Komatsu PC130-10M0 Hydraulic Excavator Shop Manual SEN06852-C3 – PDF DOWNLOAD
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DESCRIPTION:
Komatsu PC130-10M0 Hydraulic Excavator Shop Manual SEN06852-C3 – PDF DOWNLOAD
SERIAL NUMBERS C20001 and up
FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE SHOP MANUAL:
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
VIDEO PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu PC130-10M0 Hydraulic Excavator Shop Manual SEN06852-C3 – PDF DOWNLOAD
COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
FOREWORD, SAFETY, BASIC INFORMATION 16
HOW TO READ THE SHOP MANUAL 16
SAFETY NOTICE FOR OPERATION 18
PRECAUTIONS TO PREVENT FIRE 26
ACTIONS IF FIRE OCCURS 28
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 29
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 30
PRECAUTIONS FOR DEF 31
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 31
PRECAUTIONS FOR ADDING 31
PRECAUTIONS FOR STORING 31
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 31
THE OTHER PRECAUTIONS 31
STORE AdBlue/DEF 32
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 33
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 36
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 43
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 45
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 46
PRACTICAL USE OF KOMTRAX 47
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 48
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 48
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 49
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 50
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 52
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 56
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 57
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 60
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 62
HOW TO READ ELECTRICAL WIRE CODE 63
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 67
STANDARD TIGHTENING TORQUE TABLE 70
CONVERSION TABLE 77
ABBREVIATION LIST 82
01 SPECIFICATIONS 85
CONTENTS 86
SPECIFICATIONS 87
SPECIFICATION DRAWING 87
SPECIFICATION DRAWING: PC130-10M0 87
WORKING RANGE DRAWINGS 89
WORKING RANGE DRAWINGS: PC130-10M0 89
SPECIFICATIONS 90
SPECIFICATIONS: PC130-10M0 90
WEIGHT TABLE 94
WEIGHT TABLE: PC130-10M0 94
FUEL, COOLANT, LUBRICANT 96
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 96
10 STRUCTURE AND FUNCTION 99
CONTENTS 100
BOOT-UP SYSTEM 103
LAYOUT DRAWING OF BOOT-UP SYSTEM 103
SYSTEM OPERATING LAMP SYSTEM 104
SYSTEM DIAGRAM OF SYSTEM OPERATING LAMP SYSTEM 104
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 104
BATTERY DISCONNECT SWITCH 106
FUNCTION OF BATTERY DISCONNECT SWITCH 106
ENGINE SYSTEM 107
LAYOUT DRAWING OF ENGINE SYSTEM 107
ENGINE CONTROL SYSTEM 108
SYSTEM DIAGRAM OF ENGINE CONTROL SYSTEM 108
OPERATION OF ENGINE CONTROL SYSTEM 108
AUTO-DECELERATION SYSTEM 110
SYSTEM DIAGRAM OF AUTO-DECELERATION SYSTEM 110
FUNCTION OF AUTO-DECELERATION SYSTEM 110
OPERATION OF AUTO-DECELERATION SYSTEM 111
ENGINE AUTOMATIC WARM-UP SYSTEM 112
SYSTEM DIAGRAM OF ENGINE AUTOMATIC WARM-UP SYSTEM 112
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 112
OVERHEAT PREVENTION SYSTEM 114
FUNCTION OF OVERHEAT PREVENTION SYSTEM 114
TURBOCHARGER PROTECTION SYSTEM 116
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 116
COMPONENT PARTS OF ENGINE SYSTEM 117
PTO 117
COOLING SYSTEM 118
LAYOUT DRAWING OF COOLING SYSTEM 118
SPECIFICATIONS OF COOLING SYSTEM 119
CONTROL SYSTEM 120
LAYOUT DRAWING OF CONTROL SYSTEM 120
MACHINE MONITOR SYSTEM 122
SYSTEM DIAGRAM OF MACHINE MONITOR 122
FUNCTION OF MACHINE MONITOR SYSTEM 122
KOMTRAX SYSTEM 124
KOMTRAX SYSTEM DIAGRAM 124
FUNCTION OF KOMTRAX SYSTEM 124
COMPONENT PARTS OF CONTROL SYSTEM 125
MACHINE MONITOR 125
GATEWAY FUNCTION CONTROLLER 135
COMMUNICATION TERMINAL 138
PUMP CONTROLLER 140
RESISTOR FOR PC-EPC VALVE 145
CAN TERMINATING RESISTOR 146
ENGINE CONTROLLER 147
FUEL CONTROL DIAL 152
HYDRAULIC SYSTEM 154
LAYOUT DRAWING OF HYDRAULIC SYSTEM 154
ENGINE AND PUMP COMBINED CONTROL SYSTEM 159
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 159
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 160
COMPONENT PARTS OF HYDRAULIC SYSTEM 165
HYDRAULIC TANK 165
MAIN PUMP 167
CONTROL VALVE 192
WORK EQUIPMENT SYSTEM 252
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 252
STRUCTURE OF VALVE CONTROL 255
PPC LOCK SYSTEM 256
SYSTEM DIAGRAM OF PPC LOCK SYSTEM 256
FUNCTION OF PPC LOCK SYSTEM 256
ONE-TOUCH POWER MAXIMIZING SYSTEM 257
SYSTEM DIAGRAM OF ONE-TOUCH POWER MAXIMIZING SYSTEM 257
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 257
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 258
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 258
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 259
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 260
WORK EQUIPMENT AND SWING PPC VALVE 260
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 265
SOLENOID VALVE 272
VARIABLE BACK PRESSURE SOLENOID VALVE 277
PILOT CIRCUIT ACCUMULATOR 278
ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) 279
SWING SYSTEM 280
LAYOUT DRAWING OF SWING SYSTEM 280
SWING CONTROL SYSTEM DIAGRAM 282
FUNCTION OF SWING CONTROL SYSTEM 282
COMPONENT PARTS OF SWING SYSTEM 285
SWING MOTOR 285
SWING MACHINERY 293
SWING CIRCLE 295
TRAVEL SYSTEM 296
LAYOUT DRAWING OF TRAVEL SYSTEM 296
SYSTEM DIAGRAM OF TRAVEL CONTROL SYSTEM 298
FUNCTION OF TRAVEL CONTROL SYSTEM 298
COMPONENT PARTS OF TRAVEL SYSTEM 302
TRAVEL MOTOR 302
TRAVEL PPC VALVE 312
CENTER SWIVEL JOINT 316
UNDERCARRIAGE AND FRAME 319
LAYOUT DRAWING OF UNDERCARRIAGE 319
SPECIFICATIONS OF UNDERCARRIAGE 319
IDLER CUSHION 320
STRUCTURE OF IDLER CUSHION 320
SPECIFICATIONS OF IDLER CUSHION 320
WORK EQUIPMENT 321
STRUCTURE OF WORK EQUIPMENT 321
FUNCTION OF WORK EQUIPMENT 322
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 323
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 323
BUCKET CLEARANCE ADJUSTMENT SHIM 324
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 324
CAB AND ITS ATTACHMENTS 325
ROPS CAB 325
STRUCTURE OF ROPS CAB 325
FUNCTION OF ROPS CAB 325
CAB MOUNT 326
STRUCTURE OF CAB MOUNT 326
FUNCTION OF CAB MOUNT 327
CAB TIPPING STOPPER 328
STRUCTURE OF CAB TIPPING STOPPER 328
FUNCTION OF CAB TIPPING STOPPER 328
20 STANDARD VALUE TABLE 329
CONTENTS 330
STANDARD VALUE TABLE FOR ENGINE 331
STANDARD VALUE TABLE FOR ENGINE: PC130-10M0 331
STANDARD VALUE TABLE FOR MACHINE 334
STANDARD VALUE TABLE FOR MACHINE: PC130-10M0 334
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE 348
30 TESTING AND ADJUSTING 353
CONTENTS 354
RELATED INFORMATION ON TESTING AND ADJUSTING 357
TOOLS FOR TESTING AND ADJUSTING 357
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 361
ENGINE AND COOLING SYSTEM 363
TEST ENGINE SPEED 363
TEST ENGINE SPEED 363
TEST EXHAUST GAS COLOR 365
TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 365
TEST EXHAUST GAS COLOR BY SMOKE METER 366
TEST AND ADJUST VALVE CLEARANCE 367
TEST VALVE CLEARANCE 367
ADJUST VALVE CLEARANCE 368
TEST COMPRESSION PRESSURE 370
TEST COMPRESSION PRESSURE 370
TEST BLOWBY PRESSURE 372
TEST BLOWBY PRESSURE ON MACHINE MONITOR 372
TEST ENGINE OIL PRESSURE 374
TEST ENGINE OIL PRESSURE 374
TEST FUEL PRESSURE 376
TEST FUEL PRESSURE 376
TEST FUEL RETURN RATE AND LEAKAGE 377
TEST FUEL RETURN RATE AND LEAKAGE 379
BLEED AIR FROM FUEL SYSTEM 382
BLEED AIR FROM FUEL SYSTEM 382
TEST FUEL CIRCUIT FOR LEAKAGE 384
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 384
HANDLE CYLINDER CUT-OUT MODE OPERATION 386
HANDLE NO-INJECTION CRANKING OPERATION 387
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 388
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 388
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 388
TEST AND ADJUST FAN BELT TENSION 390
METHOD FOR CHECKING FAN BELT TENSION 390
METHOD FOR ADJUSTING FAN BELT TENSION 390
POWER TRAIN 392
TEST SWING CIRCLE BEARING CLEARANCE 392
TEST SWING CIRCLE BEARING CLEARANCE 392
UNDERCARRIAGE AND FRAME 393
TEST AND ADJUST TRACK TENSION 393
METHOD FOR TESTING TRACK TENSION 393
METHOD FOR ADJUSTING TRACK TENSION 393
HYDRAULIC SYSTEM 395
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 395
RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK 395
RELEASE REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 395
RELEASE REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 395
RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 396
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS 397
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS 397
ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 404
TEST OIL PRESSURE OF CONTROL CIRCUIT 407
TEST OIL PRESSURE OF CONTROL CIRCUIT 407
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 409
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 409
TEST PC-EPC VALVE OUTLET PRESSURE 410
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 411
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 412
TEST LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 412
TEST LS DIFFERENTIAL PRESSURE BY TESTING TOOL 414
TEST LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 415
METHOD FOR ADJUSTING LS VALVE 416
TEST OUTLET PRESSURE OF SOLENOID VALVE 418
TEST OUTLET PRESSURE IN SOLENOID VALVE 418
OPERATING CONDITION OF SOLENOID VALVE 419
TEST OUTLET PRESSURE IN VARIABLE BACK PRESSURE SOLENOID VALVE 421
OPERATING CONDITION OF VARIABLE BACK PRESSURE SOLENOID VALVE 422
TEST OUTLET PRESSURE IN PPC VALVE 423
TEST OUTLET PRESSURE IN PPC VALVE 423
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 425
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 425
TEST AND ADJUST TRAVEL DEVIATION 426
TEST TRAVEL DEVIATION 426
METHOD FOR ADJUSTING TRAVEL DEVIATION 426
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 429
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 429
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 429
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 430
TEST OIL LEAKAGE 431
TEST OIL LEAKAGE FROM BOOM CYLINDER 431
TEST OIL LEAKAGE FROM ARM CYLINDER 431
TEST OIL LEAKAGE FROM BUCKET CYLINDER 432
METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER 432
TEST OIL LEAKAGE FROM SWING MOTOR 433
TEST OIL LEAKAGE FROM TRAVEL MOTOR 434
BLEED AIR FROM HYDRAULIC CIRCUIT 435
BLEED AIR FROM HYDRAULIC CIRCUIT 436
CAB RELATED PARTS 439
TEST CAB TIPPING STOPPER 439
METHOD FOR TESTING CAB TIPPING STOPPER 439
ADJUST MIRRORS 440
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 441
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 442
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 444
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 445
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 446
PROCEDURE FOR ADJUSTING MACHINE REAR COUNTERWEIGHT MIRROR (D) 447
ELECTRICAL SYSTEM 448
SET AND OPERATE MACHINE MONITOR 448
OPERATOR MODE 452
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 452
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 452
CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 453
CHECKING FUNCTION OF SERVICE METER 453
USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 453
SERVICE MODE 456
OPERATE SERVICE MODE 456
CHECK PRE-DEFINED MONITORING INFORMATION 457
CHECK MONITORING INFORMATION 460
ABNORMALITY RECORD MENU 468
CHECK MAINTENANCE RECORD 472
MAINTENANCE MODE SETTING 473
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 477
DEFAULT MENU 479
DIAGNOSTIC TESTS MENU 485
ADJUSTMENT MENU 487
KOMTRAX SETTINGS MENU 500
METHOD FOR DISPLAYING SERVICE MESSAGE 502
START UP KOMTRAX SYSTEM 504
STOP USING OF KOMTRAX SYSTEM 510
ADJUST REARVIEW CAMERA ANGLE 512
ADJUST REARVIEW CAMERA ANGLE 512
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 514
BATTERY DISCONNECT SWITCH 515
TEST DIODES 516
METHOD FOR TESTING DIODE USING DIGITAL TESTER 516
METHOD FOR TESTING DIODE USING ANALOG TESTER 516
Pm-CLINIC 517
Pm CLINIC SERVICE 517
Pm CLINIC CHECK SHEET: PC130-10M0 519
40 TROUBLESHOOTING 529
CONTENTS 530
RELATED INFORMATION ON TROUBLESHOOTING 536
GENERAL TROUBLESHOOTING POINTS 536
SEQUENCE OF EVENTS IN TROUBLESHOOTING 537
CHECKS BEFORE TROUBLESHOOTING 539
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 541
WALK-AROUND CHECK 541
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 543
CHECK FUEL LEVEL AND TYPE 543
DRAIN WATER AND SEDIMENT FROM FUEL TANK 543
CHECK FUEL PREFILTER 544
CHECK WATER SEPARATOR, DRAIN WATER AND SEDIMENT 544
REPLACE FUEL PREFILTER CARTRIDGE 545
CHECK FUEL MAIN FILTER 546
TEST ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 548
CHECK OIL LEVEL IN PTO GEAR CASE 549
CHECK COOLANT LEVEL (RESERVOIR TANK) 550
CHECK CLOGGING OF AIR CLEANER 551
CLEAN OUTER ELEMENT 551
REPLACE ELEMENT 554
CHECK HYDRAULIC OIL LEVEL 555
CHECK HYDRAULIC OIL STRAINER 557
CHECK HYDRAULIC OIL FILTER 557
CHECK OIL LEVEL IN SWING MACHINERY CASE 559
CHECK OIL LEVEL IN FINAL DRIVE CASE 560
BLEED AIR FROM FUEL SYSTEM 560
BLEED AIR FROM HYDRAULIC SYSTEM 560
CHECK ELECTRIC EQUIPMENT 560
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 565
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 565
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 565
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 566
PREPARATION FOR TROUBLESHOOTING OF GATEWAY FUNCTION CONTROLLER 566
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 566
PROCEDURE FOR TESTING AND TROUBLESHOOTING 571
SYMPTOM AND TROUBLESHOOTING NUMBERS 574
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 578
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 580
CONNECTOR LIST AND LAYOUT (MACHINES WITHOUT FUEL REFILL PUMP) 583
CONNECTOR LIST AND LAYOUT (MACHINES WITH FUEL REFILL PUMP) 594
CONNECTOR CONTACT IDENTIFICATION 605
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 647
FUSE LOCATION TABLE (MACHINES WITHOUT FUEL REFILL PUMP) 653
FUSE LOCATION TABLE (MACHINES WITH FUEL REFILL PUMP) 655
FAILURE CODE TABLE 657
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 664
FAILURE CODE [879AKA] 664
FAILURE CODE [879AKB] 665
FAILURE CODE [879BKA] 666
FAILURE CODE [879BKB] 668
FAILURE CODE [879CKA] 670
FAILURE CODE [879CKB] 671
FAILURE CODE [879DKZ] 672
FAILURE CODE [879EMC] 674
FAILURE CODE [879FMC] 675
FAILURE CODE [879GKX] 676
FAILURE CODE [989L00] 678
FAILURE CODE [989M00] 679
FAILURE CODE [989N00] 680
FAILURE CODE [AA10NX] 681
FAILURE CODE [AB00KE] 683
FAILURE CODE [B@BAZG] 685
FAILURE CODE [B@BAZK] 686
FAILURE CODE [B@BCNS] 688
FAILURE CODE [B@BCQA] 689
FAILURE CODE [B@BCZK] 691
FAILURE CODE [B@HANS] 693
FAILURE CODE [CA111] 695
FAILURE CODE [CA122] 701
FAILURE CODE [CA123] 703
FAILURE CODE [CA131] 704
FAILURE CODE [CA132] 706
FAILURE CODE [CA144] 707
FAILURE CODE [CA145] 709
FAILURE CODE [CA153] 710
FAILURE CODE [CA154] 712
FAILURE CODE [CA221] 713
FAILURE CODE [CA222] 715
FAILURE CODE [CA234] 716
FAILURE CODE [CA238] 717
FAILURE CODE [CA271] 719
FAILURE CODE [CA272] 720
FAILURE CODE [CA322] 721
FAILURE CODE [CA324] 723
FAILURE CODE [CA331] 725
FAILURE CODE [CA332] 727
FAILURE CODE [CA351] 729
FAILURE CODE [CA352] 733
FAILURE CODE [CA386] 734
FAILURE CODE [CA435] 736
FAILURE CODE [CA441] 737
FAILURE CODE [CA442] 738
FAILURE CODE [CA449] 739
FAILURE CODE [CA451] 740
FAILURE CODE [CA452] 742
FAILURE CODE [CA553] 743
FAILURE CODE [CA559] 744
FAILURE CODE [CA689] 748
FAILURE CODE [CA731] 750
FAILURE CODE [CA757] 751
FAILURE CODE [CA778] 757
FAILURE CODE [CA2185] 759
FAILURE CODE [CA2186] 761
FAILURE CODE [CA2249] 762
FAILURE CODE [CA2311] 763
FAILURE CODE [D110KB] 764
FAILURE CODE [D19JKZ] 766
FAILURE CODE [D811MC] 768
FAILURE CODE [D862KA] 769
FAILURE CODE [D8ALKA] 770
FAILURE CODE [D8ALKB] 773
FAILURE CODE [D8AQKR] 775
FAILURE CODE [D8G1KT] 780
FAILURE CODE [D8G6KT] 781
FAILURE CODE [DA20MC] 782
FAILURE CODE [DA22KK] 783
FAILURE CODE [DA25KP] 785
FAILURE CODE [DA26KP] 787
FAILURE CODE [DA29KQ] 790
FAILURE CODE [DA2LKA] 792
FAILURE CODE [DA2LKB] 795
FAILURE CODE [DA2QKR] 797
FAILURE CODE [DA2RKR] 803
FAILURE CODE [DAF0MB] 809
FAILURE CODE [DAF0MC] 810
FAILURE CODE [DAF8KB] 811
FAILURE CODE [DAF9KQ] 813
FAILURE CODE [DAFGMC] 814
FAILURE CODE [DAFLKA] 815
FAILURE CODE [DAFLKB] 818
FAILURE CODE [DAFQKR] 820
FAILURE CODE [DAZ9KQ] 825
FAILURE CODE [DAZQKR] 826
FAILURE CODE [DB2QKR] 831
FAILURE CODE [DGH2KA] 837
FAILURE CODE [DGH2KB] 839
FAILURE CODE [DHA4KA] 841
FAILURE CODE [DHE5MA] 843
FAILURE CODE [DHPAMA] 847
FAILURE CODE [DHS3MA] 849
FAILURE CODE [DHS4MA] 851
FAILURE CODE [DHS8MA] 853
FAILURE CODE [DHS9MA] 855
FAILURE CODE [DHSAMA] 857
FAILURE CODE [DHSBMA] 859
FAILURE CODE [DHSCMA] 861
FAILURE CODE [DHSDMA] 863
FAILURE CODE [DHSFMA] 865
FAILURE CODE [DHSGMA] 867
FAILURE CODE [DHSHMA] 869
FAILURE CODE [DHSJMA] 871
FAILURE CODE [DHSKMA] 873
FAILURE CODE [DHSLMA] 875
FAILURE CODE [DJG1KX] 877
FAILURE CODE [DKR2MA] 881
FAILURE CODE [DKR2NX] 885
FAILURE CODE [DV20KB] 888
FAILURE CODE [DW43KA] 890
FAILURE CODE [DW43KB] 892
FAILURE CODE [DW43KY] 894
FAILURE CODE [DW45KA] 895
FAILURE CODE [DW45KB] 898
FAILURE CODE [DW45KY] 901
FAILURE CODE [DW91KA] 903
FAILURE CODE [DW91KB] 905
FAILURE CODE [DW91KY] 907
FAILURE CODE [DWA2KA] 909
FAILURE CODE [DWA2KB] 911
FAILURE CODE [DWA2KY] 913
FAILURE CODE [DWJ0KA] 915
FAILURE CODE [DWJ0KB] 917
FAILURE CODE [DWJ0KY] 919
FAILURE CODE [DWK0KA] 921
FAILURE CODE [DWK0KB] 923
FAILURE CODE [DWK0KY] 925
FAILURE CODE [DWK2KA] 927
FAILURE CODE [DWK2KB] 929
FAILURE CODE [DWK2KY] 931
FAILURE CODE [DWNSKA] 933
FAILURE CODE [DWNSKB] 935
FAILURE CODE [DWNSKY] 937
FAILURE CODE [DXA8KA] 938
FAILURE CODE [DXA8KB] 940
FAILURE CODE [DXE4KA] 942
FAILURE CODE [DXE4KB] 944
FAILURE CODE [DXE4KY] 946
FAILURE CODE [DY20KA] 948
FAILURE CODE [DY20MA] 950
FAILURE CODE [DY2CKB] 952
FAILURE CODE [DY2DKB] 954
FAILURE CODE [DY2EKB] 956
FAILURE CODE [F@BBZL] 958
FAILURE CODE [F313KA] 961
FAILURE CODE [F313KB] 963
FAILURE CODE [F318KB] 964
FAILURE CODE [F318KY] 966
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 967
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 967
MANUAL PREHEATING SYSTEM DOES NOT WORK 978
WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP 982
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR SHOWS NOTHING 985
WHILE ENGINE IS IN OPERATION, ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE 990
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS IN OPERATION 991
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS IN OPERATION 992
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 993
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 994
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 995
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 996
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 997
FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 998
FUEL GAUGE DOES NOT SHOW CORRECT FUEL LEVEL 1000
COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1001
COOLANT TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE 1002
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1003
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE 1005
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT SHOWN 1006
FUNCTION SWITCH DOES NOT OPERATE 1007
AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER) 1008
AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED 1009
AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION 1010
WORK MODE SELECTOR SCREEN IS NOT SHOWN WHILE WORK MODE SWITCH IS OPERATED 1011
ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED 1012
TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED 1013
TRAVEL SPEED DOES NOT CHANGE EVEN WHEN YOU OPERATE THE OPERATION TO CHANGE TRAVEL SPEED 1014
ALARM BUZZER CANNOT BE STOPPED 1015
SERVICE METER IS NOT SHOWN WHILE STARTING SWITCH IS IN OFF POSITION 1016
MACHINE DOES NOT CHANGE TO SERVICE MODE 1017
ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE 1018
ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK 1022
MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED 1024
WHILE SWING PARKING BRAKE RELEASE SWITCH IS TURNED ON, SWING BRAKE IS NOT OPERATED 1026
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY 1028
ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED 1032
TRAVEL ALARM DOES NOT OPERATE DURING TRAVEL 1034
TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS 1036
HORN DOES NOT MAKE SOUND 1037
HORN DOES NOT STOP 1039
WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED 1040
WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED 1041
WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED 1043
“BOOM RAISE” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1044
“BOOM LOWER” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1045
“ARM DUMP” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1046
“ARM IN” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1047
“BUCKET DUMP” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1048
“BUCKET CURL” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1049
“SWING” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1050
“TRAVEL” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1051
SERVICE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1052
BLADE RAISE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1055
BLADE LOWER IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1056
KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY 1057
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1058
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1058
FAILURE MODE AND CAUSE TABLE 1059
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1069
All WORK EQUIPMENT, SWING, AND TRAVEL SPEED IS LOW OR POWER IS LOW 1070
FINE CONTROL PERFORMANCE OR RESPONSE IS UNSATISFACTORY 1072
THERE IS UNUSUAL NOISE FROM AROUND HYDRAULIC PUMP 1073
ENGINE SPEED FALLS LARGELY OR ENGINE STOPS 1074
BOOM SPEED OR POWER IS LOW 1076
ARM SPEED IS LOW OR POWER IS LOW 1079
BUCKET SPEED OR POWER IS LOW 1082
BLADE SPEED OR POWER IS LOW 1085
WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1087
HYDRAULIC DRIFT OF BOOM IS LARGE 1088
HYDRAULIC DRIFT OF ARM IS LARGE 1089
HYDRAULIC DRIFT OF BUCKET IS LARGE 1090
HYDRAULIC DRIFT OF BLADE IS LARGE 1091
WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 1093
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 1094
TIME LAG OF WORK EQUIPMENT IS LARGE 1096
ATTACHMENT CIRCUIT CANNOT BE CHANGED 1097
OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 1098
IN COMBINED OPERATION OF WORK EQUIPMENT, WORK EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER 1099
IN COMBINATION OPERATION OF SWING AND TRAVEL, TRAVEL SPEED FALLS LARGELY 1100
IN COMBINATION OPERATION OF SWING AND BOOM RAISE, BOOM RAISE SPEED IS LOW 1101
MACHINE DOES NOT TRAVEL STRAIGHT 1102
MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 1105
TRAVEL SPEED IS SLOW 1108
ONE OF TRACKS DOES NOT RUN 1110
TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1112
MACHINE DOES NOT SWING TO RIGHT OR LEFT 1113
SWINGS ONLY IN ONE DIRECTION 1114
SWING ACCELERATION OR SWING SPEED IS LOW IN TWO DIRECTIONS OF RIGHT AND LEFT 1115
SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION 1116
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (RIGHT AND LEFT) 1117
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (ONLY ONE DIRECTION) 1118
SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWING OPERATION 1119
THERE IS A LARGE UNUSUAL NOISE WHEN UPPER STRUCTURE STOPS SWING OPERATION 1120
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 1121
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1122
50 DISASSEMBLY AND ASSEMBLY 1123
CONTENTS 1124
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1128
HOW TO READ THIS MANUAL 1128
COATING MATERIALS LIST 1130
SPECIAL TOOLS LIST 1134
SKETCHES OF SPECIAL TOOLS 1148
PREPARATION 1150
DRAIN AND ADD COOLANT 1150
DRAIN COOLANT 1150
ADD COOLANT 1151
DRAIN AND ADD HYDRAULIC OIL 1153
DRAIN HYDRAULIC OIL 1153
ADD HYDRAULIC OIL 1155
DRAIN AND ADD FUEL 1156
DRAIN FUEL 1156
ADD FUEL 1157
COLLECT AND REFILL REFRIGERANT 1158
COLLECT REFRIGERANT 1158
REFILL REFRIGERANT 1159
ENGINE AND COOLING SYSTEM 1160
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1160
REMOVE SUPPLY PUMP ASSEMBLY 1161
INSTALL SUPPLY PUMP ASSEMBLY 1164
REMOVE AND INSTALL INJECTOR ASSEMBLY 1170
REMOVE INJECTOR ASSEMBLY 1171
INSTALL INJECTOR ASSEMBLY 1174
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 1178
REMOVE CYLINDER HEAD ASSEMBLY 1179
INSTALL CYLINDER HEAD ASSEMBLY 1189
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 1202
REMOVE STARTING MOTOR ASSEMBLY 1202
INSTALL STARTING MOTOR ASSEMBLY 1204
REMOVE AND INSTALL FAN BELT 1205
REMOVE FAN BELT 1206
INSTALL FAN BELT 1207
REMOVE AND INSTALL RADIATOR ASSEMBLY 1209
REMOVE RADIATOR ASSEMBLY 1210
INSTALL RADIATOR ASSEMBLY 1213
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1217
REMOVE HYDRAULIC OIL COOLER ASSEMBLY 1218
INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1222
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 1227
REMOVE AFTERCOOLER ASSEMBLY 1228
INSTALL AFTERCOOLER ASSEMBLY 1231
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 1235
REMOVE ENGINE AND MAIN PUMP ASSEMBLY 1237
INSTALL ENGINE AND MAIN PUMP ASSEMBLY 1255
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 1276
REMOVE ENGINE FRONT OIL SEAL 1277
INSTALL ENGINE FRONT OIL SEAL 1278
REMOVE AND INSTALL ENGINE REAR OIL SEAL 1280
REMOVE ENGINE REAR OIL SEAL 1281
INSTALL ENGINE REAR OIL SEAL 1282
REMOVE AND INSTALL FUEL COOLER ASSEMBLY 1285
REMOVE FUEL COOLER ASSEMBLY 1286
INSTALL FUEL COOLER ASSEMBLY 1287
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 1288
REMOVE ENGINE HOOD ASSEMBLY 1288
INSTALL ENGINE HOOD ASSEMBLY 1289
REMOVE AND INSTALL FUEL TANK ASSEMBLY 1291
REMOVE FUEL TANK ASSEMBLY 1292
INSTALL FUEL TANK ASSEMBLY 1295
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 1299
REMOVE AIR CLEANER ASSEMBLY 1300
INSTALL AIR CLEANER ASSEMBLY 1302
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 1305
REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY 1306
INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 1307
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 1310
REMOVE AIR CONDITIONER CONDENSER ASSEMBLY 1310
INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 1312
POWER TRAIN 1314
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1314
REMOVE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1315
INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1317
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1319
DISASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1331
ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1349
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 1370
REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY 1371
INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 1374
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 1376
DISASSEMBLE SWING MACHINERY ASSEMBLY 1377
ASSEMBLE SWING MACHINERY ASSEMBLY 1380
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 1386
REMOVE SWING CIRCLE ASSEMBLY 1386
INSTALL SWING CIRCLE ASSEMBLY 1387
UNDERCARRIAGE AND FRAME 1388
SEPARATE AND INSTALL TRACK ASSEMBLY 1388
SEPARATE TRACK ASSEMBLY 1389
INSTALL TRACK ASSEMBLY 1391
REMOVE AND INSTALL SPROCKET 1394
REMOVE SPROCKET 1394
INSTALL SPROCKET 1395
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 1396
REMOVE IDLER AND IDLER CUSHION ASSEMBLY 1396
INSTALL IDLER AND IDLER CUSHION ASSEMBLY 1397
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 1398
DISASSEMBLE IDLER CUSHION ASSEMBLY 1398
ASSEMBLE IDLER ASSEMBLY 1399
DISASSEMBLE AND ASSEMBLE IDLER CUSHION ASSEMBLY 1402
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 1402
ASSEMBLE IDLER CUSHION ASSEMBLY 1404
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 1406
DISASSEMBLE TRACK ROLLER ASSEMBLY 1406
ASSEMBLE TRACK ROLLER ASSEMBLY 1407
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 1409
REMOVE REVOLVING FRAME ASSEMBLY 1410
INSTALL REVOLVING FRAME ASSEMBLY 1415
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 1420
REMOVE COUNTERWEIGHT ASSEMBLY 1421
INSTALL COUNTERWEIGHT ASSEMBLY 1422
HYDRAULIC SYSTEM 1425
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 1425
REMOVE CENTER SWIVEL JOINT ASSEMBLY 1426
INSTALL CENTER SWIVEL JOINT ASSEMBLY 1430
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 1435
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 1436
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 1437
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 1438
REMOVE HYDRAULIC TANK ASSEMBLY 1439
INSTALL HYDRAULIC TANK ASSEMBLY 1448
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 1458
REMOVE MAIN PUMP ASSEMBLY 1459
INSTALL MAIN PUMP ASSEMBLY 1465
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 1472
REMOVE CONTROL VALVE ASSEMBLY 1474
INSTALL CONTROL VALVE ASSEMBLY 1488
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 1502
ASSEMBLE CONTROL VALVE ASSEMBLY 1502
REPLACE PRESSURE REDUCING VALVE CARTRIDGE ASSEMBLY 1504
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 1507
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 1507
ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 1507
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 1509
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 1509
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 1510
WORK EQUIPMENT 1512
REMOVE AND INSTALL BLADE ASSEMBLY 1512
REMOVE BLADE ASSEMBLY 1513
INSTALL BLADE ASSEMBLY 1514
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 1516
REMOVE WORK EQUIPMENT ASSEMBLY 1518
INSTALL WORK EQUIPMENT ASSEMBLY 1521
DISASSEMBLE AND ASSEMBLE BUCKET CYLINDER ASSEMBLY 1525
DISASSEMBLE BUCKET CYLINDER ASSEMBLY 1526
ASSEMBLE BUCKET CYLINDER ASSEMBLY 1528
DISASSEMBLE AND ASSEMBLE BOOM CYLINDER ASSEMBLY 1532
DISASSEMBLE BOOM CYLINDER ASSEMBLY 1533
ASSEMBLE BOOM CYLINDER ASSEMBLY 1535
DISASSEMBLE AND ASSEMBLE ARM CYLINDER ASSEMBLY 1539
DISASSEMBLE ARM CYLINDER ASSEMBLY 1540
ASSEMBLE ARM CYLINDER ASSEMBLY 1542
DISASSEMBLE AND ASSEMBLE BLADE CYLINDER ASSEMBLY 1547
DISASSEMBLE BLADE CYLINDER ASSEMBLY 1548
ASSEMBLE BLADE CYLINDER ASSEMBLY 1550
CAB RELATED PARTS 1555
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY 1555
REMOVE OPERATOR CAB ASSEMBLY 1555
INSTALL OPERATOR CAB ASSEMBLY 1566
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 1576
REMOVE OPERATOR CAB GLASS (ADHERED GLASS) 1578
INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 1578
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 1589
REMOVE FRONT WINDOW ASSEMBLY 1589
INSTALL FRONT WINDOW ASSEMBLY 1592
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 1598
REMOVE FLOOR FRAME ASSEMBLY 1599
INSTALL FLOOR FRAME ASSEMBLY 1605
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 1612
REMOVE AIR CONDITIONER UNIT ASSEMBLY 1613
INSTALL AIR CONDITIONER UNIT ASSEMBLY 1621
REMOVE AND INSTALL OPERATOR SEAT 1629
REMOVE OPERATOR’S SEAT 1629
INSTALL OPERATOR’S SEAT 1630
REMOVE AND INSTALL SEATBELT 1631
REMOVE SEATBELT 1631
INSTALL SEATBELT 1632
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 1633
REMOVE FRONT WIPER ASSEMBLY 1633
INSTALL FRONT WIPER ASSEMBLY 1639
ELECTRICAL SYSTEM 1647
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 1647
REMOVE ENGINE CONTROLLER ASSEMBLY 1648
INSTALL ENGINE CONTROLLER ASSEMBLY 1651
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 1656
REMOVE PUMP CONTROLLER ASSEMBLY 1656
INSTALL PUMP CONTROLLER ASSEMBLY 1658
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 1662
REMOVE MACHINE MONITOR ASSEMBLY 1662
INSTALL MACHINE MONITOR ASSEMBLY 1665
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 1669
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 1669
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 1673
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 1677
REMOVE COMMUNICATION TERMINAL WIRING HARNESS 1677
INSTALL COMMUNICATION TERMINAL WIRING HARNESS 1684
REMOVE AND INSTALL COMMUNICATION TERMINAL 1693
REMOVE COMMUNICATION TERMINAL 1693
INSTALL COMMUNICATION TERMINAL 1695
60 MAINTENANCE STANDARD 1697
CONTENTS 1698
ENGINE AND COOLING SYSTEM 1699
MAINTENANCE STANDARD OF ENGINE MOUNT 1699
MAINTENANCE STANDARD OF PTO 1700
MAINTENANCE STANDARD OF COOLING SYSTEM 1701
POWER TRAIN 1702
MAINTENANCE STANDARD OF SWING CIRCLE 1702
MAINTENANCE STANDARD OF SWING MACHINERY 1703
MAINTENANCE STANDARD OF SPROCKET 1705
UNDERCARRIAGE AND FRAME 1706
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 1706
MAINTENANCE STANDARD OF IDLER 1708
MAINTENANCE STANDARD OF TRACK ROLLER 1709
MAINTENANCE STANDARD OF CARRIER ROLLER 1710
MAINTENANCE STANDARD OF TRACK SHOE 1711
MAINTENANCE STANDARD OF TRIPLE SHOE 1714
HYDRAULIC SYSTEM 1715
MAINTENANCE STANDARD OF HYDRAULIC TANK 1715
MAINTENANCE STANDARD OF MAIN PUMP 1716
MAINTENANCE STANDARD OF PC-EPC VALVE 1720
MAINTENANCE STANDARD OF SWING MOTOR 1721
MAINTENANCE STANDARD OF TRAVEL MOTOR 1724
MAINTENANCE STANDARD OF CONTROL VALVE 1725
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 1736
MAINTENANCE STANDARD OF BLADE PPC VALVE 1739
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 1741
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 1744
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 1746
MAINTENANCE STANDARD OF SOLENOID VALVE 1747
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE SOLENOID VALVE 1751
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 1752
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) 1753
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 1754
WORK EQUIPMENT 1756
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 1756
DIMENSIONS OF ARM 1761
DIMENSIONS OF BUCKET 1763
MAINTENANCE STANDARD OF BOOM CYLINDER 1765
MAINTENANCE STANDARD OF ARM CYLINDER 1766
MAINTENANCE STANDARD OF BUCKET CYLINDER 1767
MAINTENANCE STANDARD OF BLADE CYLINDER 1768
CAB AND ITS ATTACHMENTS 1769
MAINTENANCE STANDARD OF CAB MOUNT 1769
80 OTHERS 1771
CONTENTS 1772
AIR CONDITIONER SYSTEM 1774
PRECAUTIONS FOR REFRIGERANT 1774
AIR CONDITIONER 1775
SPECIFICATIONS OF AIR CONDITIONER 1777
CONFIGURATION OF REFRIGERATION CYCLE 1778
FUNCTION OF REFRIGERATION CYCLE 1779
SYSTEM DIAGRAM OF AIR CONDITIONER 1780
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 1781
AIR CONDITIONER UNIT 1781
STRUCTURE OF AIR CONDITIONER UNIT 1782
FUNCTION OF AIR CONDITIONER UNIT 1783
COMPONENT PARTS OF AIR CONDITIONER UNIT 1784
AIR CONDITIONER CONTROLLER 1788
STRUCTURE OF AIR CONDITIONER CONTROLLER 1788
FUNCTION OF AIR CONDITIONER CONTROLLER 1788
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 1788
COMPRESSOR 1790
STRUCTURE OF COMPRESSOR 1790
SPECIFICATIONS OF COMPRESSOR 1790
FUNCTION OF COMPRESSOR 1790
OPERATION OF COMPRESSOR 1790
CONDENSER 1791
STRUCTURE OF CONDENSER 1791
SPECIFICATIONS OF CONDENSOR 1791
FUNCTION OF COMPRESSOR 1791
AIR CONDITIONER RELATED SENSORS 1793
STRUCTURE OF SUNLIGHT SENSOR 1793
FUNCTION OF SUNLIGHT SENSOR 1793
STRUCTURE OF OUTSIDE TEMPERATURE SENSOR 1793
FUNCTION OF OUTSIDE AIR TEMPERATURE SENSOR 1793
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS OF AIR CONDITIONER 1794
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 1796
TEST AIR LEAKAGE (DUCT CONNECTION) 1800
TEST AIR LEAKAGE (DUCT CONNECTION) 1800
TEST AIR CONDITIONER BY SELF-DIAGNOSIS FUNCTION 1803
TEST VENT (MODE) CHANGEOVER 1804
TEST VENT (MODE) CHANGEOVER 1804
TEST FRESH/RECIRC AIR CHANGEOVER 1806
TEST FRESH/RECIRC AIR CHANGEOVER 1806
TEST SUNLIGHT SENSOR 1807
TEST SUNLIGHT SENSOR 1807
TEST DUAL PRESSURE SWITCH 1808
TEST DUAL PRESSURE SWITCH 1808
TEST RELAY 1809
TEST RELAY 1809
SIMPLE CHECK OF REFRIGERANT VOLUME THROUGH SIGHT GLASS 1811
PROCEDURE FOR TROUBLE SHOOTING OF AIR CONDITIONER 1812
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1813
FAILURE CODE [879AKA] 1816
FAILURE CODE [879AKB] 1817
FAILURE CODE [879BKA] 1818
FAILURE CODE [879BKB] 1820
FAILURE CODE [879CKA] 1822
FAILURE CODE [879CKB] 1823
FAILURE CODE [879DKZ] 1824
FAILURE CODE [879EMC] 1826
FAILURE CODE [879FMC] 1827
FAILURE CODE [879GKX] 1828
TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 1830
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 1833
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 1836
TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 1838
CONNECT SERVICE TOOL 1841
CONNECT SERVICE TOOL 1842
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPING 1843
HANDLE COMPRESSOR OIL 1845
REPLACE DESICCANT 1847
90 CIRCUIT DIAGRAMS 1849
CONTENTS 1850
HOW TO READ THE CODES FOR ELECTRIC CABLE 1851
HYDRAULIC CIRCUIT DIAGRAM 1855
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 1855
HYDRAULIC CIRCUIT DIAGRAM (1/3) 1859
HYDRAULIC CIRCUIT DIAGRAM (2/3) 1861
HYDRAULIC CIRCUIT DIAGRAM (3/3) 1863
ELECTRICAL CIRCUIT DIAGRAM 1865
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 1865
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (1/6) 1869
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (2/6) 1871
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (3/6) 1873
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (4/6) 1875
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (5/6) 1877
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (6/6) 1879
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (1/6) 1881
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (2/6) 1883
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (3/6) 1885
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (4/6) 1887
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (5/6) 1889
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (6/6) 1891
INDEX 1893
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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