Komatsu PC130-11 Hydraulic Excavator Shop Manual SEN06804-04 – PDF DOWNLOAD
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DESCRIPTION:
Komatsu PC130-11 Hydraulic Excavator Shop Manual SEN06804-04 – PDF DOWNLOAD
SERIAL NUMBERS 90001 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 PC130-11 Hydraulic Excavator Shop Manual SEN06804-04 – PDF DOWNLOAD
COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
FOREWORD, SAFETY, BASIC INFORMATION 22
HOW TO READ THE SHOP MANUAL 22
SAFETY NOTICE FOR OPERATION 24
PRECAUTIONS TO PREVENT FIRE 32
ACTIONS IF FIRE OCCURS 34
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 35
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 36
PRECAUTIONS FOR DEF 37
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 37
PRECAUTIONS FOR ADDING 37
PRECAUTIONS FOR STORING 37
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 37
THE OTHER PRECAUTIONS 37
STORE AdBlue/DEF 38
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 39
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 42
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 49
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 51
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 52
PRACTICAL USE OF KOMTRAX 53
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 54
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 54
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 55
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 56
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 58
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 62
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 63
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 65
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 68
HOW TO READ ELECTRICAL WIRE CODE 69
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 73
STANDARD TIGHTENING TORQUE TABLE 76
CONVERSION TABLE 83
ABBREVIATION LIST 88
01 SPECIFICATIONS 91
CONTENTS 92
SPECIFICATIONS 93
SPECIFICATION DRAWING 93
SPECIFICATION DRAWING: PC130-11 93
WORKING RANGE DRAWINGS 95
WORKING RANGE DRAWINGS: PC130-11 95
SPECIFICATIONS 96
SPECIFICATIONS: PC130-11 96
WEIGHT TABLE 99
WEIGHT TABLE: PC130-11 99
FUEL, COOLANT, LUBRICANT 101
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 101
10 STRUCTURE AND FUNCTION 103
CONTENTS 104
UREA SCR SYSTEM 107
LAYOUT DRAWING OF UREA SCR SYSTEM 107
UREA SCR SYSTEM DIAGRAM 110
FUNCTION OF UREA SCR SYSTEM 111
FUNCTION OF AdBlue/DEF SYSTEM (SERIAL NO : 90001 TO 92188) 111
FUNCTION OF AdBlue/DEF SYSTEM (SERIAL NO : 92189 AND UP) 113
INDUCEMENT STRATEGY 115
FUNCTION THAT CALLS FOR ATTENTION OF THE OPERATOR FOR UREA SCR SYSTEM TO STAY FUNCTIONAL 115
COMPONENT PARTS OF UREA SCR SYSTEM 123
AdBlue/DEF MIXING TUBE 123
SCR ASSEMBLY 123
AdBlue/DEF TANK 126
AdBlue/DEF PUMP 128
AdBlue/DEF INJECTOR 129
AdBlue/DEF HOSE 130
AdBlue/DEF TANK HEATING VALVE 131
BOOT-UP SYSTEM 132
LAYOUT DRAWING OF BOOT-UP SYSTEM (SERIAL NO : 90001 TO 92188) 132
LAYOUT DRAWING OF BOOT-UP SYSTEM (SERIAL NO : 92189 AND UP) 133
SYSTEM OPERATING LAMP SYSTEM 134
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 134
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (SERIAL NO : 90001 TO 92188) 134
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (SERIAL NO : 92189 AND UP) 135
BATTERY DISCONNECT SWITCH 136
FUNCTION OF BATTERY DISCONNECT SWITCH (SERIAL NO : 90001 TO 92188) 136
FUNCTION OF BATTERY DISCONNECT SWITCH (SERIAL NO : 92189 AND UP) 136
ENGINE SYSTEM 138
LAYOUT DRAWING OF ENGINE SYSTEM 138
ENGINE CONTROL SYSTEM 140
ENGINE CONTROL SYSTEM DIAGRAM 140
FUNCTION OF ENGINE CONTROL SYSTEM 141
AUTO-DECELERATION SYSTEM 143
SYSTEM DIAGRAM OF AUTO-DECELERATION SYSTEM 143
FUNCTION OF AUTO-DECELERATION SYSTEM 143
OPERATION OF AUTO-DECELERATION SYSTEM 144
ENGINE AUTOMATIC WARM-UP SYSTEM 145
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 145
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 145
OVERHEAT PREVENTION SYSTEM 147
FUNCTION OF OVERHEAT PREVENTION SYSTEM 147
TURBOCHARGER PROTECTION SYSTEM 149
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 149
AUTOMATIC IDLE STOP SYSTEM 150
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 150
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 150
COMPONENT PARTS OF ENGINE SYSTEM 153
PTO 153
VARIABLE FLOW TURBOCHARGER 153
EGR SYSTEM 157
EGR VALVE 159
EGR COOLER 160
KCCV SYSTEM 162
KCCV VENTILATOR 164
EXHAUST THROTTLE VALVE 166
KDOC 166
COOLING SYSTEM 170
LAYOUT DRAWING OF COOLING SYSTEM 170
SPECIFICATIONS OF COOLING SYSTEM 171
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 172
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 172
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 173
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 174
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 174
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 174
COMPONENT PARTS OF COOLING SYSTEM 176
FAN CLUTCH 176
CONTROL SYSTEM 177
LAYOUT DRAWING OF CONTROL SYSTEM 177
MACHINE MONITOR SYSTEM 179
MACHINE MONITOR SYSTEM DIAGRAM 179
FUNCTION OF MACHINE MONITOR SYSTEM 179
KomVision SYSTEM 181
LAYOUT DRAWING OF KomVision SYSTEM 181
SYSTEM DIAGRAM OF KomVision SYSTEM 182
FUNCTION OF KomVision SYSTEM 182
KOMTRAX SYSTEM 184
SYSTEM DIAGRAM OF KOMTRAX SYSTEM 184
FUNCTION OF KOMTRAX SYSTEM 184
COMPONENT PARTS OF CONTROL SYSTEM 185
MACHINE MONITOR 185
KomVision CONTROLLER 198
KomVision CAMERA 202
GATEWAY FUNCTION CONTROLLER 203
COMMUNICATION TERMINAL 206
PUMP CONTROLLER 207
RESISTOR FOR PC-EPC VALVE 211
CAN TERMINATING RESISTOR 211
ENGINE CONTROLLER 213
FUEL CONTROL DIAL 219
HYDRAULIC SYSTEM 221
LAYOUT DRAWING OF HYDRAULIC SYSTEM 221
CLSS 223
STRUCTURE OF CLSS 223
FUNCTION OF CLSS 224
ENGINE AND PUMP COMBINED CONTROL SYSTEM 226
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 226
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 227
COMPONENT PARTS OF HYDRAULIC SYSTEM 231
HYDRAULIC TANK 231
MAIN PUMP 233
CONTROL VALVE 257
WORK EQUIPMENT SYSTEM 318
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 318
STRUCTURE OF VALVE CONTROL 320
PPC LOCK SYSTEM 321
SYSTEM DIAGRAM OF PPC LOCK SYSTEM 321
FUNCTION OF PPC LOCK SYSTEM 321
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 322
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 322
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 322
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 323
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 324
WORK EQUIPMENT AND SWING PPC VALVE 324
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 328
SOLENOID VALVE 335
VARIABLE BACK PRESSURE SOLENOID VALVE 339
MULTI-CONTROL VALVE 340
ARM DUMP QUICK RETURN VALVE 341
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE 342
PILOT CIRCUIT ACCUMULATOR 345
ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) 346
SWING SYSTEM 348
LAYOUT DRAWING OF SWING SYSTEM 348
SWING CONTROL SYSTEM DIAGRAM 350
FUNCTION OF SWING CONTROL SYSTEM 350
COMPONENT PARTS OF SWING SYSTEM 353
SWING MOTOR 353
SWING MACHINERY 361
SWING CIRCLE 362
TRAVEL SYSTEM 364
LAYOUT DRAWING OF TRAVEL SYSTEM 364
SYSTEM DIAGRAM OF TRAVEL CONTROL SYSTEM 366
FUNCTION OF TRAVEL CONTROL SYSTEM 366
COMPONENT PARTS OF TRAVEL SYSTEM 370
TRAVEL MOTOR 370
TRAVEL PPC VALVE 380
CENTER SWIVEL JOINT 384
UNDERCARRIAGE AND FRAME 386
LAYOUT DRAWING OF UNDERCARRIAGE 386
SPECIFICATIONS OF UNDERCARRIAGE 386
IDLER CUSHION 387
STRUCTURE OF IDLER CUSHION 387
SPECIFICATIONS OF IDLER CUSHION 387
WORK EQUIPMENT 388
STRUCTURE OF WORK EQUIPMENT 388
FUNCTION OF WORK EQUIPMENT 389
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 390
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 390
BUCKET CLEARANCE ADJUSTMENT SHIM 391
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 391
CAB AND ITS ATTACHMENTS 392
ROPS CAB 392
STRUCTURE OF ROPS CAB 392
FUNCTION OF ROPS CAB 392
CAB MOUNT 393
STRUCTURE OF CAB MOUNT 393
FUNCTION OF CAB MOUNT 393
CAB TIPPING STOPPER 394
STRUCTURE OF CAB TIPPING STOPPER 394
FUNCTION OF CAB TIPPING STOPPER 394
20 STANDARD VALUE TABLE 395
CONTENTS 396
STANDARD VALUE TABLE FOR ENGINE 397
STANDARD VALUE TABLE FOR ENGINE: PC130-11 397
STANDARD VALUE TABLE FOR MACHINE 400
STANDARD VALUE TABLE FOR MACHINE: PC130-11 400
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE 414
30 TESTING AND ADJUSTING 419
CONTENTS 420
RELATED INFORMATION ON TESTING AND ADJUSTING 423
TOOLS FOR TESTING AND ADJUSTING 423
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 430
ENGINE AND COOLING SYSTEM 432
TEST ENGINE SPEED 432
TEST ENGINE SPEED 432
TEST EXHAUST GAS COLOR 435
TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 435
TEST EXHAUST GAS COLOR BY SMOKE METER 436
TEST THE CLEARANCE OF THE EXHAUST THROTTLE VALVE 437
MEASURE CLEARANCE OF THE EXHAUST THROTTLE VALVE 437
TEST AND ADJUST VALVE CLEARANCE 439
TEST VALVE CLEARANCE 439
METHOD FOR ADJUSTING VALVE CLEARANCE 440
TEST COMPRESSION PRESSURE 441
TEST COMPRESSION PRESSURE 441
TEST BLOWBY PRESSURE 444
TEST BLOWBY PRESSURE 444
TEST ENGINE OIL PRESSURE 446
TEST ENGINE OIL PRESSURE 446
VISUAL CHECK INSIDE OF EGR VALVE 447
VISUAL CHECK INSIDE OF EGR VALVE 447
CLEAN INSIDE OF EGR VALVE 449
CLEAN INSIDE OF EGR VALVE 449
TEST FUEL PRESSURE 452
TEST FUEL PRESSURE 452
TEST FUEL RETURN RATE AND LEAKAGE 454
TEST FUEL RETURN RATE AND LEAKAGE 455
BLEED AIR FROM FUEL SYSTEM 458
BLEED AIR FROM FUEL SYSTEM 458
TEST FUEL CIRCUIT FOR LEAKAGE 460
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 460
HANDLE CYLINDER CUT-OUT MODE OPERATION 462
HANDLE NO-INJECTION CRANKING OPERATION 463
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 464
CHECK AIR CONDITIONER COMPRESSOR BELT 464
ADJUST AIR CONDITIONER COMPRESSOR BELT 464
TEST ALTERNATOR BELT 466
TEST ALTERNATOR BELT TENSION 466
TEST AUTOMATIC TENSIONER 467
TEST AUTOMATIC TENSIONER 467
TEST COOLING FAN SPEED 469
METHOD FOR TESTING COOLING FAN SPEED 469
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 470
WRITE INJECTOR COMPENSATION VALUE 470
TEST SCR RELATED FUNCTIONS 476
TEST AdBlue/DEF PUMP RAISED PRESSURE 480
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 483
TEST AdBlue/DEF LINE HEATER RELAY 1 488
TEST AdBlue/DEF LINE HEATER RELAY 2 492
TEST AdBlue/DEF PUMP HEATER RELAY 496
TEST AdBlue/DEF TANK HEATER VALVE 500
TEST DENITRATION EFFICIENCY OF SCR 504
CLEAN AdBlue/DEF TANK 507
CLEAN AdBlue/DEF TANK 507
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 512
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 512
CLEAN AdBlue/DEF PUMP 514
CLEAN AdBlue/DEF PUMP 514
POWER TRAIN 520
TEST SWING CIRCLE BEARING CLEARANCE 520
TEST SWING CIRCLE BEARING CLEARANCE 520
UNDERCARRIAGE AND FRAME 521
TEST AND ADJUST TRACK TENSION 521
METHOD FOR TESTING TRACK TENSION 521
METHOD FOR ADJUSTING TRACK TENSION 521
HYDRAULIC SYSTEM 523
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 523
RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK 523
RELEASE REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 523
RELEASE REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 523
RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 524
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 525
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 525
ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 531
TEST OIL PRESSURE OF CONTROL CIRCUIT 533
TEST OIL PRESSURE OF CONTROL CIRCUIT 533
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 535
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 535
TEST PC-EPC VALVE OUTLET PRESSURE 536
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 537
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 539
TEST LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 539
TEST LS DIFFERENTIAL PRESSURE BY TESTING TOOL 541
TEST LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 542
METHOD FOR ADJUSTING LS VALVE 544
TEST OUTLET PRESSURE OF SOLENOID VALVE 545
METHOD FOR OUTLET PRESSURE OF SOLENOID VALVE 545
OPERATING CONDITION OF SOLENOID VALVE 546
VARIABLE BACK PRESSURE SOLENOID VALVE OUTLET PRESSURE 548
OPERATING CONDITION OF VARIABLE BACK PRESSURE SOLENOID VALVE 549
TEST OUTLET PRESSURE IN PPC VALVE 550
TEST OUTLET PRESSURE IN PPC VALVE 550
TEST ATTACHMENT CIRCUIT OIL PRESSURE 552
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 552
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 553
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 553
TEST AND ADJUST TRAVEL DEVIATION 554
TEST TRAVEL DEVIATION 554
METHOD FOR ADJUSTING TRAVEL DEVIATION 554
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 557
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 557
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 557
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 558
TEST OIL LEAKAGE 559
TEST OIL LEAKAGE FROM BOOM CYLINDER 559
TEST OIL LEAKAGE FROM ARM CYLINDER 559
TEST OIL LEAKAGE FROM BUCKET CYLINDER 560
TEST OIL LEAKAGE FROM SWING MOTOR 561
TEST OIL LEAKAGE FROM TRAVEL MOTOR 561
BLEED AIR FROM HYDRAULIC CIRCUIT 563
BLEED AIR FROM HYDRAULIC CIRCUIT 564
CAB RELATED PARTS 567
TEST CAB TIPPING STOPPER 567
METHOD FOR TESTING CAB TIPPING STOPPER 567
ADJUST MIRRORS 568
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 568
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 569
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 570
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 571
ADJUST MACHINE RIGHT SIDE MIRROR (C) 572
ELECTRICAL SYSTEM 573
SET AND OPERATE MACHINE MONITOR 573
OPERATOR MODE 577
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 577
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 577
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 578
CHECKING FUNCTION OF SERVICE METER 578
SET USAGE LIMITATION AND CHANGE MAINTENANCE PASSWORD 578
SERVICE MODE 581
SERVICE MODE 581
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 583
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 589
ABNORMALITY RECORD MENU 600
CHECK MAINTENANCE RECORD 604
METHOD FOR OPERATING MAINTENANCE MODE SETTING 605
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 609
DEFAULT MENU 611
DIAGNOSTIC TESTS MENU 618
ADJUSTMENT MENU 627
METHOD FOR PERFORMING NO-INJECTION CRANKING 639
KOMTRAX SETTINGS MENU 641
METHOD FOR DISPLAYING SERVICE MESSAGE 643
START UP KOMTRAX SYSTEM 645
STOP USING OF KOMTRAX SYSTEM 651
ADJUST REARVIEW CAMERA ANGLE 653
ADJUST REARVIEW CAMERA ANGLE 653
ADJUST KomVision CAMERA ANGLE 656
Angle adjustment method for KomVision camera 657
ADJUST KomVision RELATED FUNCTION 659
SETTING OF KomVision (MAIN SETTING) 659
SETTING OF KomVision (CAMERA SETTING) 662
SETTING OF KomVision (CAMERA CALIBRATION) 663
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 677
HANDLE BATTERY DISCONNECT SWITCH 678
TEST DIODES 679
METHOD FOR TESTING DIODE USING DIGITAL TESTER 679
METHOD FOR TESTING DIODE USING ANALOG TESTER 679
Pm-CLINIC 680
Pm CLINIC SERVICE 680
Pm CLINIC CHECK SHEET: PC130-11 682
40 TROUBLESHOOTING 691
CONTENTS 692
RELATED INFORMATION ON TROUBLESHOOTING 702
GENERAL TROUBLESHOOTING POINTS 702
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 703
SEQUENCE OF EVENTS IN TROUBLESHOOTING 715
CHECKS BEFORE TROUBLESHOOTING 717
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 719
WALK-AROUND CHECK 719
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 721
CHECK OF FUEL LEVEL AND TYPE 721
CHECK FUEL PREFILTER 722
CHECK WATER SEPARATOR, DRAIN WATER AND SEDIMENT 722
REPLACE FUEL PREFILTER CARTRIDGE 722
CHECK FUEL MAIN FILTER 724
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 725
CHECK OIL LEVEL IN PTO GEAR CASE 726
CHECK COOLANT LEVEL (RESERVOIR TANK) 727
CHECK CLOGGING OF AIR CLEANER 728
CLEAN OUTER ELEMENT 728
REPLACE ELEMENT 731
CHECK HYDRAULIC OIL LEVEL 732
CHECK HYDRAULIC OIL STRAINER 734
CHECK HYDRAULIC OIL FILTER 735
CHECK OF OIL LEVEL IN SWING MACHINERY CASE 736
CHECK OIL LEVEL IN FINAL DRIVE CASE 737
BLEED AIR FROM FUEL SYSTEM 737
BLEED AIR FROM HYDRAULIC SYSTEM 737
CHECK ELECTRIC EQUIPMENT 738
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 743
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 743
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 743
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 744
PREPARATION FOR TROUBLESHOOTING OF GATEWAY FUNCTION CONTROLLER 744
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 744
PROCEDURE FOR TESTING AND TROUBLESHOOTING 749
SYMPTOM AND TROUBLESHOOTING NUMBERS 752
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 756
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 758
CONNECTOR LIST AND LAYOUT 761
CONNECTOR CONTACT IDENTIFICATION 774
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 816
FUSE LOCATION TABLE 822
PRECAUTIONS FOR REPLACING KDOC 825
FAILURE CODE TABLE 826
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 842
FAILURE CODE [879AKA] 842
FAILURE CODE [879AKB] 843
FAILURE CODE [879BKA] 844
FAILURE CODE [879BKB] 846
FAILURE CODE [879CKA] 848
FAILURE CODE [879CKB] 849
FAILURE CODE [879DKZ] 850
FAILURE CODE [879EMC] 852
FAILURE CODE [879FMC] 853
FAILURE CODE [879GKX] 854
FAILURE CODE [989L00] 856
FAILURE CODE [989M00] 857
FAILURE CODE [989N00] 858
FAILURE CODE [A1U0N3] 859
FAILURE CODE [A1U0N4] 861
FAILURE CODE [A900FR] 863
FAILURE CODE [A900N6] 864
FAILURE CODE [A900NY] 865
FAILURE CODE [AA10NX] 866
FAILURE CODE [AB00KE] 868
FAILURE CODE [AQ10MB] 870
FAILURE CODE [AQ10N3] 872
FAILURE CODE [AS00R2] 873
FAILURE CODE [AS00R3] 874
FAILURE CODE [AS00R4] 875
FAILURE CODE [AS00R5] 876
FAILURE CODE [AS00R6] 877
FAILURE CODE [AS00ZK] 878
FAILURE CODE [AS10KM] 879
FAILURE CODE [AS10NR] 880
FAILURE CODE [AS10NT] 881
FAILURE CODE [AU10QA] 882
FAILURE CODE [B@BAZG] 883
FAILURE CODE [B@BAZK] 884
FAILURE CODE [B@BCNS] 886
FAILURE CODE [B@BCZK] 887
FAILURE CODE [B@HANS] 889
FAILURE CODE [CA115] 891
FAILURE CODE [CA122] 892
FAILURE CODE [CA123] 894
FAILURE CODE [CA131] 896
FAILURE CODE [CA132] 898
FAILURE CODE [CA144] 900
FAILURE CODE [CA145] 902
FAILURE CODE [CA153] 904
FAILURE CODE [CA154] 907
FAILURE CODE [CA187] 910
FAILURE CODE [CA221] 912
FAILURE CODE [CA222] 914
FAILURE CODE [CA227] 916
FAILURE CODE [CA234] 917
FAILURE CODE [CA238] 918
FAILURE CODE [CA239] 920
FAILURE CODE [CA249] 922
FAILURE CODE [CA256] 924
FAILURE CODE [CA271] 926
FAILURE CODE [CA272] 928
FAILURE CODE [CA322] 930
FAILURE CODE [CA324] 932
FAILURE CODE [CA331] 934
FAILURE CODE [CA332] 936
FAILURE CODE [CA343] 938
FAILURE CODE [CA351] 939
FAILURE CODE [CA352] 940
FAILURE CODE [CA356] 943
FAILURE CODE [CA357] 945
FAILURE CODE [CA386] 947
FAILURE CODE [CA435] 948
FAILURE CODE [CA441] 950
FAILURE CODE [CA442] 953
FAILURE CODE [CA449] 954
FAILURE CODE [CA451] 955
FAILURE CODE [CA452] 957
FAILURE CODE [CA515] 959
FAILURE CODE [CA516] 961
FAILURE CODE [CA553] 963
FAILURE CODE [CA555] 964
FAILURE CODE [CA556] 965
FAILURE CODE [CA559] 966
FAILURE CODE [CA689] 970
FAILURE CODE [CA691] 973
FAILURE CODE [CA692] 975
FAILURE CODE [CA697] 977
FAILURE CODE [CA698] 978
FAILURE CODE [CA731] 979
FAILURE CODE [CA778] 981
FAILURE CODE [CA1117] 986
FAILURE CODE [CA1664] 987
FAILURE CODE [CA1669] 989
FAILURE CODE [CA1673] 990
FAILURE CODE [CA1677] 991
FAILURE CODE [CA1678] 992
FAILURE CODE [CA1682] 993
FAILURE CODE [CA1683] 998
FAILURE CODE [CA1684] 1000
FAILURE CODE [CA1686] 1002
FAILURE CODE [CA1691] 1003
FAILURE CODE [CA1694] 1005
FAILURE CODE [CA1695] 1007
FAILURE CODE [CA1696] 1008
FAILURE CODE [CA1712] 1010
FAILURE CODE [CA1713] 1013
FAILURE CODE [CA1714] 1016
FAILURE CODE [CA1715] 1017
FAILURE CODE [CA1776] 1018
FAILURE CODE [CA1777] 1021
FAILURE CODE [CA1843] 1024
FAILURE CODE [CA1844] 1026
FAILURE CODE [CA1885] 1029
FAILURE CODE [CA1887] 1031
FAILURE CODE [CA1896] 1033
FAILURE CODE [CA1938] 1037
FAILURE CODE [CA1942] 1039
FAILURE CODE [CA1961] 1040
FAILURE CODE [CA2185] 1041
FAILURE CODE [CA2186] 1043
FAILURE CODE [CA2249] 1045
FAILURE CODE [CA2272] 1046
FAILURE CODE [CA2311] 1049
FAILURE CODE [CA2349] 1050
FAILURE CODE [CA2353] 1052
FAILURE CODE [CA2357] 1054
FAILURE CODE [CA2636] 1055
FAILURE CODE [CA2637] 1058
FAILURE CODE [CA2765] 1060
FAILURE CODE [CA2771] 1061
FAILURE CODE [CA2976] 1067
FAILURE CODE [CA3142] 1069
FAILURE CODE [CA3143] 1070
FAILURE CODE [CA3144] 1071
FAILURE CODE [CA3146] 1073
FAILURE CODE [CA3147] 1074
FAILURE CODE [CA3148] 1075
FAILURE CODE [CA3151] 1077
FAILURE CODE [CA3165] 1083
FAILURE CODE [CA3229] 1085
FAILURE CODE [CA3231] 1087
FAILURE CODE [CA3232] 1089
FAILURE CODE [CA3235] 1093
FAILURE CODE [CA3239] 1095
FAILURE CODE [CA3241] 1098
FAILURE CODE [CA3242] 1101
FAILURE CODE [CA3251] 1104
FAILURE CODE [CA3313] 1106
FAILURE CODE [CA3314] 1107
FAILURE CODE [CA3315] 1108
FAILURE CODE [CA3419] 1110
FAILURE CODE [CA3421] 1112
FAILURE CODE [CA3497] 1114
FAILURE CODE [CA3498] 1115
FAILURE CODE [CA3543] 1116
FAILURE CODE [CA3545] 1122
FAILURE CODE [CA3547] 1124
FAILURE CODE [CA3558] 1125
FAILURE CODE [CA3559] 1127
FAILURE CODE [CA3562] 1129
FAILURE CODE [CA3563] 1131
FAILURE CODE [CA3567] 1134
FAILURE CODE [CA3568] 1138
FAILURE CODE [CA3571] 1144
FAILURE CODE [CA3572] 1146
FAILURE CODE [CA3574] 1148
FAILURE CODE [CA3575] 1151
FAILURE CODE [CA3577] 1153
FAILURE CODE [CA3578] 1155
FAILURE CODE [CA3582] 1157
FAILURE CODE [CA3583] 1165
FAILURE CODE [CA3596] 1167
FAILURE CODE [CA3649] 1171
FAILURE CODE [CA3681] 1173
FAILURE CODE [CA3682] 1178
FAILURE CODE [CA3713] 1183
FAILURE CODE [CA3717] 1186
FAILURE CODE [CA3718] 1187
FAILURE CODE [CA3724] 1188
FAILURE CODE [CA3725] 1189
FAILURE CODE [CA3748] 1192
FAILURE CODE [CA3755] 1195
FAILURE CODE [CA3866] 1198
FAILURE CODE [CA3867] 1202
FAILURE CODE [CA3868] 1205
FAILURE CODE [CA3899] 1209
FAILURE CODE [CA3911] 1211
FAILURE CODE [CA3912] 1215
FAILURE CODE [CA3918] 1217
FAILURE CODE [CA3921] 1219
FAILURE CODE [CA3928] 1220
FAILURE CODE [CA3932] 1221
FAILURE CODE [CA3933] 1223
FAILURE CODE [CA3934] 1225
FAILURE CODE [CA3935] 1228
FAILURE CODE [CA3936] 1230
FAILURE CODE [CA4152] 1232
FAILURE CODE [CA4155] 1236
FAILURE CODE [CA4156] 1239
FAILURE CODE [CA4157] 1242
FAILURE CODE [CA4159] 1244
FAILURE CODE [CA4164] 1245
FAILURE CODE [CA4165] 1247
FAILURE CODE [CA4166] 1249
FAILURE CODE [CA4168] 1251
FAILURE CODE [CA4169] 1254
FAILURE CODE [CA4171] 1256
FAILURE CODE [CA4249] 1259
FAILURE CODE [CA4251] 1261
FAILURE CODE [CA4261] 1263
FAILURE CODE [CA4277] 1266
FAILURE CODE [CA4281] 1270
FAILURE CODE [CA4459] 1274
FAILURE CODE [CA4461] 1277
FAILURE CODE [CA4533] 1280
FAILURE CODE [CA4534] 1281
FAILURE CODE [CA4731] 1282
FAILURE CODE [CA4732] 1283
FAILURE CODE [CA4739] 1284
FAILURE CODE [CA4768] 1285
FAILURE CODE [CA4769] 1287
FAILURE CODE [CA4842] 1290
FAILURE CODE [CA4952] (APPLICABLE MACHINE: 90001 to 92188) 1294
FAILURE CODE [CA4952] (APPLICABLE MACHINE: 92189 and up) 1296
FAILURE CODE [CA5115] 1298
FAILURE CODE [CA5179] 1301
FAILURE CODE [CA5181] 1303
FAILURE CODE [CA5271] 1305
FAILURE CODE [CA5272] 1307
FAILURE CODE [CA5273] 1309
FAILURE CODE [CA5274] 1311
FAILURE CODE [CA5275] 1313
FAILURE CODE [CA5276] 1315
FAILURE CODE [CA5277] 1317
FAILURE CODE [CA5387] 1318
FAILURE CODE [CA5388] 1320
FAILURE CODE [CA5389] 1322
FAILURE CODE [CA5391] 1324
FAILURE CODE [CA5392] 1328
FAILURE CODE [CA5393] 1329
FAILURE CODE [CA5394] 1332
FAILURE CODE [CA5395] 1335
FAILURE CODE [CA5396] 1338
FAILURE CODE [CA5631] 1340
FAILURE CODE [CA5938] 1342
FAILURE CODE [D110KB] 1344
FAILURE CODE [D19JKZ] 1346
FAILURE CODE [D811MC] 1348
FAILURE CODE [D862KA] 1349
FAILURE CODE [D8ALKA] (APPLICABLE MACHINE: 90001 to 92188) 1350
FAILURE CODE [D8ALKA] (APPLICABLE MACHINE: 92189 and up) 1352
FAILURE CODE [D8ALKB] (APPLICABLE MACHINE: 90001 to 92188) 1354
FAILURE CODE [D8ALKB] (APPLICABLE MACHINE: 92189 and up) 1356
FAILURE CODE [D8AQKR] 1358
FAILURE CODE [D8G1KT] 1362
FAILURE CODE [D8G6KT] 1363
FAILURE CODE [DA20MC] 1364
FAILURE CODE [DA22KK] 1365
FAILURE CODE [DA25KP] 1368
FAILURE CODE [DA26KP] 1372
FAILURE CODE [DA29KQ] 1374
FAILURE CODE [DA2LKA] (APPLICABLE MACHINE: 90001 to 92188) 1376
FAILURE CODE [DA2LKA] (APPLICABLE MACHINE: 92189 and up) 1378
FAILURE CODE [DA2LKB] (APPLICABLE MACHINE: 90001 to 92188) 1380
FAILURE CODE [DA2LKB] (APPLICABLE MACHINE: 92189 and up) 1382
FAILURE CODE [DA2QKR] 1384
FAILURE CODE [DA2RKR] 1389
FAILURE CODE [DAF0KM] 1394
FAILURE CODE [DAF0MB] 1395
FAILURE CODE [DAF0MC] 1396
FAILURE CODE [DAF8KB] 1397
FAILURE CODE [DAF9KQ] 1401
FAILURE CODE [DAFGMC] 1402
FAILURE CODE [DAFLKA] (APPLICABLE MACHINE: 90001 to 92188) 1403
FAILURE CODE [DAFLKA] (APPLICABLE MACHINE: 92189 and up) 1405
FAILURE CODE [DAFLKB] (APPLICABLE MACHINE: 90001 to 92188) 1407
FAILURE CODE [DAFLKB] (APPLICABLE MACHINE: 92189 and up) 1409
FAILURE CODE [DAFQKR] 1411
FAILURE CODE [DAZ9KQ] 1415
FAILURE CODE [DAZQKR] 1416
FAILURE CODE [DB2QKR] 1420
FAILURE CODE [DB2RKR] 1426
FAILURE CODE [DBP0KM] 1432
FAILURE CODE [DBP0KT] 1433
FAILURE CODE [DBP5KB] 1434
FAILURE CODE [DBP5KY] 1437
FAILURE CODE [DBPQKR] 1439
FAILURE CODE [DDNRKA] 1444
FAILURE CODE [DDNRKY] 1447
FAILURE CODE [DDNS00] 1449
FAILURE CODE [DFB1KZ] 1451
FAILURE CODE [DFB2KZ] 1453
FAILURE CODE [DFB3L8] 1455
FAILURE CODE [DFB4L8] 1457
FAILURE CODE [DFB5KZ] 1459
FAILURE CODE [DFB6KZ] 1461
FAILURE CODE [DGH2KA] 1463
FAILURE CODE [DGH2KB] 1465
FAILURE CODE [DHA4KA] 1467
FAILURE CODE [DHPAMA] 1469
FAILURE CODE [DHS3MA] 1471
FAILURE CODE [DHS4MA] 1473
FAILURE CODE [DHS8MA] 1475
FAILURE CODE [DHS9MA] 1477
FAILURE CODE [DHSAMA] 1479
FAILURE CODE [DHSBMA] 1481
FAILURE CODE [DHSCMA] 1483
FAILURE CODE [DHSDMA] 1485
FAILURE CODE [DHSFMA] 1487
FAILURE CODE [DHSGMA] 1489
FAILURE CODE [DHSHMA] 1491
FAILURE CODE [DHSJMA] 1493
FAILURE CODE [DKULKA] 1495
FAILURE CODE [DKULKB] 1497
FAILURE CODE [DKULKY] 1499
FAILURE CODE [DLM5KA] 1501
FAILURE CODE [DLM5MB] 1503
FAILURE CODE [DR10KA] 1504
FAILURE CODE [DR12KA] 1507
FAILURE CODE [DR20KA] 1509
FAILURE CODE [DR21KX] 1511
FAILURE CODE [DR31KX] 1513
FAILURE CODE [DR40KA] 1515
FAILURE CODE [DUMBKA] (APPLICABLE MACHINE: 90001 to 92188) 1517
FAILURE CODE [DUMBKA] (APPLICABLE MACHINE: 92189 and up) 1519
FAILURE CODE [DUMBKB] (APPLICABLE MACHINE: 90001 to 92188) 1521
FAILURE CODE [DUMBKB] (APPLICABLE MACHINE: 92189 and up) 1523
FAILURE CODE [DV20KB] 1525
FAILURE CODE [DW43KA] 1527
FAILURE CODE [DW43KB] 1529
FAILURE CODE [DW43KY] 1531
FAILURE CODE [DW45KA] 1532
FAILURE CODE [DW45KB] 1535
FAILURE CODE [DW45KY] 1538
FAILURE CODE [DW4CKY] 1540
FAILURE CODE [DW4WKA] 1542
FAILURE CODE [DW4WKB] 1544
FAILURE CODE [DW4WKY] 1546
FAILURE CODE [DW91KA] 1547
FAILURE CODE [DW91KB] 1549
FAILURE CODE [DW91KY] 1551
FAILURE CODE [DWA2KA] 1553
FAILURE CODE [DWA2KB] 1555
FAILURE CODE [DWA2KY] 1557
FAILURE CODE [DWJ0KA] 1559
FAILURE CODE [DWJ0KB] 1561
FAILURE CODE [DWJ0KY] 1563
FAILURE CODE [DWK0KA] 1565
FAILURE CODE [DWK0KB] 1567
FAILURE CODE [DWK0KY] 1569
FAILURE CODE [DWK2KA] 1571
FAILURE CODE [DWK2KB] 1573
FAILURE CODE [DWK2KY] 1575
FAILURE CODE [DWN5KA] 1577
FAILURE CODE [DWN5KB] 1579
FAILURE CODE [DWN5KY] 1581
FAILURE CODE [DWNSKA] 1583
FAILURE CODE [DWNSKB] 1585
FAILURE CODE [DWNSKY] 1587
FAILURE CODE [DXA8KA] 1588
FAILURE CODE [DXA8KB] 1590
FAILURE CODE [DXE4KA] 1592
FAILURE CODE [DXE4KB] 1594
FAILURE CODE [DXE4KY] 1596
FAILURE CODE [DXEKKA] 1598
FAILURE CODE [DXEKKB] 1600
FAILURE CODE [DXEKKY] 1602
FAILURE CODE [DY20KA] 1604
FAILURE CODE [DY20MA] 1606
FAILURE CODE [DY2CKB] 1608
FAILURE CODE [DY2DKB] 1610
FAILURE CODE [DY2EKB] 1612
FAILURE CODE [F313KA] 1614
FAILURE CODE [F313KB] 1616
FAILURE CODE [F318KB] 1617
FAILURE CODE [F318KY] 1619
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1620
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1620
MANUAL PREHEATING SYSTEM DOES NOT WORK 1626
WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP 1629
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR SHOWS NOTHING 1631
WHILE ENGINE IS IN OPERATION, ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE 1634
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS IN OPERATION 1635
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS IN OPERATION 1636
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1637
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1638
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1639
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1640
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1641
FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1642
FUEL GAUGE DOES NOT SHOW CORRECT FUEL LEVEL 1644
COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1645
COOLANT TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE 1646
AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 1647
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1650
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE 1652
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT SHOWN 1653
FUNCTION SWITCH DOES NOT OPERATE 1654
AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER) 1655
AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED 1656
AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION 1657
WORK MODE SELECTOR SCREEN IS NOT SHOWN WHILE WORK MODE SWITCH IS OPERATED 1658
ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED 1659
TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED 1660
TRAVEL SPEED DOES NOT CHANGE EVEN WHEN YOU OPERATE THE OPERATION TO CHANGE TRAVEL SPEED 1661
ALARM BUZZER CANNOT BE STOPPED 1662
SERVICE METER IS NOT SHOWN WHILE STARTING SWITCH IS IN OFF POSITION 1663
MACHINE DOES NOT CHANGE TO SERVICE MODE 1664
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE 1665
ALL WORK EQUIPMENT, SWING OR TRAVEL CANNOT BE LOCKED 1668
MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED 1670
WHILE SWING PARKING BRAKE RELEASE SWITCH IS TURNED ON, SWING BRAKE IS NOT OPERATED 1672
WHEN LOCK LEVER AUTOMATIC CANCEL SWITCH IS OPERATED, WORK EQUIPMENT CANNOT BE OPERATED 1674
TRAVEL ALARM DOES NOT OPERATE DURING TRAVEL 1676
TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS 1678
HORN DOES NOT MAKE SOUND 1679
HORN DOES NOT STOP 1681
WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED 1682
WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED 1683
WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED 1685
“BOOM RAISE” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1686
“BOOM LOWER” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1687
“ARM DUMP” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1688
“ARM IN” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1689
“BUCKET DUMP” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1690
“BUCKET CURL” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1691
“SWING” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1692
“TRAVEL” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1693
SERVICE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1694
KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY 1696
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1697
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1697
FAILURE MODE AND CAUSE TABLE 1698
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1707
All WORK EQUIPMENT, SWING, AND TRAVEL SPEED IS LOW OR POWER IS LOW 1708
FINE CONTROL PERFORMANCE OR RESPONSE IS UNSATISFACTORY 1710
THERE IS UNUSUAL NOISE FROM AROUND HYDRAULIC PUMP 1711
ENGINE SPEED FALLS LARGELY OR ENGINE STOPS 1712
BOOM SPEED OR POWER IS LOW 1714
ARM SPEED IS LOW OR POWER IS LOW 1717
BUCKET SPEED OR POWER IS LOW 1720
WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1723
HYDRAULIC DRIFT OF BOOM IS LARGE 1724
HYDRAULIC DRIFT OF ARM IS LARGE 1725
HYDRAULIC DRIFT OF BUCKET IS LARGE 1726
WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 1727
TIME LAG OF WORK EQUIPMENT IS LARGE 1728
ATTACHMENT CIRCUIT CANNOT BE CHANGED 1729
OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 1730
IN COMBINED OPERATION OF WORK EQUIPMENT, WORK EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER 1731
IN COMBINATION OPERATION OF SWING AND TRAVEL, TRAVEL SPEED FALLS LARGELY 1732
IN COMBINATION OPERATION OF SWING AND BOOM RAISE, BOOM RAISE SPEED IS LOW 1733
MACHINE DOES NOT TRAVEL STRAIGHT 1734
MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 1737
TRAVEL SPEED IS SLOW 1740
ONE OF TRACKS DOES NOT RUN 1742
TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1744
MACHINE DOES NOT SWING TO RIGHT OR LEFT 1745
SWINGS ONLY IN ONE DIRECTION 1746
SWING ACCELERATION OR SWING SPEED IS LOW IN TWO DIRECTIONS OF RIGHT AND LEFT 1747
SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION 1748
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (RIGHT AND LEFT) 1749
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (ONLY ONE DIRECTION) 1750
SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWING OPERATION 1751
THERE IS A LARGE UNUSUAL NOISE WHEN UPPER STRUCTURE STOPS SWING OPERATION 1752
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 1753
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1754
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT ROTATE) 1755
THERE IS UNUSUAL NOISE FROM AROUND FAN 1756
TROUBLESHOOTING OF ENGINE (S-MODE) 1757
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1757
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1758
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT 1759
FUEL IS INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1760
ENGINE STARTABILITY IS UNSATISFACTORY 1761
ENGINE DOES NOT PICK UP SMOOTHLY 1763
ENGINE STOPS DURING OPERATION 1765
ENGINE RUNS ROUGH OR IS NOT STABLE 1767
ENGINE LACKS POWER 1768
EXHAUST IS BLACK 1770
ENGINE OIL CONSUMPTION IS EXCESSIVE 1772
OIL BECOMES CONTAMINATED QUICKLY 1773
FUEL CONSUMPTION IS EXCESSIVE 1774
OIL MIXES INTO COOLANT (OR COOLANT SPURTS BACK AND COOLANT LEVEL DOES DOWN) 1775
ENGINE OIL PRESSURE FALLS 1776
FUEL MIXES INTO ENGINE OIL 1777
WATER MIXES INTO ENGINE OIL (MILKY) 1778
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEAT) 1779
THERE IS AN UNUSUAL NOISE 1780
VIBRATION IS EXCESSIVE 1782
AIR CANNOT BE BLED FROM FUEL CIRCUIT 1783
ACTIVE REGENERATION IS DONE FREQUENTLY 1784
ACTIVE REGENERATION TAKES LONG 1785
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1786
AdBlue/DEF CONSUMPTION IS EXCESSIVE 1787
THERE IS AN UNUSUAL SMELL (IRRITATING ODOR) 1789
FOREIGN MATERIAL MIXES INTO ADBLUE/DEF (ADBLUE/DEF LEVEL INCREASES) 1790
50 DISASSEMBLY AND ASSEMBLY 1791
CONTENTS 1792
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1797
HOW TO READ THIS MANUAL 1797
COATING MATERIALS LIST 1799
SPECIAL TOOLS LIST 1803
SKETCHES OF SPECIAL TOOLS 1822
ENGINE AND COOLING SYSTEM 1825
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1825
REMOVE SUPPLY PUMP ASSEMBLY 1825
INSTALL SUPPLY PUMP ASSEMBLY 1829
REMOVE AND INSTALL INJECTOR ASSEMBLY 1836
REMOVE INJECTOR ASSEMBLY 1836
INSTALL INJECTOR ASSEMBLY 1845
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 1858
REMOVE CYLINDER HEAD ASSEMBLY 1858
INSTALL CYLINDER HEAD ASSEMBLY 1876
REMOVE AND INSTALL EGR VALVE ASSEMBLY 1899
REMOVE EGR VALVE ASSEMBLY 1899
INSTALL EGR VALVE ASSEMBLY 1900
REMOVE AND INSTALL EGR COOLER ASSEMBLY 1902
REMOVE EGR COOLER ASSEMBLY 1902
INSTALL EGR COOLER ASSEMBLY 1906
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 1911
REMOVE STARTING MOTOR ASSEMBLY 1911
INSTALL STARTING MOTOR ASSEMBLY 1914
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT 1917
REMOVE AIR CONDITIONER COMPRESSOR BELT 1917
INSTALL AIR CONDITIONER COMPRESSOR BELT 1918
REMOVE AND INSTALL ALTERNATOR BELT 1919
REMOVE ALTERNATOR BELT 1919
INSTALL ALTERNATOR BELT 1922
REMOVE AND INSTALL AUTOMATIC TENSIONER 1924
METHOD FOR REMOVING AUTOMATIC TENSIONER 1924
METHOD FOR INSTALLING AUTOMATIC TENSIONER 1924
REMOVE AND INSTALL RADIATOR ASSEMBLY 1925
REMOVE RADIATOR ASSEMBLY 1925
INSTALL RADIATOR ASSEMBLY 1928
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1933
REMOVE HYDRAULIC OIL COOLER ASSEMBLY 1933
INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1938
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 1943
REMOVE AFTERCOOLER ASSEMBLY 1943
INSTALL AFTERCOOLER ASSEMBLY 1945
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 1950
REMOVE FAN CLUTCH ASSEMBLY 1950
INSTALL FAN CLUTCH ASSEMBLY 1954
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 1959
REMOVE ENGINE AND MAIN PUMP ASSEMBLY 1960
INSTALL ENGINE AND MAIN PUMP ASSEMBLY 1972
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 1985
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 1985
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 1986
REMOVE AND INSTALL ENGINE REAR OIL SEAL 1988
METHOD FOR REMOVING ENGINE REAR OIL SEAL 1988
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 1989
REMOVE AND INSTALL FUEL COOLER ASSEMBLY 1993
REMOVE FUEL COOLER ASSEMBLY 1993
INSTALL FUEL COOLER ASSEMBLY 1994
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 1995
REMOVE ENGINE HOOD ASSEMBLY 1995
INSTALL ENGINE HOOD ASSEMBLY 1997
REMOVE AND INSTALL KDOC ASSEMBLY 2001
REMOVE KDOC ASSEMBLY 2002
INSTALL KDOC ASSEMBLY 2009
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY 2021
REMOVE KDOC AND SCR ASSEMBLY 2022
INSTALL KDOC AND SCR ASSEMBLY 2028
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2037
REMOVE FUEL TANK ASSEMBLY 2037
INSTALL FUEL TANK ASSEMBLY 2047
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2057
REMOVE AdBlue/DEF TANK ASSEMBLY 2058
INSTALL AdBlue/DEF TANK ASSEMBLY 2070
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2081
REMOVE AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2081
INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2091
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2100
REMOVE AdBlue/DEF TANK SENSOR 2100
INSTALL AdBlue/DEF TANK SENSOR 2101
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2108
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2108
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2108
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2109
REMOVE AdBlue/DEF TANK FILLER PORT FILTER 2109
INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2111
REMOVE AND INSTALL SCR ASSEMBLY 2114
REMOVE SCR ASSEMBLY 2114
INSTALL SCR ASSEMBLY 2123
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY BRACKET 2136
REMOVE KDOC AND SCR ASSEMBLY BRACKET 2137
INSTALL KDOC AND SCR ASSEMBLY BRACKET 2150
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 2165
REMOVE BELLOWS PIPE ASSEMBLY 2165
INSTALL BELLOWS PIPE ASSEMBLY 2168
REMOVE AND INSTALL KCCV ASSEMBLY 2171
REMOVE KCCV ASSEMBLY 2171
INSTALL KCCV ASSEMBLY 2172
REMOVE AND INSTALL EXHAUST THROTTLE VALVE 2174
REMOVE EXHAUST THROTTLE VALVE 2174
INSTALL EXHAUST THROTTLE VALVE 2181
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2189
REMOVE AdBlue/DEF MIXING TUBE 2189
INSTALL AdBlue/DEF MIXING TUBE 2193
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2198
REMOVE AdBlue/DEF INJECTOR 2198
INSTALL AdBlue/DEF INJECTOR 2201
REMOVE AND INSTALL AdBlue/DEF PUMP 2205
REMOVE AdBlue/DEF PUMP 2205
INSTALL AdBlue/DEF PUMP 2212
REMOVE AND INSTALL AdBlue/DEF HOSE 2218
REMOVE AdBlue/DEF HOSE 2218
INSTALL AdBlue/DEF HOSE 2227
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2236
REMOVE AIR CLEANER ASSEMBLY 2236
INSTALL AIR CLEANER ASSEMBLY 2240
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2247
REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY 2247
INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2249
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2252
REMOVE AIR CONDITIONER CONDENSER ASSEMBLY 2252
INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2253
POWER TRAIN 2256
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2256
REMOVE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2256
INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2258
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2260
DISASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2272
ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2290
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2311
REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY 2311
INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2313
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2316
DISASSEMBLE SWING MACHINERY ASSEMBLY 2317
ASSEMBLE SWING MACHINERY ASSEMBLY 2320
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2326
REMOVE SWING CIRCLE ASSEMBLY 2326
INSTALL SWING CIRCLE ASSEMBLY 2327
UNDERCARRIAGE AND FRAME 2328
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2328
METHOD FOR SEPARATING TRACK ASSEMBLY 2328
METHOD FOR INSTALLING TRACK ASSEMBLY 2330
REMOVE AND INSTALL SPROCKET 2333
REMOVE SPROCKET 2333
INSTALL SPROCKET 2334
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2335
REMOVE IDLER AND IDLER CUSHION ASSEMBLY 2335
INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2335
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2337
DISASSEMBLE IDLER CUSHION ASSEMBLY 2337
ASSEMBLE IDLER ASSEMBLY 2338
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2341
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 2341
ASSEMBLE IDLER CUSHION ASSEMBLY 2343
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2345
DISASSEMBLE TRACK ROLLER ASSEMBLY 2345
ASSEMBLE TRACK ROLLER ASSEMBLY 2347
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2349
REMOVE REVOLVING FRAME ASSEMBLY 2349
INSTALL REVOLVING FRAME ASSEMBLY 2352
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2354
REMOVE COUNTERWEIGHT ASSEMBLY 2354
INSTALL COUNTERWEIGHT ASSEMBLY 2356
HYDRAULIC SYSTEM 2359
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2359
REMOVE CENTER SWIVEL JOINT ASSEMBLY 2359
INSTALL CENTER SWIVEL JOINT ASSEMBLY 2363
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2366
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2366
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2367
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2368
REMOVE HYDRAULIC TANK ASSEMBLY 2368
INSTALL HYDRAULIC TANK ASSEMBLY 2382
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 2394
REMOVE MAIN PUMP ASSEMBLY 2394
INSTALL MAIN PUMP ASSEMBLY 2397
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2401
REMOVE CONTROL VALVE ASSEMBLY 2401
INSTALL CONTROL VALVE ASSEMBLY 2409
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 2418
ASSEMBLE CONTROL VALVE ASSEMBLY 2418
REPLACE PRESSURE REDUCING VALVE CARTRIDGE ASSEMBLY 2420
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2423
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2423
ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2423
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2425
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2425
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2426
WORK EQUIPMENT 2428
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2428
REMOVE WORK EQUIPMENT ASSEMBLY 2429
INSTALL WORK EQUIPMENT ASSEMBLY 2434
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2440
DISASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2441
ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2443
CAB AND ITS ATTACHMENTS 2450
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY 2450
REMOVE OPERATOR CAB ASSEMBLY 2450
INSTALL OPERATOR CAB ASSEMBLY 2458
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 2465
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2467
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2467
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2477
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 2477
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 2480
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 2486
REMOVE FLOOR FRAME ASSEMBLY 2486
INSTALL FLOOR FRAME ASSEMBLY 2492
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2499
REMOVE AIR CONDITIONER UNIT ASSEMBLY 2499
INSTALL AIR CONDITIONER UNIT ASSEMBLY 2505
REMOVE AND INSTALL OPERATOR’S SEAT 2512
REMOVE OPERATOR’S SEAT 2512
METHOD FOR INSTALLING OPERATOR’S SEAT 2513
REMOVE AND INSTALL SEAT BELT 2516
METHOD FOR REMOVING SEAT BELT 2516
METHOD FOR INSTALLING SEAT BELT 2516
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 2518
REMOVE FRONT WIPER ASSEMBLY 2518
INSTALL FRONT WIPER ASSEMBLY 2523
ELECTRICAL SYSTEM 2532
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2532
REMOVE ENGINE CONTROLLER ASSEMBLY 2532
INSTALL ENGINE CONTROLLER ASSEMBLY 2534
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 2535
REMOVE PUMP CONTROLLER ASSEMBLY 2535
INSTALL PUMP CONTROLLER ASSEMBLY 2538
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2540
REMOVE KomVision CONTROLLER ASSEMBLY 2540
INSTALL KomVision CONTROLLER ASSEMBLY 2541
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2543
REMOVE MACHINE MONITOR ASSEMBLY 2543
INSTALL MACHINE MONITOR ASSEMBLY 2545
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2549
REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR 2549
INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2551
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2553
REMOVE KCCV CRANKCASE PRESSURE SENSOR 2553
INSTALL KCCV CRANKCASE PRESSURE SENSOR 2555
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2557
REMOVE SCR TEMPERATURE SENSOR 2557
INSTALL SCR TEMPERATURE SENSOR 2558
REMOVE AND INSTALL REARVIEW CAMERA 2560
REMOVE REARVIEW CAMERA 2560
INSTALL REARVIEW CAMERA 2562
REMOVE AND INSTALL KomVision CAMERA 2564
REMOVE KomVision CAMERA 2564
INSTALL KomVision CAMERA 2568
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2572
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 2572
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2576
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2582
REMOVE COMMUNICATION TERMINAL WIRING HARNESS 2582
INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2589
REMOVE AND INSTALL COMMUNICATION TERMINAL 2598
REMOVE COMMUNICATION TERMINAL 2598
INSTALL COMMUNICATION TERMINAL 2599
60 MAINTENANCE STANDARD 2603
CONTENTS 2604
ENGINE AND COOLING SYSTEM 2605
MAINTENANCE STANDARD OF ENGINE MOUNT 2605
MAINTENANCE STANDARD OF PTO 2606
MAINTENANCE STANDARD OF COOLING SYSTEM 2607
POWER TRAIN 2608
MAINTENANCE STANDARD OF SWING CIRCLE 2608
MAINTENANCE STANDARD OF SWING MACHINERY 2609
MAINTENANCE STANDARD OF SPROCKET 2611
UNDERCARRIAGE AND FRAME 2612
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2612
MAINTENANCE STANDARD OF IDLER 2614
MAINTENANCE STANDARD OF TRACK ROLLER 2615
MAINTENANCE STANDARD OF CARRIER ROLLER 2616
MAINTENANCE STANDARD OF TRACK SHOE 2617
MAINTENANCE STANDARD OF TRIPLE SHOE 2620
MAINTENANCE STANDARD OF ROAD LINER 2621
HYDRAULIC SYSTEM 2622
MAINTENANCE STANDARD OF HYDRAULIC TANK 2622
MAINTENANCE STANDARD OF MAIN PUMP 2623
MAINTENANCE STANDARD OF PC-EPC VALVE 2627
MAINTENANCE STANDARD OF SWING MOTOR 2628
MAINTENANCE STANDARD OF TRAVEL MOTOR 2631
MAINTENANCE STANDARD OF CONTROL VALVE 2632
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2644
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2647
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2650
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2652
MAINTENANCE STANDARD OF SOLENOID VALVE 2653
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE SOLENOID VALVE 2657
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2658
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) 2659
MAINTENANCE STANDARD OF ARM OUT QUICK RETURN VALVE 2660
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 2661
WORK EQUIPMENT 2663
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2663
DIMENSIONS OF ARM 2668
DIMENSIONS OF BUCKET 2670
MAINTENANCE STANDARD OF BOOM CYLINDER 2672
MAINTENANCE STANDARD OF ARM CYLINDER 2673
MAINTENANCE STANDARD OF BUCKET CYLINDER 2674
CAB AND ITS ATTACHMENTS 2675
MAINTENANCE STANDARD OF CAB MOUNT 2675
80 APPENDIX 2677
CONTENTS 2678
AIR CONDITIONER SYSTEM 2680
PRECAUTIONS FOR REFRIGERANT 2680
AIR CONDITIONER 2681
SPECIFICATIONS OF AIR CONDITIONER 2683
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2684
OUTLINE OF REFRIGERATION CYCLE 2685
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2687
AIR CONDITIONER UNIT 2687
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2687
FUNCTION OF AIR CONDITIONER UNIT 2689
COMPONENT PARTS OF AIR CONDITIONER UNIT 2691
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2692
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2692
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2692
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 2692
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2693
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2693
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2693
FUNCTION OF DUAL PRESSURE SWITCH 2694
AIR CONDITIONER CONTROLLER 2695
STRUCTURE OF AIR CONDITIONER CONTROLLER 2695
COMPRESSOR 2696
STRUCTURE OF COMPRESSOR 2696
SPECIFICATIONS OF COMPRESSOR 2696
FUNCTION OF COMPRESSOR 2696
CONDENSER 2697
STRUCTURE OF CONDENSER 2697
SPECIFICATIONS OF CONDENSER 2697
FUNCTION OF CONDENSER 2697
SENSORS FOR AIR CONDITIONER SYSTEM 2699
STRUCTURE OF SUNLIGHT SENSOR 2699
FUNCTION OF SUNLIGHT SENSOR 2699
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 2699
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2699
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2701
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2703
AIR CONDITIONER SYSTEM DIAGRAM 2705
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2706
FUNCTION OF AIR CONDITIONER CONTROLLER 2707
LOCATIONS OF AIR CONDITIONER PARTS AND LAYOUT OF CONNECTORS 2708
TESTING AIR LEAKAGE (DUCT) 2712
METHOD FOR TESTING AIR LEAKAGE (DUCT) 2712
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2714
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2715
TEST VENT (MODE) CHANGEOVER 2716
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2716
TESTING FRESH/RECIRC AIR CHANGEOVER 2718
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2718
TEST SUNLIGHT SENSOR 2719
METHOD FOR TESTING SUNLIGHT SENSOR 2719
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2720
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2720
TEST RELAYS 2721
METHOD FOR TESTING RELAYS 2721
AIR CONDITIONER TROUBLESHOOTING CHART 1 2722
AIR CONDITIONER TROUBLESHOOTING CHART 2 2723
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2726
FAILURE CODE [879AKA] 2728
FAILURE CODE [879AKB] 2729
FAILURE CODE [879BKA] 2730
FAILURE CODE [879BKB] 2732
FAILURE CODE [879CKA] 2734
FAILURE CODE [879CKB] 2735
FAILURE CODE [879DKZ] 2736
FAILURE CODE [879EMC] 2738
FAILURE CODE [879FMC] 2739
FAILURE CODE [879GKX] 2740
TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2742
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2744
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2747
TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 2749
TROUBLESHOOTING USING GAUGE PRESSURE 2751
CONNECTION OF SERVICE TOOL 2754
METHOD FOR CONNECTING SERVICE TOOL 2754
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2756
COMPRESSOR OIL 2758
METHOD FOR REPLACING DESICCANT 2760
90 CIRCUIT DIAGRAMS 2763
CONTENTS 2764
HOW TO READ THE CODES FOR ELECTRIC CABLE 2766
HYDRAULIC CIRCUIT DIAGRAM 2770
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2770
HYDRAULIC CIRCUIT DIAGRAM (1/3) 2775
HYDRAULIC CIRCUIT DIAGRAM (2/3) 2777
HYDRAULIC CIRCUIT DIAGRAM (3/3) 2779
ELECTRICAL CIRCUIT DIAGRAM 2781
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2781
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 90001 TO 92188) (1/10) 2785
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 90001 TO 92188) (2/10) 2787
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 90001 TO 92188) (3/10) 2789
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 90001 TO 92188) (4/10) 2791
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 90001 TO 92188) (5/10) 2793
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 90001 TO 92188) (1/10) 2795
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 90001 TO 92188) (7/10) 2797
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 90001 TO 92188) (8/10) 2799
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 90001 TO 92188) (9/10) 2801
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 90001 TO 92188) (10/10) 2803
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 92189 AND UP) (1/10) 2805
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 92189 AND UP) (2/10) 2807
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 92189 AND UP) (3/10) 2809
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 92189 AND UP) (4/10) 2811
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 92189 AND UP) (5/10) 2813
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 92189 AND UP) (6/10) 2815
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 92189 AND UP) (7/10) 2817
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 92189 AND UP) (8/10) 2819
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 92189 AND UP) (9/10) 2821
ELECTRICAL CIRCUIT DIAGRAM (SERIAL NO : 92189 AND UP) (10/10) 2823
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 90001 TO 92188) (1/10) 2825
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 90001 TO 92188) (2/10) 2827
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 90001 TO 92188) (3/10) 2829
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 90001 TO 92188) (4/10) 2831
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 90001 TO 92188) (5/10) 2833
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 90001 TO 92188) (6/10) 2835
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 90001 TO 92188) (7/10) 2837
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 90001 TO 92188) (8/10) 2839
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 90001 TO 92188) (9/10) 2841
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 90001 TO 92188) (10/10) 2843
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 92189 AND UP) (1/10) 2845
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 92189 AND UP) (2/10) 2847
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 92189 AND UP) (3/10) 2849
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 92189 AND UP) (4/10) 2851
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 92189 AND UP) (5/10) 2853
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 92189 AND UP) (6/10) 2855
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 92189 AND UP) (7/10) 2857
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 92189 AND UP) (8/10) 2859
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 92189 AND UP) (9/10) 2861
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH PROPORTIONAL CONTROL LEVER) (SERIAL NO : 92189 AND UP) (10/10) 2863
INDEX 2865
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