Komatsu PC135F-10M0 Hydraulic Excavator Shop Manual LEBMP13X00 – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC135F-10M0 Hydraulic Excavator Shop Manual LEBMP13X00 – PDF DOWNLOAD
SERIAL NUMBERS J10001 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.
VIDEO PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu PC135F-10M0 Hydraulic Excavator Shop Manual LEBMP13X00 – PDF DOWNLOAD
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 144
CAN TERMINATING RESISTOR 144
ENGINE CONTROLLER 145
FUEL CONTROL DIAL 149
HYDRAULIC SYSTEM 152
LAYOUT DRAWING OF HYDRAULIC SYSTEM 152
CLSS 154
STRUCTURE OF CLSS 154
FUNCTION OF CLSS 155
ENGINE AND PUMP COMBINED CONTROL SYSTEM 157
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 157
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 158
COMPONENT PARTS OF HYDRAULIC SYSTEM 163
HYDRAULIC TANK 163
MAIN PUMP 165
CONTROL VALVE 190
WORK EQUIPMENT SYSTEM 250
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 250
STRUCTURE OF VALVE CONTROL 253
PPC LOCK SYSTEM 254
SYSTEM DIAGRAM OF PPC LOCK SYSTEM 254
FUNCTION OF PPC LOCK SYSTEM 254
ONE-TOUCH POWER MAXIMIZING SYSTEM 255
SYSTEM DIAGRAM OF ONE-TOUCH POWER MAXIMIZING SYSTEM 255
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 255
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 256
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 256
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 257
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 258
WORK EQUIPMENT AND SWING PPC VALVE 258
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 262
SOLENOID VALVE 269
VARIABLE BACK PRESSURE SOLENOID VALVE 273
PILOT CIRCUIT ACCUMULATOR 274
ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) 275
SWING SYSTEM 276
LAYOUT DRAWING OF SWING SYSTEM 276
SWING CONTROL SYSTEM DIAGRAM 278
FUNCTION OF SWING CONTROL SYSTEM 278
COMPONENT PARTS OF SWING SYSTEM 281
SWING MOTOR 281
SWING MACHINERY 289
SWING CIRCLE 290
TRAVEL SYSTEM 292
LAYOUT DRAWING OF TRAVEL SYSTEM 292
SYSTEM DIAGRAM OF TRAVEL CONTROL SYSTEM 294
FUNCTION OF TRAVEL CONTROL SYSTEM 294
COMPONENT PARTS OF TRAVEL SYSTEM 298
TRAVEL MOTOR 298
TRAVEL PPC VALVE 308
CENTER SWIVEL JOINT 312
UNDERCARRIAGE AND FRAME 314
LAYOUT DRAWING OF UNDERCARRIAGE 314
SPECIFICATIONS OF UNDERCARRIAGE 314
IDLER CUSHION 315
STRUCTURE OF IDLER CUSHION 315
SPECIFICATIONS OF IDLER CUSHION 315
WORK EQUIPMENT 316
STRUCTURE OF WORK EQUIPMENT 316
FUNCTION OF WORK EQUIPMENT 317
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 318
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 318
BUCKET CLEARANCE ADJUSTMENT SHIM 319
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 319
CAB AND ITS ATTACHMENTS 320
ROPS CAB 320
STRUCTURE OF ROPS CAB 320
FUNCTION OF ROPS CAB 320
CAB MOUNT 321
STRUCTURE OF CAB MOUNT 321
FUNCTION OF CAB MOUNT 322
CAB TIPPING STOPPER 323
STRUCTURE OF CAB TIPPING STOPPER 323
FUNCTION OF CAB TIPPING STOPPER 323
20 STANDARD VALUE TABLE 324
CONTENTS 325
STANDARD VALUE TABLE FOR ENGINE 326
STANDARD VALUE TABLE FOR ENGINE: PC130-10M0 326
STANDARD VALUE TABLE FOR MACHINE 329
STANDARD VALUE TABLE FOR MACHINE: PC130-10M0 329
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE 343
30 TESTING AND ADJUSTING 348
CONTENTS 349
RELATED INFORMATION ON TESTING AND ADJUSTING 352
TOOLS FOR TESTING AND ADJUSTING 352
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 356
ENGINE AND COOLING SYSTEM 358
TEST ENGINE SPEED 358
TEST ENGINE SPEED 358
TEST EXHAUST GAS COLOR 360
TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 360
TEST EXHAUST GAS COLOR BY SMOKE METER 361
TEST AND ADJUST VALVE CLEARANCE 362
TEST VALVE CLEARANCE 362
ADJUST VALVE CLEARANCE 363
TEST COMPRESSION PRESSURE 365
TEST COMPRESSION PRESSURE 365
TEST BLOWBY PRESSURE 367
TEST BLOWBY PRESSURE ON MACHINE MONITOR 367
TEST ENGINE OIL PRESSURE 369
TEST ENGINE OIL PRESSURE 369
TEST FUEL PRESSURE 371
TEST FUEL PRESSURE 371
TEST FUEL RETURN RATE AND LEAKAGE 372
TEST FUEL RETURN RATE AND LEAKAGE 374
BLEED AIR FROM FUEL SYSTEM 377
BLEED AIR FROM FUEL SYSTEM 377
TEST FUEL CIRCUIT FOR LEAKAGE 379
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 379
HANDLE CYLINDER CUT-OUT MODE OPERATION 381
HANDLE NO-INJECTION CRANKING OPERATION 382
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 383
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 383
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 383
TEST AND ADJUST FAN BELT TENSION 385
METHOD FOR CHECKING FAN BELT TENSION 385
METHOD FOR ADJUSTING FAN BELT TENSION 385
POWER TRAIN 387
TEST SWING CIRCLE BEARING CLEARANCE 387
TEST SWING CIRCLE BEARING CLEARANCE 387
UNDERCARRIAGE AND FRAME 388
TEST AND ADJUST TRACK TENSION 388
METHOD FOR TESTING TRACK TENSION 388
METHOD FOR ADJUSTING TRACK TENSION 388
HYDRAULIC SYSTEM 390
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 390
RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK 390
RELEASE REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 390
RELEASE REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 390
RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 391
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 392
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 392
ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 399
TEST OIL PRESSURE OF CONTROL CIRCUIT 402
TEST OIL PRESSURE OF CONTROL CIRCUIT 402
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 404
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 404
TEST PC-EPC VALVE OUTLET PRESSURE 405
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 406
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 407
TEST LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 407
TEST LS DIFFERENTIAL PRESSURE BY TESTING TOOL 409
TEST LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 410
METHOD FOR ADJUSTING LS VALVE 411
TEST OUTLET PRESSURE OF SOLENOID VALVE 413
TEST OUTLET PRESSURE IN SOLENOID VALVE 413
OPERATING CONDITION OF SOLENOID VALVE 414
TEST OUTLET PRESSURE IN VARIABLE BACK PRESSURE SOLENOID VALVE 416
OPERATING CONDITION OF VARIABLE BACK PRESSURE SOLENOID VALVE 417
TEST OUTLET PRESSURE IN PPC VALVE 418
TEST OUTLET PRESSURE IN PPC VALVE 418
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 420
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 420
TEST AND ADJUST TRAVEL DEVIATION 421
TEST TRAVEL DEVIATION 421
METHOD FOR ADJUSTING TRAVEL DEVIATION 421
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 424
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 424
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 424
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 425
TEST OIL LEAKAGE 426
TEST OIL LEAKAGE FROM BOOM CYLINDER 426
TEST OIL LEAKAGE FROM ARM CYLINDER 426
TEST OIL LEAKAGE FROM BUCKET CYLINDER 427
METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER 427
TEST OIL LEAKAGE FROM SWING MOTOR 428
TEST OIL LEAKAGE FROM TRAVEL MOTOR 429
BLEED AIR FROM HYDRAULIC CIRCUIT 430
BLEED AIR FROM HYDRAULIC CIRCUIT 431
CAB RELATED PARTS 434
TEST CAB TIPPING STOPPER 434
METHOD FOR TESTING CAB TIPPING STOPPER 434
ADJUST MIRRORS 435
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 436
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 437
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 439
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 440
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 441
PROCEDURE FOR ADJUSTING MACHINE REAR COUNTERWEIGHT MIRROR (D) 442
ELECTRICAL SYSTEM 443
SET AND OPERATE MACHINE MONITOR 443
OPERATOR MODE 447
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 447
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 447
CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 448
CHECKING FUNCTION OF SERVICE METER 448
USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 448
SERVICE MODE 451
OPERATE SERVICE MODE 451
CHECK PRE-DEFINED MONITORING INFORMATION 452
CHECK MONITORING INFORMATION 455
ABNORMALITY RECORD MENU 463
CHECK MAINTENANCE RECORD 467
MAINTENANCE MODE SETTING 468
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 472
DEFAULT MENU 474
DIAGNOSTIC TESTS MENU 480
ADJUSTMENT MENU 482
KOMTRAX SETTINGS MENU 495
METHOD FOR DISPLAYING SERVICE MESSAGE 497
START UP KOMTRAX SYSTEM 499
STOP USING OF KOMTRAX SYSTEM 505
ADJUST REARVIEW CAMERA ANGLE 507
ADJUST REARVIEW CAMERA ANGLE 507
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 510
BATTERY DISCONNECT SWITCH 511
TEST DIODES 512
METHOD FOR TESTING DIODE USING DIGITAL TESTER 512
METHOD FOR TESTING DIODE USING ANALOG TESTER 512
Pm-CLINIC 513
Pm CLINIC SERVICE 513
Pm CLINIC CHECK SHEET: PC130-10M0 515
40 TROUBLESHOOTING 524
CONTENTS 525
RELATED INFORMATION ON TROUBLESHOOTING 531
GENERAL TROUBLESHOOTING POINTS 531
SEQUENCE OF EVENTS IN TROUBLESHOOTING 532
CHECKS BEFORE TROUBLESHOOTING 534
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 536
WALK-AROUND CHECK 536
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 538
CHECK FUEL LEVEL AND TYPE 538
DRAIN WATER AND SEDIMENT FROM FUEL TANK 538
CHECK FUEL PREFILTER 539
CHECK WATER SEPARATOR, DRAIN WATER AND SEDIMENT 539
REPLACE FUEL PREFILTER CARTRIDGE 540
CHECK FUEL MAIN FILTER 541
TEST ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 543
CHECK OIL LEVEL IN PTO GEAR CASE 544
CHECK COOLANT LEVEL (RESERVOIR TANK) 545
CHECK CLOGGING OF AIR CLEANER 546
CLEAN OUTER ELEMENT 546
REPLACE ELEMENT 549
CHECK HYDRAULIC OIL LEVEL 550
CHECK HYDRAULIC OIL STRAINER 552
CHECK HYDRAULIC OIL FILTER 552
CHECK OIL LEVEL IN SWING MACHINERY CASE 554
CHECK OIL LEVEL IN FINAL DRIVE CASE 555
BLEED AIR FROM FUEL SYSTEM 555
BLEED AIR FROM HYDRAULIC SYSTEM 555
CHECK ELECTRIC EQUIPMENT 555
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 560
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 560
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 560
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 561
PREPARATION FOR TROUBLESHOOTING OF GATEWAY FUNCTION CONTROLLER 561
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 561
PROCEDURE FOR TESTING AND TROUBLESHOOTING 566
SYMPTOM AND TROUBLESHOOTING NUMBERS 569
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 573
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 575
CONNECTOR LIST AND LAYOUT 578
CONNECTOR CONTACT IDENTIFICATION 589
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 631
FUSE LOCATION TABLE 637
FAILURE CODE TABLE 639
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 646
FAILURE CODE [879AKA] 646
FAILURE CODE [879AKB] 647
FAILURE CODE [879BKA] 648
FAILURE CODE [879BKB] 650
FAILURE CODE [879CKA] 652
FAILURE CODE [879CKB] 653
FAILURE CODE [879DKZ] 654
FAILURE CODE [879EMC] 656
FAILURE CODE [879FMC] 657
FAILURE CODE [879GKX] 658
FAILURE CODE [989L00] 660
FAILURE CODE [989M00] 661
FAILURE CODE [989N00] 662
FAILURE CODE [AA10NX] 663
FAILURE CODE [AB00KE] 665
FAILURE CODE [B@BAZG] 667
FAILURE CODE [B@BAZK] 668
FAILURE CODE [B@BCNS] 670
FAILURE CODE [B@BCQA] 671
FAILURE CODE [B@BCZK] 673
FAILURE CODE [B@HANS] 675
FAILURE CODE [CA111] 677
FAILURE CODE [CA122] 682
FAILURE CODE [CA123] 684
FAILURE CODE [CA131] 685
FAILURE CODE [CA132] 687
FAILURE CODE [CA144] 688
FAILURE CODE [CA145] 690
FAILURE CODE [CA153] 691
FAILURE CODE [CA154] 693
FAILURE CODE [CA221] 694
FAILURE CODE [CA222] 696
FAILURE CODE [CA234] 697
FAILURE CODE [CA238] 698
FAILURE CODE [CA271] 700
FAILURE CODE [CA272] 701
FAILURE CODE [CA322] 702
FAILURE CODE [CA324] 704
FAILURE CODE [CA331] 706
FAILURE CODE [CA332] 708
FAILURE CODE [CA351] 710
FAILURE CODE [CA352] 713
FAILURE CODE [CA386] 714
FAILURE CODE [CA435] 716
FAILURE CODE [CA441] 717
FAILURE CODE [CA442] 718
FAILURE CODE [CA449] 719
FAILURE CODE [CA451] 720
FAILURE CODE [CA452] 722
FAILURE CODE [CA553] 723
FAILURE CODE [CA559] 724
FAILURE CODE [CA689] 728
FAILURE CODE [CA731] 730
FAILURE CODE [CA757] 731
FAILURE CODE [CA778] 736
FAILURE CODE [CA2185] 738
FAILURE CODE [CA2186] 740
FAILURE CODE [CA2249] 741
FAILURE CODE [CA2311] 742
FAILURE CODE [D110KB] 743
FAILURE CODE [D19JKZ] 745
FAILURE CODE [D811MC] 747
FAILURE CODE [D862KA] 748
FAILURE CODE [D8ALKA] 749
FAILURE CODE [D8ALKB] 751
FAILURE CODE [D8AQKR] 753
FAILURE CODE [D8G1KT] 757
FAILURE CODE [D8G6KT] 758
FAILURE CODE [DA20MC] 759
FAILURE CODE [DA22KK] 760
FAILURE CODE [DA25KP] 762
FAILURE CODE [DA26KP] 764
FAILURE CODE [DA29KQ] 767
FAILURE CODE [DA2LKA] 769
FAILURE CODE [DA2LKB] 771
FAILURE CODE [DA2QKR] 773
FAILURE CODE [DA2RKR] 778
FAILURE CODE [DAF0MB] 783
FAILURE CODE [DAF0MC] 784
FAILURE CODE [DAF8KB] 785
FAILURE CODE [DAF9KQ] 787
FAILURE CODE [DAFGMC] 788
FAILURE CODE [DAFLKA] 789
FAILURE CODE [DAFLKB] 791
FAILURE CODE [DAFQKR] 793
FAILURE CODE [DAZ9KQ] 797
FAILURE CODE [DAZQKR] 798
FAILURE CODE [DB2QKR] 802
FAILURE CODE [DGH2KA] 807
FAILURE CODE [DGH2KB] 809
FAILURE CODE [DHA4KA] 811
FAILURE CODE [DHE5MA] 813
FAILURE CODE [DHPAMA] 817
FAILURE CODE [DHS3MA] 819
FAILURE CODE [DHS4MA] 821
FAILURE CODE [DHS8MA] 823
FAILURE CODE [DHS9MA] 825
FAILURE CODE [DHSAMA] 827
FAILURE CODE [DHSBMA] 829
FAILURE CODE [DHSCMA] 831
FAILURE CODE [DHSDMA] 833
FAILURE CODE [DHSFMA] 835
FAILURE CODE [DHSGMA] 837
FAILURE CODE [DHSHMA] 839
FAILURE CODE [DHSJMA] 841
FAILURE CODE [DHSKMA] 843
FAILURE CODE [DHSLMA] 845
FAILURE CODE [DJG1KX] 847
FAILURE CODE [DKR2MA] 851
FAILURE CODE [DKR2NX] 855
FAILURE CODE [DV20KB] 858
FAILURE CODE [DW43KA] 860
FAILURE CODE [DW43KB] 862
FAILURE CODE [DW43KY] 864
FAILURE CODE [DW45KA] 865
FAILURE CODE [DW45KB] 868
FAILURE CODE [DW45KY] 871
FAILURE CODE [DW91KA] 873
FAILURE CODE [DW91KB] 875
FAILURE CODE [DW91KY] 877
FAILURE CODE [DWA2KA] 879
FAILURE CODE [DWA2KB] 881
FAILURE CODE [DWA2KY] 883
FAILURE CODE [DWJ0KA] 885
FAILURE CODE [DWJ0KB] 887
FAILURE CODE [DWJ0KY] 889
FAILURE CODE [DWK0KA] 891
FAILURE CODE [DWK0KB] 893
FAILURE CODE [DWK0KY] 895
FAILURE CODE [DWK2KA] 897
FAILURE CODE [DWK2KB] 899
FAILURE CODE [DWK2KY] 901
FAILURE CODE [DWNSKA] 903
FAILURE CODE [DWNSKB] 905
FAILURE CODE [DWNSKY] 907
FAILURE CODE [DXA8KA] 908
FAILURE CODE [DXA8KB] 910
FAILURE CODE [DXE4KA] 912
FAILURE CODE [DXE4KB] 914
FAILURE CODE [DXE4KY] 916
FAILURE CODE [DY20KA] 918
FAILURE CODE [DY20MA] 920
FAILURE CODE [DY2CKB] 922
FAILURE CODE [DY2DKB] 924
FAILURE CODE [DY2EKB] 926
FAILURE CODE [F@BBZL] 928
FAILURE CODE [F313KA] 931
FAILURE CODE [F313KB] 933
FAILURE CODE [F318KB] 934
FAILURE CODE [F318KY] 936
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 937
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 937
MANUAL PREHEATING SYSTEM DOES NOT WORK 947
WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP 950
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR SHOWS NOTHING 952
WHILE ENGINE IS IN OPERATION, ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE 955
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS IN OPERATION 956
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS IN OPERATION 957
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 958
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 959
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 960
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 961
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 962
FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 963
FUEL GAUGE DOES NOT SHOW CORRECT FUEL LEVEL 965
COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 966
COOLANT TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE 967
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 968
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE 970
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT SHOWN 971
FUNCTION SWITCH DOES NOT OPERATE 972
AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER) 973
AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED 974
AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION 975
WORK MODE SELECTOR SCREEN IS NOT SHOWN WHILE WORK MODE SWITCH IS OPERATED 976
ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED 977
TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED 978
TRAVEL SPEED DOES NOT CHANGE EVEN WHEN YOU OPERATE THE OPERATION TO CHANGE TRAVEL SPEED 979
ALARM BUZZER CANNOT BE STOPPED 980
SERVICE METER IS NOT SHOWN WHILE STARTING SWITCH IS IN OFF POSITION 981
MACHINE DOES NOT CHANGE TO SERVICE MODE 982
ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE 983
ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK 987
MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED 989
WHILE SWING PARKING BRAKE RELEASE SWITCH IS TURNED ON, SWING BRAKE IS NOT OPERATED 991
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY 993
ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED 997
TRAVEL ALARM DOES NOT OPERATE DURING TRAVEL 999
TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS 1001
HORN DOES NOT MAKE SOUND 1002
HORN DOES NOT STOP 1004
WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED 1005
WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED 1006
WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED 1008
“BOOM RAISE” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1009
“BOOM LOWER” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1010
“ARM DUMP” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1011
“ARM IN” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1012
“BUCKET DUMP” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1013
“BUCKET CURL” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1014
“SWING” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1015
“TRAVEL” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1016
SERVICE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1017
BLADE RAISE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1020
BLADE LOWER IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1021
KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY 1022
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1023
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1023
FAILURE MODE AND CAUSE TABLE 1024
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1034
All WORK EQUIPMENT, SWING, AND TRAVEL SPEED IS LOW OR POWER IS LOW 1035
FINE CONTROL PERFORMANCE OR RESPONSE IS UNSATISFACTORY 1037
THERE IS UNUSUAL NOISE FROM AROUND HYDRAULIC PUMP 1038
ENGINE SPEED FALLS LARGELY OR ENGINE STOPS 1039
BOOM SPEED OR POWER IS LOW 1041
ARM SPEED IS LOW OR POWER IS LOW 1044
BUCKET SPEED OR POWER IS LOW 1047
BLADE SPEED OR POWER IS LOW 1050
WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1052
HYDRAULIC DRIFT OF BOOM IS LARGE 1053
HYDRAULIC DRIFT OF ARM IS LARGE 1054
HYDRAULIC DRIFT OF BUCKET IS LARGE 1055
HYDRAULIC DRIFT OF BLADE IS LARGE 1056
WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 1058
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 1059
TIME LAG OF WORK EQUIPMENT IS LARGE 1061
ATTACHMENT CIRCUIT CANNOT BE CHANGED 1062
OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 1063
IN COMBINED OPERATION OF WORK EQUIPMENT, WORK EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER 1064
IN COMBINATION OPERATION OF SWING AND TRAVEL, TRAVEL SPEED FALLS LARGELY 1065
IN COMBINATION OPERATION OF SWING AND BOOM RAISE, BOOM RAISE SPEED IS LOW 1066
MACHINE DOES NOT TRAVEL STRAIGHT 1067
MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 1070
TRAVEL SPEED IS SLOW 1073
ONE OF TRACKS DOES NOT RUN 1075
TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1077
MACHINE DOES NOT SWING TO RIGHT OR LEFT 1078
SWINGS ONLY IN ONE DIRECTION 1079
SWING ACCELERATION OR SWING SPEED IS LOW IN TWO DIRECTIONS OF RIGHT AND LEFT 1080
SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION 1081
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (RIGHT AND LEFT) 1082
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (ONLY ONE DIRECTION) 1083
SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWING OPERATION 1084
THERE IS A LARGE UNUSUAL NOISE WHEN UPPER STRUCTURE STOPS SWING OPERATION 1085
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 1086
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1087
50 DISASSEMBLY AND ASSEMBLY 1088
CONTENTS 1089
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1093
HOW TO READ THIS MANUAL 1093
COATING MATERIALS LIST 1095
SPECIAL TOOLS LIST 1099
SKETCHES OF SPECIAL TOOLS 1113
PREPARATION 1115
DRAIN AND ADD COOLANT 1115
DRAIN COOLANT 1115
ADD COOLANT 1116
DRAIN AND ADD HYDRAULIC OIL 1118
DRAIN HYDRAULIC OIL 1118
ADD HYDRAULIC OIL 1120
DRAIN AND ADD FUEL 1121
DRAIN FUEL 1121
ADD FUEL 1122
COLLECT AND REFILL REFRIGERANT 1123
COLLECT REFRIGERANT 1123
REFILL REFRIGERANT 1124
ENGINE AND COOLING SYSTEM 1125
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1125
REMOVE SUPPLY PUMP ASSEMBLY 1126
INSTALL SUPPLY PUMP ASSEMBLY 1129
REMOVE AND INSTALL INJECTOR ASSEMBLY 1135
REMOVE INJECTOR ASSEMBLY 1136
INSTALL INJECTOR ASSEMBLY 1139
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 1143
REMOVE CYLINDER HEAD ASSEMBLY 1144
INSTALL CYLINDER HEAD ASSEMBLY 1154
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 1167
REMOVE STARTING MOTOR ASSEMBLY 1167
INSTALL STARTING MOTOR ASSEMBLY 1169
REMOVE AND INSTALL FAN BELT 1170
REMOVE FAN BELT 1171
INSTALL FAN BELT 1172
REMOVE AND INSTALL RADIATOR ASSEMBLY 1174
REMOVE RADIATOR ASSEMBLY 1175
INSTALL RADIATOR ASSEMBLY 1178
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1182
REMOVE HYDRAULIC OIL COOLER ASSEMBLY 1183
INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1187
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 1192
REMOVE AFTERCOOLER ASSEMBLY 1193
INSTALL AFTERCOOLER ASSEMBLY 1196
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 1200
REMOVE ENGINE AND MAIN PUMP ASSEMBLY 1202
INSTALL ENGINE AND MAIN PUMP ASSEMBLY 1220
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 1241
REMOVE ENGINE FRONT OIL SEAL 1242
INSTALL ENGINE FRONT OIL SEAL 1243
REMOVE AND INSTALL ENGINE REAR OIL SEAL 1245
REMOVE ENGINE REAR OIL SEAL 1246
INSTALL ENGINE REAR OIL SEAL 1247
REMOVE AND INSTALL FUEL COOLER ASSEMBLY 1250
REMOVE FUEL COOLER ASSEMBLY 1251
INSTALL FUEL COOLER ASSEMBLY 1252
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 1253
REMOVE ENGINE HOOD ASSEMBLY 1253
INSTALL ENGINE HOOD ASSEMBLY 1254
REMOVE AND INSTALL FUEL TANK ASSEMBLY 1256
REMOVE FUEL TANK ASSEMBLY 1257
INSTALL FUEL TANK ASSEMBLY 1260
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 1264
REMOVE AIR CLEANER ASSEMBLY 1265
INSTALL AIR CLEANER ASSEMBLY 1267
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 1270
REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY 1271
INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 1272
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 1275
REMOVE AIR CONDITIONER CONDENSER ASSEMBLY 1275
INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 1277
POWER TRAIN 1279
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1279
REMOVE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1280
INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1282
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1284
DISASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1293
ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1311
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 1332
REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY 1333
INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 1336
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 1338
DISASSEMBLE SWING MACHINERY ASSEMBLY 1339
ASSEMBLE SWING MACHINERY ASSEMBLY 1342
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 1345
REMOVE SWING CIRCLE ASSEMBLY 1345
INSTALL SWING CIRCLE ASSEMBLY 1346
UNDERCARRIAGE AND FRAME 1347
SEPARATE AND INSTALL TRACK ASSEMBLY 1347
SEPARATE TRACK ASSEMBLY 1348
INSTALL TRACK ASSEMBLY 1350
REMOVE AND INSTALL SPROCKET 1353
REMOVE SPROCKET 1353
INSTALL SPROCKET 1354
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 1355
REMOVE IDLER AND IDLER CUSHION ASSEMBLY 1355
INSTALL IDLER AND IDLER CUSHION ASSEMBLY 1356
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 1357
DISASSEMBLE IDLER CUSHION ASSEMBLY 1357
ASSEMBLE IDLER ASSEMBLY 1358
DISASSEMBLE AND ASSEMBLE IDLER CUSHION ASSEMBLY 1361
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 1361
ASSEMBLE IDLER CUSHION ASSEMBLY 1363
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 1365
DISASSEMBLE TRACK ROLLER ASSEMBLY 1365
ASSEMBLE TRACK ROLLER ASSEMBLY 1366
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 1368
REMOVE REVOLVING FRAME ASSEMBLY 1369
INSTALL REVOLVING FRAME ASSEMBLY 1374
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 1379
REMOVE COUNTERWEIGHT ASSEMBLY 1380
INSTALL COUNTERWEIGHT ASSEMBLY 1381
HYDRAULIC SYSTEM 1384
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 1384
REMOVE CENTER SWIVEL JOINT ASSEMBLY 1385
INSTALL CENTER SWIVEL JOINT ASSEMBLY 1389
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 1394
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 1395
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 1396
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 1397
REMOVE HYDRAULIC TANK ASSEMBLY 1398
INSTALL HYDRAULIC TANK ASSEMBLY 1407
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 1417
REMOVE MAIN PUMP ASSEMBLY 1418
INSTALL MAIN PUMP ASSEMBLY 1424
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 1431
REMOVE CONTROL VALVE ASSEMBLY 1433
INSTALL CONTROL VALVE ASSEMBLY 1447
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 1461
ASSEMBLE CONTROL VALVE ASSEMBLY 1461
REPLACE PRESSURE REDUCING VALVE CARTRIDGE ASSEMBLY 1463
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 1466
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 1466
ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 1466
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 1468
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 1468
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 1469
WORK EQUIPMENT 0
REMOVE AND INSTALL BLADE ASSEMBLY 0
REMOVE BLADE ASSEMBLY 0
INSTALL BLADE ASSEMBLY 0
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 1471
REMOVE WORK EQUIPMENT ASSEMBLY 1473
INSTALL WORK EQUIPMENT ASSEMBLY 1476
DISASSEMBLE AND ASSEMBLE BUCKET CYLINDER ASSEMBLY 1480
DISASSEMBLE BUCKET CYLINDER ASSEMBLY 1481
ASSEMBLE BUCKET CYLINDER ASSEMBLY 1483
DISASSEMBLE AND ASSEMBLE BOOM CYLINDER ASSEMBLY 1487
DISASSEMBLE BOOM CYLINDER ASSEMBLY 1488
ASSEMBLE BOOM CYLINDER ASSEMBLY 1490
DISASSEMBLE AND ASSEMBLE ARM CYLINDER ASSEMBLY 1494
DISASSEMBLE ARM CYLINDER ASSEMBLY 1495
ASSEMBLE ARM CYLINDER ASSEMBLY 1497
DISASSEMBLE AND ASSEMBLE BLADE CYLINDER ASSEMBLY 0
DISASSEMBLE BLADE CYLINDER ASSEMBLY 0
ASSEMBLE BLADE CYLINDER ASSEMBLY 0
CAB RELATED PARTS 1502
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY 1502
REMOVE OPERATOR CAB ASSEMBLY 1502
INSTALL OPERATOR CAB ASSEMBLY 1513
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 1523
REMOVE OPERATOR CAB GLASS (ADHERED GLASS) 1525
INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 1525
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 1536
REMOVE FRONT WINDOW ASSEMBLY 1536
INSTALL FRONT WINDOW ASSEMBLY 1539
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 1545
REMOVE FLOOR FRAME ASSEMBLY 1546
INSTALL FLOOR FRAME ASSEMBLY 1552
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 1559
REMOVE AIR CONDITIONER UNIT ASSEMBLY 1560
INSTALL AIR CONDITIONER UNIT ASSEMBLY 1568
REMOVE AND INSTALL OPERATOR SEAT 1576
REMOVE OPERATOR’S SEAT 1576
INSTALL OPERATOR’S SEAT 1577
REMOVE AND INSTALL SEATBELT 1578
REMOVE SEATBELT 1578
INSTALL SEATBELT 1579
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 1580
REMOVE FRONT WIPER ASSEMBLY 1580
INSTALL FRONT WIPER ASSEMBLY 1586
ELECTRICAL SYSTEM 1594
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 1594
REMOVE ENGINE CONTROLLER ASSEMBLY 1595
INSTALL ENGINE CONTROLLER ASSEMBLY 1598
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 1603
REMOVE PUMP CONTROLLER ASSEMBLY 1603
INSTALL PUMP CONTROLLER ASSEMBLY 1605
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 1609
REMOVE MACHINE MONITOR ASSEMBLY 1609
INSTALL MACHINE MONITOR ASSEMBLY 1612
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 1616
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 1616
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 1620
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 1624
REMOVE COMMUNICATION TERMINAL WIRING HARNESS 1624
INSTALL COMMUNICATION TERMINAL WIRING HARNESS 1631
REMOVE AND INSTALL COMMUNICATION TERMINAL 1640
REMOVE COMMUNICATION TERMINAL 1640
INSTALL COMMUNICATION TERMINAL 1642
60 MAINTENANCE STANDARD 1644
CONTENTS 1645
ENGINE AND COOLING SYSTEM 1646
MAINTENANCE STANDARD OF ENGINE MOUNT 1646
MAINTENANCE STANDARD OF PTO 1647
MAINTENANCE STANDARD OF COOLING SYSTEM 1648
POWER TRAIN 1649
MAINTENANCE STANDARD OF SWING CIRCLE 1649
MAINTENANCE STANDARD OF SWING MACHINERY 1650
MAINTENANCE STANDARD OF SPROCKET 1652
UNDERCARRIAGE AND FRAME 1653
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 1653
MAINTENANCE STANDARD OF IDLER 1655
MAINTENANCE STANDARD OF TRACK ROLLER 1656
MAINTENANCE STANDARD OF CARRIER ROLLER 1658
MAINTENANCE STANDARD OF TRACK SHOE 1659
MAINTENANCE STANDARD OF TRIPLE SHOE 1662
HYDRAULIC SYSTEM 1663
MAINTENANCE STANDARD OF HYDRAULIC TANK 1663
MAINTENANCE STANDARD OF MAIN PUMP 1664
MAINTENANCE STANDARD OF PC-EPC VALVE 1668
MAINTENANCE STANDARD OF SWING MOTOR 1669
MAINTENANCE STANDARD OF TRAVEL MOTOR 1672
MAINTENANCE STANDARD OF CONTROL VALVE 1673
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 1684
MAINTENANCE STANDARD OF BLADE PPC VALVE 1687
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 1689
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 1692
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 1694
MAINTENANCE STANDARD OF SOLENOID VALVE 1695
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE SOLENOID VALVE 1699
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 1700
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) 1701
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 1702
WORK EQUIPMENT 1704
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 1704
DIMENSIONS OF ARM 1709
DIMENSIONS OF BUCKET 1711
MAINTENANCE STANDARD OF BOOM CYLINDER 1713
MAINTENANCE STANDARD OF ARM CYLINDER 1714
MAINTENANCE STANDARD OF BUCKET CYLINDER 1715
MAINTENANCE STANDARD OF BLADE CYLINDER 1716
CAB AND ITS ATTACHMENTS 1717
MAINTENANCE STANDARD OF CAB MOUNT 1717
80 OTHERS 1719
CONTENTS 1720
AIR CONDITIONER SYSTEM 1722
PRECAUTIONS FOR REFRIGERANT 1722
AIR CONDITIONER 1723
SPECIFICATIONS OF AIR CONDITIONER 1725
CONFIGURATION OF REFRIGERATION CYCLE 1726
FUNCTION OF REFRIGERATION CYCLE 1727
SYSTEM DIAGRAM OF AIR CONDITIONER 1728
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 1729
AIR CONDITIONER UNIT 1729
STRUCTURE OF AIR CONDITIONER UNIT 1730
FUNCTION OF AIR CONDITIONER UNIT 1731
COMPONENT PARTS OF AIR CONDITIONER UNIT 1732
AIR CONDITIONER CONTROLLER 1736
STRUCTURE OF AIR CONDITIONER CONTROLLER 1736
FUNCTION OF AIR CONDITIONER CONTROLLER 1736
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 1736
COMPRESSOR 1738
STRUCTURE OF COMPRESSOR 1738
SPECIFICATIONS OF COMPRESSOR 1738
FUNCTION OF COMPRESSOR 1738
OPERATION OF COMPRESSOR 1738
CONDENSER 1739
STRUCTURE OF CONDENSER 1739
SPECIFICATIONS OF CONDENSOR 1739
FUNCTION OF COMPRESSOR 1739
AIR CONDITIONER RELATED SENSORS 1741
STRUCTURE OF SUNLIGHT SENSOR 1741
FUNCTION OF SUNLIGHT SENSOR 1741
STRUCTURE OF OUTSIDE TEMPERATURE SENSOR 1741
FUNCTION OF OUTSIDE AIR TEMPERATURE SENSOR 1741
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS OF AIR CONDITIONER 1742
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 1744
TEST AIR LEAKAGE (DUCT CONNECTION) 1748
TEST AIR LEAKAGE (DUCT CONNECTION) 1748
TEST AIR CONDITIONER BY SELF-DIAGNOSIS FUNCTION 1751
TEST VENT (MODE) CHANGEOVER 1752
TEST VENT (MODE) CHANGEOVER 1752
TEST FRESH/RECIRC AIR CHANGEOVER 1754
TEST FRESH/RECIRC AIR CHANGEOVER 1754
TEST SUNLIGHT SENSOR 1755
TEST SUNLIGHT SENSOR 1755
TEST DUAL PRESSURE SWITCH 1756
TEST DUAL PRESSURE SWITCH 1756
TEST RELAY 1757
TEST RELAY 1757
SIMPLE CHECK OF REFRIGERANT VOLUME THROUGH SIGHT GLASS 1759
PROCEDURE FOR TROUBLE SHOOTING OF AIR CONDITIONER 1760
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1761
FAILURE CODE [879AKA] 1764
FAILURE CODE [879AKB] 1765
FAILURE CODE [879BKA] 1766
FAILURE CODE [879BKB] 1768
FAILURE CODE [879CKA] 1770
FAILURE CODE [879CKB] 1771
FAILURE CODE [879DKZ] 1772
FAILURE CODE [879EMC] 1774
FAILURE CODE [879FMC] 1775
FAILURE CODE [879GKX] 1776
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 1778
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 1780
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 1783
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 1785
CONNECT SERVICE TOOL 1787
CONNECT SERVICE TOOL 1788
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPING 1789
HANDLE COMPRESSOR OIL 1791
REPLACE DESICCANT 1793
90 CIRCUIT DIAGRAMS 1795
CONTENTS 1796
HOW TO READ THE CODES FOR ELECTRIC CABLE 1797
HYDRAULIC CIRCUIT DIAGRAM 1801
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 1801
HYDRAULIC CIRCUIT DIAGRAM (1/3) 1805
HYDRAULIC CIRCUIT DIAGRAM (2/3) 1807
HYDRAULIC CIRCUIT DIAGRAM (3/3) 1809
ELECTRICAL CIRCUIT DIAGRAM 1811
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 1811
ELECTRICAL CIRCUIT DIAGRAM (1/6) 1815
ELECTRICAL CIRCUIT DIAGRAM (2/6) 1817
ELECTRICAL CIRCUIT DIAGRAM (3/6) 1819
ELECTRICAL CIRCUIT DIAGRAM (4/6) 1821
ELECTRICAL CIRCUIT DIAGRAM (5/6) 1823
ELECTRICAL CIRCUIT DIAGRAM (6/6) 1825
INDEX 1827
Blank Page 1657
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