE [CA4732]1477
FAILURE CODE [CA4739]1478
FAILURE CODE [CA4768]1479
FAILURE CODE [CA4769]1481
FAILURE CODE [CA4842]1484
FAILURE CODE [CA4952]1488
FAILURE CODE [CA5115]1490
FAILURE CODE [CA5179]1493
FAILURE CODE [CA5181]1495
FAILURE CODE [CA5383]1497
FAILURE CODE [D110KB]1499
FAILURE CODE [D163KB]1501
FAILURE CODE [D195KA]1503
FAILURE CODE [D195KB]1505
FAILURE CODE [D19JKZ]1507
FAILURE CODE [D811MC]1509
FAILURE CODE [D862KA]1510
FAILURE CODE [D8ALKA]1511
FAILURE CODE [D8ALKB]1513
FAILURE CODE [D8AQKR]1515
FAILURE CODE [DA20MC]1519
FAILURE CODE [DA22KK]1520
FAILURE CODE [DA25KP]1522
FAILURE CODE [DA26KP]1524
FAILURE CODE [DA29KQ]1527
FAILURE CODE [DA2LKA]1529
FAILURE CODE [DA2LKB]1531
FAILURE CODE [DA2QKR]1533
FAILURE CODE [DA2RKR]1538
FAILURE CODE [DAF0KM]1543
FAILURE CODE [DAF0MB]1544
FAILURE CODE [DAF0MC]1545
FAILURE CODE [DAF8KB]1546
FAILURE CODE [DAF9KQ]1548
FAILURE CODE [DAFGMC]1549
FAILURE CODE [DAFLKA]1550
FAILURE CODE [DAFLKB]1552
FAILURE CODE [DAFQKR]1554
FAILURE CODE [DAZ9KQ]1558
FAILURE CODE [DAZQKR]1559
FAILURE CODE [DB2QKR]1563
FAILURE CODE [DB2RKR]1568
FAILURE CODE [DBP0KM]1573
FAILURE CODE [DBP0KT]1574
FAILURE CODE [DBP5KB]1575
FAILURE CODE [DBP5KY]1578
FAILURE CODE [DBPQKR]1581
FAILURE CODE [DDNRKA]1586
FAILURE CODE [DDNRKY]1588
FAILURE CODE [DDNS00]1590
FAILURE CODE [DGE5KB]1592
FAILURE CODE [DGH2KA]1593
FAILURE CODE [DGH2KB]1595
FAILURE CODE [DHA4KA]1597
FAILURE CODE [DHAAMA]1599
FAILURE CODE [DHACMA]1601
FAILURE CODE [DHPAMA]1603
FAILURE CODE [DHPBMA]1605
FAILURE CODE [DHS3MA]1607
FAILURE CODE [DHS4MA]1610
FAILURE CODE [DHS8MA]1613
FAILURE CODE [DHS9MA]1616
FAILURE CODE [DHSAMA]1619
FAILURE CODE [DHSBMA]1622
FAILURE CODE [DHSCMA]1625
FAILURE CODE [DHSDMA]1628
FAILURE CODE [DHSFMA]1631
FAILURE CODE [DHSGMA]1634
FAILURE CODE [DHSHMA]1637
FAILURE CODE [DHSJMA]1640
FAILURE CODE [DHSVMA]1643
FAILURE CODE [DKULKA]1645
FAILURE CODE [DKULKB]1647
FAILURE CODE [DKULKY]1649
FAILURE CODE [DLM3KA]1651
FAILURE CODE [DLM3KB]1653
FAILURE CODE [DLM3MB]1655
FAILURE CODE [DR10KA]1656
FAILURE CODE [DR12KA]1659
FAILURE CODE [DR20KA]1661
FAILURE CODE [DR21KX]1663
FAILURE CODE [DR30KA]1665
FAILURE CODE [DR31KX]1667
FAILURE CODE [DR40KA]1669
FAILURE CODE [DUMBKA]1671
FAILURE CODE [DUMBKB]1673
FAILURE CODE [DV20KB]1675
FAILURE CODE [DW43KA]1676
FAILURE CODE [DW43KB]1678
FAILURE CODE [DW43KY]1680
FAILURE CODE [DW45KA]1681
FAILURE CODE [DW45KB]1684
FAILURE CODE [DW45KY]1687
FAILURE CODE [DW48KA]1689
FAILURE CODE [DW48KB]1691
FAILURE CODE [DW48KY]1693
FAILURE CODE [DW4CKY]1694
FAILURE CODE [DW4XKA]1696
FAILURE CODE [DW4XKB]1698
FAILURE CODE [DW4XKY]1700
FAILURE CODE [DW7BKA]1701
FAILURE CODE [DW7BKB]1703
FAILURE CODE [DW7BKY]1705
FAILURE CODE [DWK0KA]1706
FAILURE CODE [DWK0KB]1708
FAILURE CODE [DWK0KY]1710
FAILURE CODE [DWK2KA]1711
FAILURE CODE [DWK2KB]1713
FAILURE CODE [DWK2KY]1715
FAILURE CODE [DWK8KA]1716
FAILURE CODE [DWK8KB]1718
FAILURE CODE [DWK8KY]1720
FAILURE CODE [DX16KA]1721
FAILURE CODE [DX16KB]1723
FAILURE CODE [DXA2KA]1724
FAILURE CODE [DXA2KB]1727
FAILURE CODE [DXA3KA]1729
FAILURE CODE [DXA3KB]1732
FAILURE CODE [DY20KA]1734
FAILURE CODE [DY20MA]1736
FAILURE CODE [DY2CKB]1738
FAILURE CODE [DY2DKB]1740
FAILURE CODE [DY2EKB]1742
FAILURE CODE [DY2FMA]1744
FAILURE CODE [DY2GKM]1746
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1748
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1748
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1754
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1757
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1759
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING1761
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW1764
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW1765
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1766
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1767
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING1768
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1769
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1770
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1771
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1772
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1773
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1774
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL1776
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1777
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE1778
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1779
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE1781
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED1782
E-23 FUNCTION SWITCH DOES NOT OPERATE1783
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)1784
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF1785
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER1786
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED1787
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED1788
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE1789
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE1790
E-31 ALARM BUZZER CANNOT BE CANCELED1791
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION1792
E-33 SERVICE MODE CANNOT BE SELECTED1793
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE1794
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK1797
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING1799
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE1802
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR1804
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED1806
E-40 ALARM DOES NOT SOUND DURING TRAVEL1807
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED1809
E-42 HORN DOES NOT SOUND1810
E-43 HORN DOES NOT STOP SOUNDING1813
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF1815
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE1816
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE1818
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1819
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1820
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1821
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1822
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1823
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1824
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1825
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1826
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1827
E-56 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY1829
E-57 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED1830
E-58 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE1832
E-59 STEP LIGHT DOES NOT LIGHT UP1833
E-60 STEP LIGHT DOES NOT GO OUT1835
E-61 BOOM SHOCKLESS FUNCTION CANNOT BE CANCELED1837
E-62 BOOM SHOCKLESS FUNCTION DOES NOT WORK1839
E-63 ELECTRIC GREASE GUN DOES NOT WORK1840
E-64 ELECTRIC GREASE GUN DOES NOT STOP1842
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1843
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK1843
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER1844
H-3 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP1846
H-4 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS1847
H-5 TRAVEL SPEED OR POWER IS LOW1848
H-6 AUTO-DECELERATION FUNCTION CANNOT BE CANCELED1849
H-7 SPEED OR POWER OF BOOM IS LOW1850
H-8 ARM SPEED OR POWER IS LOW1852
H-9 BUCKET SPEED OR POWER IS LOW1853
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION1854
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE1855
H-12 HYDRAULIC DRIFT OF ARM IS LARGE1856
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE1857
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE1858
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE1859
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE1860
H-17 MACHINE DOES NOT TRAVEL STRAIGHT1861
H-18 SPEED OF BOOM AND BUCKET IS SLOW AT COMBINED OPERATION OF ARM, BOOM AND BUCKET1862
H-19 SPEED OF BOOM, ARM, SWING AND TRAVEL IS SLOW AT COMBINED OPERATION OF BUCKET, BOOM AND ARM1863
H-20 SWING SPEED IS SLOW AT COMBINED OPERATION OF ARM AND SWING1864
H-21 TRAVEL DEVIATION IS LARGE AT START OF TRAVELING1865
H-22 TRAVEL DEVIATION IS LARGE AT COMBINED OPERATION1867
H-23 ONE OF TRACKS DOES NOT RUN1868
H-24 TRAVEL SPEED DOES NOT CHANGE1870
H-25 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT1871
H-26 SWINGS ONLY IN ONE DIRECTION1872
H-27 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)1873
H-28 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION1874
H-29 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)1875
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)1876
H-31 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING1877
H-32 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING1878
H-33 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)1879
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)1880
H-35 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)1881
H-36 UNUSUAL NOISE IS HEARD FROM AROUND FAN1882
TROUBLESHOOTING OF ENGINE (S-MODE)1883
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)1883
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION1884
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT1885
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)1886
S-4 ENGINE STARTABILITY IS POOR1887
S-5 ENGINE DOES NOT PICK UP SMOOTHLY1889
S-6 ENGINE STOPS DURING OPERATION1891
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE1893
S-8 ENGINE LACKS POWER1894
S-9 KDPF GETS CLOGGED IN A SHORT TIME1896
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE1898
S-11 OIL BECOMES CONTAMINATED QUICKLY1899
S-1 FUEL CONSUMPTION IS EXCESSIVE1900
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)1901
S-14 OIL PRESSURE DROPS1902
S-15 FUEL MIXES INTO ENGINE OIL1904
S-16 WATER MIXES INTO ENGINE OIL (MILKY)1905
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)1906
S-18 UNUSUAL NOISE IS HEARD1907
S-19 VIBRATION IS EXCESSIVE1908
S-2 AIR CANNOT BE BLED FROM FUEL CIRCUIT1909
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY1910
S-22 ACTIVE REGENERATION TAKES TIME1912
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION1914
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE1915
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)1917
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)1918
50 DISASSEMBLY AND ASSEMBLY1919
CONTENTS1920
ABBREVIATION LIST1925
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY1931
HOW TO READ THIS MANUAL1931
COATING MATERIALS LIST1933
SPECIAL TOOLS LIST1937
SPECIAL TOOLS LIST1954
SKETCHES OF SPECIAL TOOLS1971
ENGINE AND COOLING SYSTEM1978
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY1978
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY1978
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY1981
REMOVE AND INSTALL INJECTOR ASSEMBLY1986
METHOD FOR REMOVING INJECTOR ASSEMBLY1986
METHOD FOR INSTALLING INJECTOR ASSEMBLY1991
REMOVE AND INSTALL FUEL DOSER ASSEMBLY2000
METHOD FOR REMOVING FUEL DOSER ASSEMBLY2000
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY2001
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2003
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2004
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2014
REMOVE AND INSTALL EGR VALVE ASSEMBLY2031
METHOD FOR REMOVING EGR VALVE ASSEMBLY2031
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2033
REMOVE AND INSTALL EGR COOLER ASSEMBLY2035
METHOD FOR REMOVING EGR COOLER ASSEMBLY2035
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2038
REMOVE AND INSTALL STARTER ASSEMBLY2042
METHOD FOR REMOVING STARTER ASSEMBLY2042
METHOD FOR INSTALLING STARTER ASSEMBLY2042
REMOVE AND INSTALL ALTERNATOR BELT2044
METHOD FOR REMOVING ALTERNATOR BELT2044
METHOD FOR INSTALLING ALTERNATOR BELT2045
REMOVE AND INSTALL RADIATOR ASSEMBLY2047
METHOD FOR REMOVING RADIATOR ASSEMBLY2047
METHOD FOR INSTALLING RADIATOR ASSEMBLY2050
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2054
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2054
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2057
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2061
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2061
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2063
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY2066
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY2066
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY2075
REMOVE AND INSTALL ENGINE PTO AND HYDRAULIC ASSEMBLY2084
METHOD FOR REMOVING ENGINE PTO AND HYDRAULIC ASSEMBLY2084
METHOD FOR INSTALLING ENGINE PTO AND HYDRAULIC ASSEMBLY2095
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2106
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2106
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2107
REMOVE AND INSTALL ENGINE REAR OIL SEAL2110
METHOD FOR REMOVING ENGINE REAR OIL SEAL2110
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2112
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2119
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2119
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2124
REMOVE AND INSTALL FUEL TANK ASSEMBLY2129
METHOD FOR REMOVING FUEL TANK ASSEMBLY2129
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2132
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2136
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2137
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2143
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2148
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2148
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2149
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2151
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2151
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2151
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2153
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2153
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2153
REMOVE AND INSTALL KDPF ASSEMBLY2154
METHOD FOR REMOVING KDPF ASSEMBLY2154
METHOD FOR INSTALLING KDPF ASSEMBLY2158
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2167
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2168
METHOD FOR ASSEMBLING KDPF ASSEMBLY2172
REMOVE AND INSTALL SCR ASSEMBLY2177
METHOD FOR REMOVING SCR ASSEMBLY2177
METHOD FOR INSTALLING SCR ASSEMBLY2179
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2183
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2184
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2190
REMOVE AND INSTALL KCCV ASSEMBLY2202
METHOD FOR REMOVING KCCV ASSEMBLY2202
METHOD FOR INSTALLING KCCV ASSEMBLY2203
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2206
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2206
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2211
REMOVE AND INSTALL AdBlue/DEF INJECTOR2218
METHOD FOR REMOVING AdBlue/DEF INJECTOR2218
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2221
REMOVE AND INSTALL AdBlue/DEF PUMP2225
METHOD FOR REMOVING AdBlue/DEF PUMP2225
METHOD FOR INSTALLING AdBlue/DEF PUMP2228
REMOVE AND INSTALL AdBlue/DEF HOSE2231
METHOD FOR REMOVING AdBlue/DEF HOSE2232
METHOD FOR INSTALLING AdBlue/DEF HOSE2240
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2246
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2246
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2247
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2248
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2248
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2249
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2250
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2250
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2251
POWER TRAIN2252
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY2252
METHOD FOR DISASSEMBLING PTO ASSEMBLY2252
METHOD FOR ASSEMBLING PTO ASSEMBLY2253
REMOVE AND INSTALL PTO ASSEMBLY2256
METHOD FOR REMOVING PTO ASSEMBLY2256
METHOD FOR INSTALLING PTO ASSEMBLY2257
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2260
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2260
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2261
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY2262
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY2263
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY2268
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY2277
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY2277
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY2278
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY2280
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY2280
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY2284
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY2289
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY2289
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY2290
UNDERCARRIAGE AND FRAME2291
DISASSEMBLE AND ASSEMBLE RECOIL SPRING2291
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING2291
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY2292
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY2294
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY2294
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY2295
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY2296
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY2296
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY2296
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD2298
METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD2300
METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD2301
SEPARATION AND CONNECTION OF TRACK ASSEMBLY2304
METHOD FOR SEPARATING TRACK ASSEMBLY2304
METHOD FOR INSTALLING TRACK ASSEMBLY2305
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY2307
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY2307
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY2308
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2309
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2309
METHOD FOR ASSEMBLING IDLER ASSEMBLY2310
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY2313
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY2313
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY2314
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2316
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2316
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2317
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY2320
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY2320
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY2321
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY2323
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY2323
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY2324
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2326
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2326
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2326
HYDRAULIC SYSTEM2329
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY2329
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY2329
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY2330
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2331
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2332
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2333
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2334
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2334
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2336
REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY2339
METHOD FOR REMOVING HYDRAULIC PUMP ASSEMBLY2339
METHOD FOR INSTALLING HYDRAULIC PUMP ASSEMBLY2341
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2347
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2347
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2350
REMOVE AND INSTALL SWING MOTOR ASSEMBLY2354
METHOD FOR REMOVING SWING MOTOR ASSEMBLY2354
METHOD FOR INSTALLING SWING MOTOR ASSEMBLY2355
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2356
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2356
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2357
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2359
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY2359
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY2360
DISASSEMBLE AND ASSEMBLE GREASE GUN ASSEMBLY2362
METHOD FOR DISASSEMBLING GREASE GUN ASSEMBLY2362
METHOD FOR ASSEMBLING GREASE GUN ASSEMBLY2362
WORK EQUIPMENT2363
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY2363
METHOD FOR REMOVING BUCKET CYLINDER ASSEMBLY2363
METHOD FOR INSTALLING BUCKET CYLINDER ASSEMBLY2364
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY2366
METHOD FOR REMOVING ARM CYLINDER ASSEMBLY2366
METHOD FOR INSTALLING ARM CYLINDER ASSEMBLY2367
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY2369
METHOD FOR REMOVING BOOM CYLINDER ASSEMBLY2369
METHOD FOR INSTALLING BOOM CYLINDER ASSEMBLY2370
REMOVE AND INSTALL BUCKET ASSEMBLY2372
METHOD FOR REMOVING BUCKET ASSEMBLY2372
METHOD FOR INSTALLING BUCKET ASSEMBLY2373
REMOVE AND INSTALL ARM ASSEMBLY2374
METHOD FOR REMOVING ARM ASSEMBLY2374
METHOD FOR INSTALLING ARM ASSEMBLY2376
REMOVE AND INSTALL BOOM ASSEMBLY2378
METHOD FOR REMOVING BOOM ASSEMBLY2378
METHOD FOR INSTALLING BOOM ASSEMBLY2379
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2381
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2381
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2383
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM2385
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM2385
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM2387
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM2388
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM2388
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM2390
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY2391
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY2391
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY2391
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2392
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2393
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2395
CAB AND ITS ATTACHMENTS2400
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2400
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY2400
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY2407
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)2416
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)2418
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)2418
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY2428
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY2428
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY2431
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY2437
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY2437
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY2440
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2445
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2445
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2450
REMOVE AND INSTALL OPERATOR’S SEAT2457
METHOD FOR REMOVING OPERATOR’S SEAT2457
METHOD FOR INSTALLING OPERATOR’S SEAT2459
REMOVE AND INSTALL SEAT BELT2462
METHOD FOR REMOVING SEAT BELT2462
METHOD FOR INSTALLING SEAT BELT2462
REMOVE AND INSTALL FRONT WIPER ASSEMBLY2464
METHOD FOR REMOVING FRONT WIPER ASSEMBLY2464
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY2469
ELECTRICAL SYSTEM2478
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2478
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2478
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2479
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY2482
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY2482
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY2484
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY2487
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY2487
METHOD FOR INSTALLING KomVision CONTROLLER2488
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2489
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2489
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY2491
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2495
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR2495
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR2496
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2497
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR2497
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR2498
REMOVE AND INSTALL SCR TEMPERATURE SENSOR2500
METHOD FOR REMOVING SCR TEMPERATURE SENSOR2500
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR2502
REMOVE AND INSTALL KomVision CAMERA2504
METHOD FOR REMOVING KomVision CAMERA2504
METHOD FOR INSTALLING KomVision CAMERA2505
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY2507
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY2507
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY2509
60 MAINTENANCE STANDARD2511
CONTENTS2512
ABBREVIATION LIST2513
ENGINE AND COOLING SYSTEM2519
MAINTENANCE STANDARD OF ENGINE MOUNT2519
MAINTENANCE STANDARD FOR PTO2521
MAINTENANCE STANDARD OF COOLING SYSTEM2522
MAINTENANCE STANDARD OF COOLING FAN PUMP2523
MAINTENANCE STANDARD OF SERVO VALVE2524
MAINTENANCE STANDARD OF COOLING FAN MOTOR2525
POWER TRAIN2526
MAINTENANCE STANDARD OF SWING CIRCLE2526
MAINTENANCE STANDARD OF SWING MACHINERY2527
MAINTENANCE STANDARD OF FINAL DRIVE2529
MAINTENANCE STANDARD OF SPROCKET2531
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING2532
UNDERCARRIAGE AND FRAME2534
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION2534
MAINTENANCE STANDARD OF IDLER2536
MAINTENANCE STANDARD OF TRACK ROLLER2538
MAINTENANCE STANDARD OF CARRIER ROLLER2540
MAINTENANCE STANDARD OF TRACK SHOE2541
MAINTENANCE STANDARD OF DOUBLE SHOE2544
MAINTENANCE STANDARD OF TRIPLE SHOE2545
HYDRAULIC SYSTEM2546
MAINTENANCE STANDARD OF MAIN PUMP2546
MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE2548
MAINTENANCE STANDARD OF MAIN PUMP TVC VALVE2550
MAINTENANCE STANDARD OF MAIN PUMP CO AND NC VALVE2551
MAINTENANCE STANDARD OF SWING MOTOR2552
MAINTENANCE STANDARD OF CONTROL VALVE2553
MAINTENANCE STANDARD OF TRAVEL SHUTTLE VALVE OF CONTROL VALVE2559
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE VALVE2560
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM2561
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM2563
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE2565
MAINTENANCE STANDARD OF TRAVEL PPC VALVE2568
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE2571
MAINTENANCE STANDARD OF SOLENOID VALVE2573
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT2574
WORK EQUIPMENT2575
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE2575
DIMENSION OF ARM2580
DIMENSIONS OF BUCKET2582
MAINTENANCE STANDARD OF BOOM CYLINDER2584
MAINTENANCE STANDARD OF ARM CYLINDER2585
MAINTENANCE STANDARD OF BUCKET CYLINDER2586
80 APPENDIX2587
CONTENTS2588
ABBREVIATION LIST2590
AIR CONDITIONER SYSTEM2596
PRECAUTIONS FOR REFRIGERANT2596
AIR CONDITIONER COMPONENT2597
SPECIFICATIONS OF AIR CONDITIONER2599
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2600
OUTLINE OF REFRIGERATION CYCLE2601
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2603
AIR CONDITIONER UNIT2603
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2603
FUNCTION OF AIR CONDITIONER UNIT2605
COMPONENT PARTS OF AIR CONDITIONER UNIT2607
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2608
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2608
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT2608
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT2608
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2609
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2609
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2609
FUNCTION OF DUAL PRESSURE SWITCH2610
AIR CONDITIONER CONTROLLER2611
STRUCTURE OF AIR CONDITIONER CONTROLLER2611
COMPRESSOR2612
STRUCTURE OF COMPRESSOR2612
SPECIFICATIONS OF COMPRESSOR2612
FUNCTION OF COMPRESSOR2612
CONDENSER2613
STRUCTURE OF CONDENSER2613
SPECIFICATIONS OF CONDENSER2613
FUNCTION OF CONDENSER2613
RECEIVER DRIER2614
STRUCTURE OF RECEIVER DRIER2614
SPECIFICATIONS OF RECEIVER DRIER2614
FUNCTION OF RECEIVER DRIER2614
SENSORS FOR AIR CONDITIONER SYSTEM2615
STRUCTURE OF SUNLIGHT SENSOR2615
FUNCTION OF SUNLIGHT SENSOR2615
STRUCTURE OF AMBIENT TEMPERATURE SENSOR2615
FUNCTION OF AMBIENT TEMPERATURE SENSOR2615
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2617
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER2619
AIR CONDITIONER SYSTEM DIAGRAM2621
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER2622
FUNCTION OF AIR CONDITIONER CONTROLLER2623
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2624
TESTING AIR LEAKAGE (DUCT)2628
METHOD FOR TESTING AIR LEAKAGE (DUCT)2628
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION2630
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR2631
TEST VENT (MODE) CHANGEOVER2632
METHOD FOR TESTING VENT (MODE) CHANGEOVER2632
TESTING FRESH/RECIRC AIR CHANGEOVER2634
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER2634
TEST SUNLIGHT SENSOR2635
METHOD FOR TESTING SUNLIGHT SENSOR2635
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT2636
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT2636
TEST RELAYS2637
METHOD FOR TESTING RELAYS2637
AIR CONDITIONER TROUBLESHOOTING CHART 12638
AIR CONDITIONER TROUBLESHOOTING CHART 22639
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2642
FAILURE CODE [879AKA]2644
FAILURE CODE [879AKB]2645
FAILURE CODE [879BKA]2646
FAILURE CODE [879BKB]2648
FAILURE CODE [879CKA]2650
FAILURE CODE [879CKB]2651
FAILURE CODE [879DKZ]2652
FAILURE CODE [879EMC]2654
FAILURE CODE [879FMC]2655
FAILURE CODE [879GKX]2656
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)2658
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)2660
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)2663
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER2665
TROUBLESHOOTING USING GAUGE PRESSURE2667
CONNECTION OF SERVICE TOOL2670
METHOD FOR CONNECTING SERVICE TOOL2670
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS2672
HANDLE COMPRESSOR OIL2674
90 CIRCUIT DIAGRAMS2677
CONTENTS2678
ABBREVIATION LIST2679
HYDRAULIC CIRCUIT DIAGRAM2685
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2685
HYDRAULIC CIRCUIT DIAGRAM2689
ELECTRICAL CIRCUIT DIAGRAM2691
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM2691
ELECTRICAL CIRCUIT DIAGRAM (1/12)2695
ELECTRICAL CIRCUIT DIAGRAM (2/12)2697
ELECTRICAL CIRCUIT DIAGRAM (3/12)2699
ELECTRICAL CIRCUIT DIAGRAM (4/12)2701
ELECTRICAL CIRCUIT DIAGRAM (5/12)2703
ELECTRICAL CIRCUIT DIAGRAM (6/12)2705
ELECTRICAL CIRCUIT DIAGRAM (7/12)2707
ELECTRICAL CIRCUIT DIAGRAM (8/12)2709
ELECTRICAL CIRCUIT DIAGRAM (9/12)2711
ELECTRICAL CIRCUIT DIAGRAM (10/12)2713
ELECTRICAL CIRCUIT DIAGRAM (11/12)2715
ELECTRICAL CIRCUIT DIAGRAM (12/12)2717
INDEX2719

S.M 31/12/24