Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06806-03 – PDF DOWNLOAD
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DESCRIPTION:
Komatsu PC170LC-11 Hydraulic Excavator Shop Manual SEN06806-03 – PDF DOWNLOAD
SERIAL NUMBERS 35877 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 PC170LC-11 Hydraulic Excavator Shop Manual SEN06806-03 – PDF DOWNLOAD
COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 22
FOREWORD, SAFETY, BASIC INFORMATION 28
HOW TO READ THE SHOP MANUAL 28
SAFETY NOTICE FOR OPERATION 30
PRECAUTIONS TO PREVENT FIRE 38
ACTIONS IF FIRE OCCURS 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 42
PRECAUTIONS FOR DEF 43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 43
PRECAUTIONS FOR ADDING 43
PRECAUTIONS FOR STORING 43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 43
THE OTHER PRECAUTIONS 43
STORE AdBlue/DEF 44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 58
PRACTICAL USE OF KOMTRAX 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 74
HOW TO READ ELECTRICAL WIRE CODE 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 79
STANDARD TIGHTENING TORQUE TABLE 82
CONVERSION TABLE 89
01 SPECIFICATIONS 95
CONTENTS 96
ABBREVIATION LIST 97
SPECIFICATIONS 103
SPECIFICATION DRAWING 103
SPECIFICATION DRAWING: PC170LCLC-11 103
WORKING RANGE DRAWINGS 105
WORKING RANGE: PC170LCLC-11 105
SPECIFICATIONS 106
SPECIFICATIONS: PC170LCLC-11 106
WEIGHT TABLE 109
WEIGHT TABLE: PC170LC-11 109
TABLE OF FUEL, COOLANT, AND LUBRICANTS 111
10 STRUCTURE AND FUNCTION 113
CONTENTS 114
ABBREVIATION LIST 117
UREA SCR SYSTEM 123
LAYOUT DRAWING OF UREA SCR SYSTEM 123
UREA SCR SYSTEM DIAGRAM 128
FUNCTION OF UREA SCR SYSTEM 129
FUNCTION OF AdBlue/DEF SYSTEM 129
INDUCEMENT STRATEGY 131
COMPONENT PARTS OF UREA SCR SYSTEM 139
AdBlue/DEF MIXING TUBE 139
SCR ASSEMBLY 139
AdBlue/DEF TANK 142
AdBlue/DEF PUMP 144
AdBlue/DEF INJECTOR 145
AdBlue/DEF HOSE 146
AdBlue/DEF TANK HEATING VALVE 147
BOOT-UP SYSTEM 148
LAYOUT DRAWING OF BOOT-UP SYSTEM 148
SYSTEM OPERATING LAMP SYSTEM 150
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 150
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 150
BATTERY ISOLATOR 152
FUNCTION OF BATTERY ISOLATOR 152
ENGINE SYSTEM 153
LAYOUT DRAWING OF ENGINE SYSTEM 153
SPECIFICATIONS OF ENGINE SYSTEM 154
FUNCTION OF ENGINE SYSTEM 154
ENGINE CONTROL SYSTEM 155
ENGINE CONTROL SYSTEM DIAGRAM 155
FUNCTION OF ENGINE CONTROL SYSTEM 156
AUTO-DECELERATION SYSTEM 159
AUTO-DECELERATION SYSTEM DIAGRAM 159
FUNCTION OF AUTO-DECELERATION SYSTEM 159
OPERATION OF AUTO-DECELERATION SYSTEM 160
ENGINE AUTOMATIC WARM-UP SYSTEM 161
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 161
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 161
OVERHEAT PREVENTION SYSTEM 163
OVERHEAT PREVENTION SYSTEM DIAGRAM 163
FUNCTION OF OVERHEAT PREVENTION SYSTEM 163
TURBOCHARGER PROTECTION SYSTEM 165
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 165
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 165
AUTOMATIC IDLE STOP SYSTEM 167
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 167
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 167
COMPONENT PARTS OF ENGINE SYSTEM 170
VGT 170
EGR SYSTEM 172
EGR VALVE 174
EGR COOLER 176
KCCV SYSTEM 177
KCCV VENTILATOR 179
KDOC 181
COOLING SYSTEM 185
LAYOUT DRAWING OF COOLING SYSTEM 185
SPECIFICATIONS OF COOLING SYSTEM 186
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 187
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 187
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 188
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 189
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 189
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 189
COMPONENT PARTS OF COOLING SYSTEM 191
FAN CLUTCH 191
CONTROL SYSTEM 192
LAYOUT DRAWING OF CONTROL SYSTEM 192
MACHINE MONITOR SYSTEM 195
MACHINE MONITOR SYSTEM DIAGRAM 195
FUNCTION OF MACHINE MONITOR SYSTEM 195
KomVision SYSTEM 197
LAYOUT DRAWING OF KOMVISION SYSTEM 197
KomVision SYSTEM DIAGRAM 199
FUNCTION OF KomVision SYSTEM 199
KOMTRAX SYSTEM 201
KOMTRAX SYSTEM DIAGRAM 201
FUNCTION OF KOMTRAX SYSTEM 201
PPC LEVERS 202
LH PPC LEVER 202
RH PPC LEVER 203
AUTOMATIC GREASE SYSTEM 204
OUTLINE OF AUTO GREASE SYSTEM 204
COMPONENT PARTS OF CONTROL SYSTEM 216
MACHINE MONITOR 216
KomVision CONTROLLER 229
KomVision CAMERA 233
GATEWAY FUNCTION CONTROLLER 234
COMMUNICATION TERMINAL 237
PUMP CONTROLLER 239
RESISTOR FOR PC-EPC VALVE 243
CAN TERMINATING RESISTOR 243
PPC OIL PRESSURE SWITCH 244
ENGINE CONTROLLER 245
FUEL CONTROL DIAL 251
HYDRAULIC SYSTEM 254
LAYOUT DRAWING OF HYDRAULIC SYSTEM 254
CLSS 258
STRUCTURE OF CLSS 258
FUNCTION OF CLSS 259
ENGINE AND PUMP COMBINED CONTROL SYSTEM 261
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 261
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 262
PUMP AND VALVE CONTROL SYSTEM 267
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 267
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 268
COMPONENT PARTS OF HYDRAULIC SYSTEM 270
HYDRAULIC TANK 270
MAIN PUMP 272
PILOT OIL FILTER 295
CONTROL VALVE 295
WORK EQUIPMENT SYSTEM 361
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 361
ONE-TOUCH POWER MAXIMIZING SYSTEM 365
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 365
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 365
PPC LOCK SYSTEM 367
PPC LOCK SYSTEM DIAGRAM 367
FUNCTION OF PPC LOCK SYSTEM 367
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 368
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 368
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 368
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 369
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 370
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 370
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 371
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 372
WORK EQUIPMENT AND SWING PPC VALVE 372
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 378
2ND-LINE ATTACHMENT PPC VALVE 384
SOLENOID VALVE 387
ANTI-DROP VALVE FOR BOOM 389
ANTI-DROP VALVE FOR ARM 393
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 397
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 399
PILOT CIRCUIT ACCUMULATOR 402
ATTACHMENT CIRCUIT ACCUMULATOR 403
SWING SYSTEM 404
LAYOUT DRAWING OF SWING SYSTEM 404
SWING CONTROL SYSTEM DIAGRAM 408
FUNCTION OF SWING CONTROL SYSTEM 408
COMPONENT PARTS OF SWING SYSTEM 411
SWING MOTOR 411
SWING MACHINERY 414
SWING CIRCLE 416
TRAVEL SYSTEM 418
LAYOUT DRAWING OF TRAVEL SYSTEM 418
TRAVEL CONTROL SYSTEM DIAGRAM 421
FUNCTION OF TRAVEL CONTROL SYSTEM 421
COMPONENT PARTS OF TRAVEL SYSTEM 423
TRAVEL MOTOR 423
FINAL DRIVE 436
TRAVEL PPC VALVE 437
CENTER SWIVEL JOINT 442
UNDERCARRIAGE AND FRAME 444
LAYOUT DRAWING OF UNDERCARRIAGE 444
SPECIFICATIONS OF UNDERCARRIAGE 445
WORK EQUIPMENT 446
STRUCTURE OF WORK EQUIPMENT 446
FUNCTION OF WORK EQUIPMENT 447
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 448
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 448
BUCKET CLEARANCE ADJUSTMENT SHIM 449
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 449
CAB AND ITS ATTACHMENTS 450
ROPS CAB 450
STRUCTURE OF ROPS CAB 450
FUNCTION OF ROPS CAB 450
CAB MOUNT 451
STRUCTURE OF CAB MOUNT 451
FUNCTION OF CAB MOUNT 451
CAB TIPPING STOPPER 452
STRUCTURE OF CAB TIPPING STOPPER 452
FUNCTION OF CAB TIPPING STOPPER 452
20 STANDARD VALUE TABLE 453
CONTENTS 454
ABBREVIATION LIST 455
STANDARD VALUE TABLE FOR ENGINE 461
STANDARD VALUE TABLE FOR ENGINE: PC170LC-11 461
STANDARD VALUE TABLE FOR MACHINE 465
STANDARD VALUE TABLE FOR MACHINE: PC170LC-11 465
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 478
30 TESTING AND ADJUSTING 483
CONTENTS 484
ABBREVIATION LIST 488
RELATED INFORMATION ON TESTING AND ADJUSTING 494
TOOLS FOR TESTING AND ADJUSTING 494
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 501
ENGINE AND COOLING SYSTEM 503
TEST ENGINE SPEED 503
METHOD FOR TESTING ENGINE SPEED 503
TEST BOOST PRESSURE 505
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 505
METHOD FOR TESTING BOOST PRESSURE 506
TEST EXHAUST GAS COLOR 507
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 507
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 508
TEST AND ADJUST VALVE CLEARANCE 509
METHOD FOR TESTING VALVE CLEARANCE 509
METHOD FOR ADJUSTING VALVE CLEARANCE 510
TEST COMPRESSION PRESSURE 512
METHOD FOR TESTING COMPRESSION PRESSURE 512
TEST BLOWBY PRESSURE 517
METHOD FOR TESTING BLOWBY PRESSURE 517
TEST ENGINE OIL PRESSURE 519
METHOD FOR TESTING ENGINE OIL PRESSURE 519
TEST FUEL PRESSURE 520
METHOD FOR TESTING FUEL PRESSURE 521
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 525
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 526
BLEEDING AIR FROM FUEL SYSTEM 530
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 530
TEST FUEL CIRCUIT FOR LEAKAGE 531
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 531
HANDLE CYLINDER CUT-OUT MODE OPERATION 533
HANDLE NO-INJECTION CRANKING OPERATION 534
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 535
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 535
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 535
TEST FAN BELT AND ALTERNATOR BELT 537
METHOD FOR TESTING FAN BELT AND ALTERNATOR BELT 537
TEST AUTO-TENSIONER 538
METHOD FOR TESTING AUTO-TENSIONER 538
METHOD FOR REPLACING FAN BELT 539
TEST COOLING FAN SPEED 540
METHOD FOR TESTING COOLING FAN SPEED 540
TEST SCR RELATED FUNCTIONS 541
TEST AdBlue/DEF PUMP RAISED PRESSURE 544
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 547
TEST AdBlue/DEF LINE HEATER RELAY 1 550
TEST AdBlue/DEF LINE HEATER RELAY 2 553
TEST AdBlue/DEF PUMP HEATER RELAY 556
TEST AdBlue/DEF TANK HEATER VALVE 559
TEST DENITRATION EFFICIENCY OF SCR 562
CLEAN AdBlue/DEF TANK 565
METHOD FOR CLEANING AdBlue/DEF TANK 565
CLEAN AdBlue/DEF PUMP 569
METHOD FOR CLEAN AdBlue/DEF PUMP 569
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 576
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 576
POWER TRAIN 578
TEST SWING CIRCLE BEARING CLEARANCE 578
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 578
UNDERCARRIAGE AND FRAME 579
TEST AND ADJUST TRACK TENSION 579
METHOD FOR TESTING TRACK TENSION 579
METHOD FOR ADJUSTING TRACK TENSION 579
HYDRAULIC SYSTEM 581
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 581
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 581
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 581
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 583
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 583
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 584
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 584
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 591
TEST OIL PRESSURE OF CONTROL CIRCUIT 593
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 593
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 595
METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 595
METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE 596
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 597
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 599
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 599
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE 601
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 604
METHOD FOR ADJUSTING LS VALVE 605
TEST OUTLET PRESSURE OF SOLENOID VALVE 606
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 606
OPERATING CONDITION OF SOLENOID VALVE 607
TEST PPC VALVE OUTLET PRESSURE 610
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 610
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 612
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 612
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE 613
TEST PUMP SWASH PLATE SENSOR 615
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 615
TEST AND ADJUST TRAVEL DEVIATION 616
METHOD FOR TESTING TRAVEL DEVIATION 616
METHOD FOR ADJUSTING TRAVEL DEVIATION 616
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 619
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 619
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 619
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 620
TEST OIL LEAKAGE 621
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 621
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 621
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 622
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 623
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 623
BLEED AIR FROM HYDRAULIC CIRCUIT 624
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 625
TEST AND CHARGE ACCUMULATOR (MANUFACTURED BY NOK) NITROGEN GAS PRESSURE FOR ATTACHMENT (LOW PRESSURE SIDE) 628
TEST ACCUMULATOR (MANUFACTURED BY NOK) NITROGEN GAS PRESSURE FOR ATTACHMENT (LOW PRESSURE SIDE) 628
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH PRESSURE SIDE) 632
TEST ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH PRESSURE SIDE) 632
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ATTACHMENT PIPING 636
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ATTACHMENT PIPING 636
CAB AND ITS ATTACHMENTS 643
TEST CAB TIPPING STOPPER 643
METHOD FOR TESTING CAB TIPPING STOPPER 643
METHOD FOR ADJUSTING MIRRORS 644
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 644
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 645
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 646
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 647
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 649
ELECTRICAL SYSTEM 650
SET AND OPERATE MACHINE MONITOR 650
OPERATOR MODE 653
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 654
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 654
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 655
CHECKING FUNCTION OF SERVICE METER 655
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 655
SERVICE MODE 658
METHOD FOR OPERATING SERVICE MODE 658
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 659
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 666
ABNORMALITY RECORD MENU 676
METHOD FOR CONFIRMING MAINTENANCE RECORD 680
METHOD FOR OPERATING MAINTENANCE MODE SETTING 682
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 685
DEFAULT MENU 686
DIAGNOSTIC TESTS MENU 694
ADJUSTMENT MENU 701
METHOD FOR PERFORMING NO-INJECTION CRANKING 723
KOMTRAX SETTINGS MENU 724
METHOD FOR DISPLAYING SERVICE MESSAGE 726
METHOD FOR STARTING UP KOMTRAX SYSTEM 728
ADJUST REARVIEW CAMERA ANGLE 733
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 733
ADJUST KomVision CAMERA ANGLE 736
METHOD FOR ADJUSTING KomVision CAMERA ANGLE 737
ADJUST KomVision RELATED ITEMS 741
SETTING OF KomVision (MAIN SETTING) 741
SETTING OF KomVision (CAMERA SETTING) 743
SETTING OF KomVision (CAMERA CALIBRATION) 745
KomVision screen – Check 12 m visibility 758
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 761
HANDLE BATTERY ISOLATOR SWITCH 762
TEST DIODES 763
METHOD FOR TESTING DIODE USING DIGITAL TESTER 763
METHOD FOR TESTING DIODE USING ANALOG TESTER 763
Pm CLINIC 764
Pm CLINIC SERVICE 764
Pm CLINIC CHECK SHEET:PC170LC-11 768
40 TROUBLESHOOTING 779
CONTENTS 780
ABBREVIATION LIST 791
RELATED INFORMATION ON TROUBLESHOOTING 797
GENERAL TROUBLESHOOTING POINTS 797
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 798
SEQUENCE OF EVENTS IN TROUBLESHOOTING 813
CHECKS BEFORE TROUBLESHOOTING 815
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 817
WALK-AROUND CHECK 817
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 819
CHECK FUEL LEVEL AND TYPE 819
CHECK IMPURE INGREDIENT IN FUEL 819
CHECK FUEL PREFILTER 820
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 820
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 821
CHECK MAIN FILTER 823
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 824
CHECK COOLANT LEVEL (RESERVOIR TANK) 825
CHECK CLOGGING OF AIR CLEANER 826
OUTER ELEMENT – CLEAN 826
ELEMENTS – REPLACE 829
CHECK HYDRAULIC OIL LEVEL 831
CHECK HYDRAULIC OIL STRAINER 832
CHECK HYDRAULIC FILTER 833
CHECK OIL LEVEL IN SWING MACHINERY CASE 834
CHECK OIL LEVEL IN DAMPER CASE 835
CHECK OIL LEVEL IN FINAL DRIVE CASE 835
BLEED AIR FROM FUEL SYSTEM 836
BLEED AIR FROM HYDRAULIC SYSTEM 836
ELECTRICAL EQUIPMENT – CHECK METHOD 836
AUTOMATIC GREASE SYSTEM 842
FINDING MALFUNCTIONS 842
MALFUNCTION FINDING PROCEDURES 844
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 846
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 846
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 846
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 846
PREPARATION FOR TROUBLESHOOTING OF GATEWAY FUNCTION CONTROLLER 847
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 847
PROCEDURE FOR TESTING AND TROUBLESHOOTING 851
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 854
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 858
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 860
CONNECTOR LIST AND LAYOUT 863
CONNECTOR CONTACT IDENTIFICATION 876
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 916
FUSE LOCATION TABLE 922
PRECAUTIONS FOR REPLACING KDOC 925
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 926
FAILURE CODE TABLE 928
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 946
FAILURE CODE [879AKA] 946
FAILURE CODE [879AKB] 947
FAILURE CODE [879BKA] 948
FAILURE CODE [879BKB] 950
FAILURE CODE [879CKA] 952
FAILURE CODE [879CKB] 953
FAILURE CODE [879DKZ] 954
FAILURE CODE [879EMC] 956
FAILURE CODE [879FMC] 957
FAILURE CODE [879GKX] 958
FAILURE CODE [989L00] 960
FAILURE CODE [989M00] 961
FAILURE CODE [989N00] 962
FAILURE CODE [A1U0N3] 963
FAILURE CODE [A1U0N4] 965
FAILURE CODE [A900FR] 967
FAILURE CODE [A900N6] 968
FAILURE CODE [A900NY] 969
FAILURE CODE [AA10NX] 970
FAILURE CODE [AB00KE] 972
FAILURE CODE [AQ10MB] 975
FAILURE CODE [AQ10N3] 977
FAILURE CODE [AS00N3] 979
FAILURE CODE [AS00R2] 981
FAILURE CODE [AS00R3] 982
FAILURE CODE [AS00R4] 983
FAILURE CODE [AS00R5] 984
FAILURE CODE [AS00R6] 985
FAILURE CODE [AS00ZK] 986
FAILURE CODE [AS10KM] 987
FAILURE CODE [AS10NR] 988
FAILURE CODE [AS10NT] 990
FAILURE CODE [B@BAZG] 991
FAILURE CODE [B@BAZK] 992
FAILURE CODE [B@BCNS] 994
FAILURE CODE [B@BCZK] 995
FAILURE CODE [B@HANS] 997
FAILURE CODE [CA115] 998
FAILURE CODE [CA122] 999
FAILURE CODE [CA123] 1001
FAILURE CODE [CA131] 1003
FAILURE CODE [CA132] 1005
FAILURE CODE [CA144] 1007
FAILURE CODE [CA145] 1009
FAILURE CODE [CA153] 1011
FAILURE CODE [CA154] 1014
FAILURE CODE [CA187] 1017
FAILURE CODE [CA221] 1019
FAILURE CODE [CA222] 1021
FAILURE CODE [CA227] 1023
FAILURE CODE [CA234] 1025
FAILURE CODE [CA238] 1026
FAILURE CODE [CA239] 1027
FAILURE CODE [CA249] 1028
FAILURE CODE [CA256] 1030
FAILURE CODE [CA271] 1032
FAILURE CODE [CA272] 1034
FAILURE CODE [CA295] 1036
FAILURE CODE [CA322] 1037
FAILURE CODE [CA324] 1039
FAILURE CODE [CA331] 1041
FAILURE CODE [CA332] 1043
FAILURE CODE [CA343] 1045
FAILURE CODE [CA351] 1046
FAILURE CODE [CA352] 1048
FAILURE CODE [CA356] 1050
FAILURE CODE [CA357] 1052
FAILURE CODE [CA386] 1054
FAILURE CODE [CA428] 1055
FAILURE CODE [CA429] 1057
FAILURE CODE [CA435] 1059
FAILURE CODE [CA441] 1061
FAILURE CODE [CA442] 1063
FAILURE CODE [CA451] 1065
FAILURE CODE [CA452] 1067
FAILURE CODE [CA488] 1069
FAILURE CODE [CA515] 1070
FAILURE CODE [CA516] 1072
FAILURE CODE [CA553] 1074
FAILURE CODE [CA555] 1075
FAILURE CODE [CA556] 1076
FAILURE CODE [CA559] 1077
FAILURE CODE [CA595] 1080
FAILURE CODE [CA687] 1082
FAILURE CODE [CA689] 1084
FAILURE CODE [CA691] 1086
FAILURE CODE [CA692] 1088
FAILURE CODE [CA697] 1090
FAILURE CODE [CA698] 1091
FAILURE CODE [CA731] 1092
FAILURE CODE [CA778] 1094
FAILURE CODE [CA1117] 1099
FAILURE CODE [CA1664] 1101
FAILURE CODE [CA1669] 1103
FAILURE CODE [CA1673] 1104
FAILURE CODE [CA1677] 1105
FAILURE CODE [CA1678] 1106
FAILURE CODE [CA1682] 1107
FAILURE CODE [CA1683] 1109
FAILURE CODE [CA1684] 1111
FAILURE CODE [CA1686] 1113
FAILURE CODE [CA1691] 1114
FAILURE CODE [CA1694] 1116
FAILURE CODE [CA1695] 1118
FAILURE CODE [CA1696] 1119
FAILURE CODE [CA1712] 1121
FAILURE CODE [CA1713] 1124
FAILURE CODE [CA1714] 1127
FAILURE CODE [CA1715] 1128
FAILURE CODE [CA1776] 1129
FAILURE CODE [CA1777] 1131
FAILURE CODE [CA1843] 1134
FAILURE CODE [CA1844] 1136
FAILURE CODE [CA1885] 1138
FAILURE CODE [CA1887] 1140
FAILURE CODE [CA1896] 1142
FAILURE CODE [CA1898] 1143
FAILURE CODE [CA1938] 1145
FAILURE CODE [CA1942] 1147
FAILURE CODE [CA1961] 1148
FAILURE CODE [CA1962] 1149
FAILURE CODE [CA2185] 1150
FAILURE CODE [CA2186] 1151
FAILURE CODE [CA2198] 1153
FAILURE CODE [CA2249] 1155
FAILURE CODE [CA2272] 1156
FAILURE CODE [CA2288] 1158
FAILURE CODE [CA2311] 1159
FAILURE CODE [CA2349] 1160
FAILURE CODE [CA2353] 1162
FAILURE CODE [CA2357] 1164
FAILURE CODE [CA2373] 1165
FAILURE CODE [CA2374] 1167
FAILURE CODE [CA2375] 1169
FAILURE CODE [CA2376] 1171
FAILURE CODE [CA2387] 1174
FAILURE CODE [CA2554] 1175
FAILURE CODE [CA2634] 1177
FAILURE CODE [CA2635] 1179
FAILURE CODE [CA2636] 1180
FAILURE CODE [CA2637] 1182
FAILURE CODE [CA2771] 1184
FAILURE CODE [CA2961] 1188
FAILURE CODE [CA2973] 1189
FAILURE CODE [CA2976] 1190
FAILURE CODE [CA3142] 1192
FAILURE CODE [CA3143] 1193
FAILURE CODE [CA3144] 1194
FAILURE CODE [CA3146] 1196
FAILURE CODE [CA3147] 1197
FAILURE CODE [CA3148] 1198
FAILURE CODE [CA3151] 1200
FAILURE CODE [CA3165] 1205
FAILURE CODE [CA3228] 1207
FAILURE CODE [CA3229] 1210
FAILURE CODE [CA3231] 1212
FAILURE CODE [CA3232] 1214
FAILURE CODE [CA3235] 1218
FAILURE CODE [CA3239] 1220
FAILURE CODE [CA3241] 1223
FAILURE CODE [CA3242] 1226
FAILURE CODE [CA3251] 1229
FAILURE CODE [CA3313] 1231
FAILURE CODE [CA3314] 1232
FAILURE CODE [CA3315] 1233
FAILURE CODE [CA3419] 1235
FAILURE CODE [CA3421] 1237
FAILURE CODE [CA3497] 1239
FAILURE CODE [CA3498] 1240
FAILURE CODE [CA3545] 1241
FAILURE CODE [CA3547] 1243
FAILURE CODE [CA3558] 1244
FAILURE CODE [CA3559] 1246
FAILURE CODE [CA3562] 1248
FAILURE CODE [CA3563] 1250
FAILURE CODE [CA3567] 1253
FAILURE CODE [CA3568] 1256
FAILURE CODE [CA3571] 1260
FAILURE CODE [CA3572] 1262
FAILURE CODE [CA3574] 1264
FAILURE CODE [CA3575] 1266
FAILURE CODE [CA3577] 1268
FAILURE CODE [CA3578] 1270
FAILURE CODE [CA3582] 1272
FAILURE CODE [CA3583] 1278
FAILURE CODE [CA3596] 1280
FAILURE CODE [CA3649] 1283
FAILURE CODE [CA3681] 1285
FAILURE CODE [CA3682] 1289
FAILURE CODE [CA3713] 1293
FAILURE CODE [CA3717] 1296
FAILURE CODE [CA3718] 1297
FAILURE CODE [CA3724] 1298
FAILURE CODE [CA3725] 1299
FAILURE CODE [CA3741] 1302
FAILURE CODE [CA3748] 1303
FAILURE CODE [CA3755] 1306
FAILURE CODE [CA3866] 1308
FAILURE CODE [CA3868] 1311
FAILURE CODE [CA4152] 1314
FAILURE CODE [CA4155] 1318
FAILURE CODE [CA4156] 1320
FAILURE CODE [CA4157] 1323
FAILURE CODE [CA4159] 1325
FAILURE CODE [CA4164] 1326
FAILURE CODE [CA4165] 1328
FAILURE CODE [CA4166] 1330
FAILURE CODE [CA4168] 1331
FAILURE CODE [CA4169] 1334
FAILURE CODE [CA4171] 1336
FAILURE CODE [CA4249] 1339
FAILURE CODE [CA4251] 1341
FAILURE CODE [CA4261] 1344
FAILURE CODE [CA4277] 1347
FAILURE CODE [CA4459] 1351
FAILURE CODE [CA4461] 1354
FAILURE CODE [CA4533] 1357
FAILURE CODE [CA4534] 1358
FAILURE CODE [CA4731] 1359
FAILURE CODE [CA4732] 1360
FAILURE CODE [CA4739] 1361
FAILURE CODE [CA4768] 1362
FAILURE CODE [CA4769] 1364
FAILURE CODE [CA4842] 1367
FAILURE CODE [CA4952] 1370
FAILURE CODE [CA5115] 1372
FAILURE CODE [CA5179] 1375
FAILURE CODE [CA5181] 1377
FAILURE CODE [CA5387] 1379
FAILURE CODE [CA5388] 1381
FAILURE CODE [CA5389] 1384
FAILURE CODE [CA5391] 1386
FAILURE CODE [CA5392] 1390
FAILURE CODE [CA5393] 1392
FAILURE CODE [CA5394] 1394
FAILURE CODE [CA5395] 1396
FAILURE CODE [CA5396] 1399
FAILURE CODE [CA5631] 1400
FAILURE CODE [CA5632] 1402
FAILURE CODE [CA5938] 1403
FAILURE CODE [D110KB] 1405
FAILURE CODE [D19JKZ] 1407
FAILURE CODE [D811MC] 1410
FAILURE CODE [D862KA] 1411
FAILURE CODE [D8ALKA] 1413
FAILURE CODE [D8ALKB] 1416
FAILURE CODE [D8AQKR] 1418
FAILURE CODE [D8G1KT] 1425
FAILURE CODE [D8G6KT] 1426
FAILURE CODE [DA20MC] 1427
FAILURE CODE [DA22KK] 1428
FAILURE CODE [DA25KP] 1431
FAILURE CODE [DA29KQ] 1434
FAILURE CODE [DA2LKA] 1436
FAILURE CODE [DA2LKB] 1439
FAILURE CODE [DA2QKR] 1441
FAILURE CODE [DA2RKR] 1450
FAILURE CODE [DAF0KM] 1455
FAILURE CODE [DAF0MB] 1456
FAILURE CODE [DAF0MC] 1457
FAILURE CODE [DAF8KB] 1458
FAILURE CODE [DAF9KQ] 1460
FAILURE CODE [DAFGMC] 1461
FAILURE CODE [DAFLKA] 1462
FAILURE CODE [DAFLKB] 1465
FAILURE CODE [DAFQKR] 1467
FAILURE CODE [DAZ9KQ] 1475
FAILURE CODE [DAZQKR] 1476
FAILURE CODE [DB2QKR] 1483
FAILURE CODE [DB2RKR] 1491
FAILURE CODE [DBP0KM] 1496
FAILURE CODE [DBP0KT] 1497
FAILURE CODE [DBP5KB] 1498
FAILURE CODE [DBP5KY] 1501
FAILURE CODE [DBPQKR] 1504
FAILURE CODE [DDNRKA] 1512
FAILURE CODE [DDNRKY] 1514
FAILURE CODE [DDNS00] 1516
FAILURE CODE [DFB1KZ] 1518
FAILURE CODE [DFB2KZ] 1520
FAILURE CODE [DFB3L8] 1522
FAILURE CODE [DFB4L8] 1524
FAILURE CODE [DFB5KZ] 1526
FAILURE CODE [DFB6KZ] 1528
FAILURE CODE [DGH2KA] 1530
FAILURE CODE [DGH2KB] 1532
FAILURE CODE [DHA4KA] 1534
FAILURE CODE [DHPAMA] 1536
FAILURE CODE [DHPBMA] 1539
FAILURE CODE [DHS3MA] 1542
FAILURE CODE [DHS4MA] 1545
FAILURE CODE [DHS5MA] 1548
FAILURE CODE [DHS8MA] 1551
FAILURE CODE [DHS9MA] 1554
FAILURE CODE [DHSAMA] 1557
FAILURE CODE [DHSBMA] 1560
FAILURE CODE [DHSCMA] 1563
FAILURE CODE [DHSDMA] 1566
FAILURE CODE [DHX1MA] 1569
FAILURE CODE [DKR0MA] 1571
FAILURE CODE [DKULKA] 1574
FAILURE CODE [DKULKB] 1576
FAILURE CODE [DKULKY] 1578
FAILURE CODE [DLM5KA] 1580
FAILURE CODE [DLM5MB] 1582
FAILURE CODE [DR10KA] 1584
FAILURE CODE [DR12KA] 1587
FAILURE CODE [DR20KA] 1589
FAILURE CODE [DR21KX] 1591
FAILURE CODE [DR30KA] 1593
FAILURE CODE [DR31KX] 1595
FAILURE CODE [DR40KA] 1597
FAILURE CODE [DUMBKA] 1599
FAILURE CODE [DUMBKB] 1602
FAILURE CODE [DV20KB] 1604
FAILURE CODE [DW43KA] 1606
FAILURE CODE [DW43KB] 1608
FAILURE CODE [DW43KY] 1610
FAILURE CODE [DW45KA] 1612
FAILURE CODE [DW45KB] 1615
FAILURE CODE [DW45KY] 1618
FAILURE CODE [DW4CKY] 1620
FAILURE CODE [DW91KA] 1622
FAILURE CODE [DW91KB] 1624
FAILURE CODE [DW91KY] 1626
FAILURE CODE [DWA2KA] 1628
FAILURE CODE [DWA2KB] 1630
FAILURE CODE [DWA2KY] 1632
FAILURE CODE [DWJ0KA] 1634
FAILURE CODE [DWJ0KB] 1636
FAILURE CODE [DWJ0KY] 1638
FAILURE CODE [DWK0KA] 1640
FAILURE CODE [DWK0KB] 1642
FAILURE CODE [DWK0KY] 1644
FAILURE CODE [DWK2KA] 1646
FAILURE CODE [DWK2KB] 1648
FAILURE CODE [DWK2KY] 1650
FAILURE CODE [DWN5KA] 1652
FAILURE CODE [DWN5KB] 1654
FAILURE CODE [DWN5KY] 1656
FAILURE CODE [DWNSKA] 1658
FAILURE CODE [DWNSKB] 1660
FAILURE CODE [DWNSKY] 1662
FAILURE CODE [DXA8KA] 1663
FAILURE CODE [DXA8KB] 1665
FAILURE CODE [DXE4KA] 1667
FAILURE CODE [DXE4KB] 1669
FAILURE CODE [DXE4KY] 1671
FAILURE CODE [DXE7KA] 1673
FAILURE CODE [DXE7KB] 1675
FAILURE CODE [DXE7KY] 1677
FAILURE CODE [DXE8KA] 1679
FAILURE CODE [DXE8KB] 1681
FAILURE CODE [DXE8KY] 1683
FAILURE CODE [DXE9KA] 1685
FAILURE CODE [DXE9KB] 1687
FAILURE CODE [DXE9KY] 1689
FAILURE CODE [DXEAKA] 1691
FAILURE CODE [DXEAKB] 1693
FAILURE CODE [DXEAKY] 1695
FAILURE CODE [DY20KA] 1697
FAILURE CODE [DY20MA] 1699
FAILURE CODE [DY2CKB] 1701
FAILURE CODE [DY2DKB] 1704
FAILURE CODE [DY2EKB] 1706
FAILURE CODE [F311KA] 1708
FAILURE CODE [F311KB] 1710
FAILURE CODE [F312KA] 1712
FAILURE CODE [F312KB] 1714
FAILURE CODE [F313KA] 1716
FAILURE CODE [F313KB] 1718
FAILURE CODE [F314KA] 1721
FAILURE CODE [F314KB] 1723
FAILURE CODE [F315KB] 1725
FAILURE CODE [F315KY] 1727
FAILURE CODE [F316KB] 1729
FAILURE CODE [F316KY] 1731
FAILURE CODE [F318KB] 1733
FAILURE CODE [F318KY] 1736
FAILURE CODE [F31AKB] 1738
FAILURE CODE [F31AKY] 1740
FAILURE CODE [F31BKB] 1742
FAILURE CODE [F31BKY] 1744
FAILURE CODE [F31CKB] 1746
FAILURE CODE [F31CKY] 1748
FAILURE CODE [F31DKB] 1750
FAILURE CODE [F31DKY] 1752
FAILURE CODE [F31EKB] 1754
FAILURE CODE [F31EKY] 1756
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1758
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1758
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1764
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1767
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1769
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1771
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1774
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1775
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1776
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1777
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1778
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1779
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1780
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1781
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1782
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1783
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1784
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1785
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 1787
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1788
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1789
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1790
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 1792
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 1793
E-24 FUNCTION SWITCH DOES NOT OPERATE 1794
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 1795
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1796
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1797
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 1798
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1799
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 1800
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1801
E-32 ALARM BUZZER CANNOT BE CANCELED 1803
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 1804
E-34 SERVICE MODE CANNOT BE SELECTED 1805
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1806
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 1809
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 1811
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 1814
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 1816
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 1819
E-41 ALARM DOES NOT SOUND DURING TRAVEL 1820
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1822
E-43 HORN DOES NOT SOUND 1823
E-44 HORN DOES NOT STOP SOUNDING 1826
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 1828
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 1829
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1831
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1832
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1833
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1834
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1835
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1836
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1837
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1838
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1839
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1840
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED 1842
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1843
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1844
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1844
FAILURE MODE AND CAUSE TABLE 1845
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1855
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 1856
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1858
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 1859
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1860
H-6 SPEED OR POWER OF BOOM IS LOW 1862
H-7 ARM SPEED OR POWER IS LOW 1865
H-8 BUCKET SPEED OR POWER IS LOW 1869
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1871
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE 1872
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1873
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE 1875
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 1876
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1877
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 1878
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED 1879
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 1880
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1881
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1882
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1883
H-21 MACHINE DOES NOT TRAVEL STRAIGHT 1884
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 1887
H-23 TRAVEL SPEED IS LOW 1889
H-24 ONE OF TRACKS DOES NOT RUN 1891
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1892
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1893
H-27 SWINGS ONLY IN ONE DIRECTION 1894
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 1895
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1896
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1897
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1898
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 1899
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 1900
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 1901
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1902
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 1903
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN 1904
H-38 Quick coupler cylinder will not extend 1905
H-39 Quick coupler cylinder will not retract (but buzzer doesnot sound) 1907
H-40 Buzzer does not sound (but quick coupler cylinder doesretract) 1909
H-41 Quick coupler cylinder extends and retracts slowly 1910
TROUBLESHOOTING OF ENGINE (S-MODE) 1911
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1911
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1912
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1913
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1914
S-4 ENGINE STARTABILITY IS POOR 1916
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1918
S-6 ENGINE STOPS DURING OPERATION 1920
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1922
S-8 ENGINE LACKS POWER 1923
S-9 EXHAUST SMOKE IS BLACK 1925
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1927
S-11 OIL BECOMES CONTAMINATED QUICKLY 1928
S-12 FUEL CONSUMPTION IS EXCESSIVE 1929
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1930
S-14 OIL PRESSURE DROPS 1931
S-15 FUEL MIXES INTO ENGINE OIL 1933
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1934
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 1935
S-18 UNUSUAL NOISE IS HEARD 1936
S-19 VIBRATION IS EXCESSIVE 1937
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 1938
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 1939
S-22 ACTIVE REGENERATION TAKES TIME 1940
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1941
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1942
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 1944
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1945
50 DISASSEMBLY AND ASSEMBLY 1947
CONTENTS 1948
ABBREVIATION LIST 1953
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1959
HOW TO READ THIS MANUAL 1959
COATING MATERIALS LIST 1961
SPECIAL TOOLS LIST 1965
SKETCHES OF SPECIAL TOOLS 1979
ENGINE AND COOLING SYSTEM 1987
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1987
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1987
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1991
REMOVE AND INSTALL INJECTOR ASSEMBLY 1995
METHOD FOR REMOVING INJECTOR ASSEMBLY 1995
METHOD FOR INSTALLING INJECTOR ASSEMBLY 1998
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2004
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2004
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2014
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2031
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2031
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2032
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2034
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2034
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2036
REMOVE AND INSTALL STARTER ASSEMBLY 2039
METHOD FOR REMOVING STARTER ASSEMBLY 2039
METHOD FOR INSTALLING STARTER ASSEMBLY 2041
REMOVE AND INSTALL ALTERNATOR BELT 2044
METHOD FOR REMOVING ALTERNATOR BELT 2044
METHOD FOR INSTALLING ALTERNATOR BELT 2046
REMOVE AND INSTALL RADIATOR ASSEMBLY 2049
METHOD FOR REMOVING RADIATOR ASSEMBLY 2049
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2053
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2057
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2057
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2061
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2065
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2065
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2067
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2070
REMOVE FAN CLUTCH ASSEMBLY 2070
INSTALL FAN CLUTCH ASSEMBLY 2074
REMOVE AND INSTALL FAN 2078
METHOD FOR INSTALLING FAN 2078
METHOD FOR REMOVING FAN 2078
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2079
REMOVE ENGINE AND MAIN PUMP ASSEMBLY 2079
INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2095
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2112
REMOVE ENGINE FRONT OIL SEAL 2112
INSTALL ENGINE FRONT OIL SEAL 2116
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2122
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2122
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2123
REMOVE AND INSTALL FUEL COOLER ASSEMBLY 2126
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2126
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2128
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2131
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2131
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2133
REMOVE AND INSTALL KDOC ASSEMBLY 2139
METHOD FOR REMOVING KDOC ASSEMBLY 2139
METHOD FOR INSTALLING KDOC ASSEMBLY 2142
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY 2145
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY 2145
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY 2152
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 2159
REMOVE BELLOWS PIPE ASSEMBLY 2159
INSTALL BELLOWS PIPE ASSEMBLY 2161
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2166
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2166
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2171
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2177
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2177
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2185
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2191
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2191
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2192
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2194
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2194
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2195
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2197
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2197
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2197
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2198
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2198
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2200
REMOVE AND INSTALL SCR ASSEMBLY 2203
METHOD FOR REMOVING SCR ASSEMBLY 2203
METHOD FOR INSTALLING SCR ASSEMBLY 2205
REMOVE AND INSTALL KCCV ASSEMBLY 2207
METHOD FOR REMOVING KCCV ASSEMBLY 2207
METHOD FOR INSTALLING KCCV ASSEMBLY 2208
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2210
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2210
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2217
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2223
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2223
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2226
REMOVE AND INSTALL AdBlue/DEF PUMP 2229
METHOD FOR REMOVING AdBlue/DEF PUMP 2229
METHOD FOR INSTALLING AdBlue/DEF PUMP 2232
REMOVE AND INSTALL AdBlue/DEF HOSE 2235
METHOD FOR REMOVING AdBlue/DEF HOSE 2235
METHOD FOR INSTALLING AdBlue/DEF HOSE 2245
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2255
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2255
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2256
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2259
REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY 2259
INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2261
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2264
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2264
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2265
POWER TRAIN 2267
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2267
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2267
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2268
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2269
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2270
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2273
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2281
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2281
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2283
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2286
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 2286
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2290
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2297
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 2297
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 2297
UNDERCARRIAGE AND FRAME 2299
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2299
METHOD FOR SEPARATING TRACK ASSEMBLY 2299
METHOD FOR INSTALLING TRACK ASSEMBLY 2300
REMOVE AND INSTALL SPROCKET 2303
METHOD FOR REMOVING SPROCKET 2303
METHOD FOR INSTALLING SPROCKET 2304
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2305
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2305
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2306
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2307
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2307
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2308
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2312
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 2312
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2313
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2315
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2315
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2316
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 2319
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2319
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2321
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2323
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2323
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2326
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2329
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2329
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2330
HYDRAULIC SYSTEM 2333
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2333
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2333
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2336
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2339
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2339
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2340
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2342
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2342
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2349
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 2357
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2357
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2359
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2362
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2362
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2365
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 2369
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2369
METHOD FOR REPLACING PRESSURE REDUCING VALVE CARTRIDGE ASSEMBLY 2371
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2374
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2374
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2375
WORK EQUIPMENT 2377
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2377
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2377
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2380
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 2384
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM 2384
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM 2386
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM 2387
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM 2387
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM 2389
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY 2390
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY 2390
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY 2390
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2391
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2392
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2394
CAB AND ITS ATTACHMENTS 2400
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2400
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY 2400
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY 2407
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 2415
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2417
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2417
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2427
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 2427
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 2430
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 2436
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2436
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2440
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2445
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2445
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2449
REMOVE AND INSTALL OPERATOR’S SEAT 2455
METHOD FOR REMOVING OPERATOR’S SEAT 2455
METHOD FOR INSTALLING OPERATOR’S SEAT 2457
REMOVE AND INSTALL SEAT BELT 2460
METHOD FOR REMOVING SEAT BELT 2460
METHOD FOR INSTALLING SEAT BELT 2460
REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY 2462
REMOVE WORK EQUIPMENT CONTROL LEVER ASSEMBLY 2462
INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY 2468
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 2477
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2477
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2482
ELECTRICAL SYSTEM 2491
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2491
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2491
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2493
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 2496
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2496
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2499
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2502
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY 2502
METHOD FOR INSTALLING KomVision CONTROLLER 2503
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2505
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2505
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2507
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2511
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR 2511
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR 2511
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2513
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2513
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2514
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2516
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2516
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2517
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2519
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2519
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2520
REMOVE AND INSTALL KomVision CAMERA 2522
METHOD FOR REMOVING KomVision CAMERA 2522
METHOD FOR INSTALLING KomVision CAMERA 2523
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2525
METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2525
METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2530
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2535
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS 2535
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS 2543
REMOVE AND INSTALL COMMUNICATION TERMINAL 2552
METHOD FOR REMOVING COMMUNICATION TERMINAL 2552
METHOD FOR INSTALLING COMMUNICATION TERMINAL 2554
60 MAINTENANCE STANDARD 2557
CONTENTS 2558
ABBREVIATION LIST 2559
ENGINE AND COOLING SYSTEM 2565
MAINTENANCE STANDARD OF ENGINE MOUNT 2565
MAINTENANCE STANDARD OF COOLING SYSTEM 2566
POWER TRAIN 2568
MAINTENANCE STANDARD OF SWING CIRCLE 2568
MAINTENANCE STANDARD OF SWING MACHINERY 2569
MAINTENANCE STANDARD OF FINAL DRIVE 2571
MAINTENANCE STANDARD OF SPROCKET 2573
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 2574
UNDERCARRIAGE AND FRAME 2576
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2576
MAINTENANCE STANDARD OF IDLER 2578
MAINTENANCE STANDARD OF TRACK ROLLER 2580
MAINTENANCE STANDARD OF CARRIER ROLLER 2581
MAINTENANCE STANDARD OF TRACK SHOE 2582
MAINTENANCE STANDARD OF TRIPLE SHOE 2585
HYDRAULIC SYSTEM 2586
MAINTENANCE STANDARD OF HYDRAULIC TANK 2586
MAINTENANCE STANDARD OF MAIN PUMP 2587
MAINTENANCE STANDARD OF PC-EPC VALVE 2589
MAINTENANCE STANDARD OF TRAVEL MOTOR 2590
MAINTENANCE STANDARD OF CONTROL VALVE 2593
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2604
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM 2606
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2608
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2611
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2614
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2616
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE 2617
MAINTENANCE STANDARD OF SOLENOID VALVE 2619
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 2620
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2621
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 2622
WORK EQUIPMENT 2623
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2623
DIMENSION OF ARM 2628
DIMENSIONS OF BUCKET 2630
MAINTENANCE STANDARD OF BOOM CYLINDER 2632
MAINTENANCE STANDARD OF ARM CYLINDER 2633
MAINTENANCE STANDARD OF BUCKET CYLINDER 2634
80 APPENDIX 2635
CONTENTS 2636
ABBREVIATION LIST 2638
AIR CONDITIONER SYSTEM 2644
PRECAUTIONS FOR REFRIGERANT 2644
AIR CONDITIONER COMPONENT 2645
SPECIFICATIONS OF AIR CONDITIONER 2647
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2648
OUTLINE OF REFRIGERATION CYCLE 2649
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2651
AIR CONDITIONER UNIT 2651
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2651
FUNCTION OF AIR CONDITIONER UNIT 2653
COMPONENT PARTS OF AIR CONDITIONER UNIT 2655
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2656
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2656
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2656
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 2656
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2657
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2657
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2657
FUNCTION OF DUAL PRESSURE SWITCH 2658
AIR CONDITIONER CONTROLLER 2659
STRUCTURE OF AIR CONDITIONER CONTROLLER 2659
COMPRESSOR 2660
STRUCTURE OF COMPRESSOR 2660
SPECIFICATIONS OF COMPRESSOR 2660
FUNCTION OF COMPRESSOR 2660
CONDENSER 2661
STRUCTURE OF CONDENSER 2661
SPECIFICATIONS OF CONDENSER 2661
FUNCTION OF CONDENSER 2661
SENSORS FOR AIR CONDITIONER SYSTEM 2663
STRUCTURE OF SUNLIGHT SENSOR 2663
FUNCTION OF SUNLIGHT SENSOR 2663
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 2663
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2663
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2665
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2667
AIR CONDITIONER SYSTEM DIAGRAM 2669
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2670
FUNCTION OF AIR CONDITIONER CONTROLLER 2671
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2672
TESTING AIR LEAKAGE (DUCT) 2676
METHOD FOR TESTING AIR LEAKAGE (DUCT) 2676
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2678
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2679
TEST VENT (MODE) CHANGEOVER 2680
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2680
TESTING FRESH/RECIRC AIR CHANGEOVER 2682
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2682
TEST SUNLIGHT SENSOR 2683
METHOD FOR TESTING SUNLIGHT SENSOR 2683
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2684
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2684
TEST RELAYS 2685
METHOD FOR TESTING RELAYS 2685
AIR CONDITIONER TROUBLESHOOTING CHART 1 2686
AIR CONDITIONER TROUBLESHOOTING CHART 2 2687
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2690
FAILURE CODE [879AKA] 2692
FAILURE CODE [879AKB] 2693
FAILURE CODE [879BKA] 2694
FAILURE CODE [879BKB] 2696
FAILURE CODE [879CKA] 2698
FAILURE CODE [879CKB] 2699
FAILURE CODE [879DKZ] 2700
FAILURE CODE [879EMC] 2702
FAILURE CODE [879FMC] 2703
FAILURE CODE [879GKX] 2704
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2706
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2708
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2711
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 2713
TROUBLESHOOTING USING GAUGE PRESSURE 2715
CONNECTION OF SERVICE TOOL 2718
METHOD FOR CONNECTING SERVICE TOOL 2718
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2720
HANDLE COMPRESSOR OIL 2722
METHOD FOR REPLACING DESICCANT 2724
90 CIRCUIT DIAGRAMS 2727
CONTENTS 2728
ABBREVIATION LIST 2729
HYDRAULIC CIRCUIT DIAGRAM 2735
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2735
HYDRAULIC CIRCUIT DIAGRAM (1/2) 2739
HYDRAULIC CIRCUIT DIAGRAM (2/2) 2741
ELECTRICAL CIRCUIT DIAGRAM 2743
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2743
ELECTRICAL CIRCUIT DIAGRAM (1/9) 2747
ELECTRICAL CIRCUIT DIAGRAM (2/9) 2749
ELECTRICAL CIRCUIT DIAGRAM (3/9) 2751
ELECTRICAL CIRCUIT DIAGRAM (4/9) 2753
ELECTRICAL CIRCUIT DIAGRAM (5/9) 2755
ELECTRICAL CIRCUIT DIAGRAM (6/9) 2757
ELECTRICAL CIRCUIT DIAGRAM (7/9) 2759
ELECTRICAL CIRCUIT DIAGRAM (8/9) 2761
ELECTRICAL CIRCUIT DIAGRAM (9/9) 2763
INDEX 2765
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