Komatsu PC210LCi-11 Hydraulic Excavator Shop Manual SEN06882-02 – PDF DOWNLOAD

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Komatsu PC210LCi-11 Hydraulic Excavator Shop Manual SEN06882-02 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu PC210LCi-11 Hydraulic Excavator Shop Manual SEN06882-02 – PDF DOWNLOAD

SERIAL NUMBERS 505280 and up

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

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TABLE OF CONTENTS:

Komatsu PC210LCi-11 Hydraulic Excavator Shop Manual SEN06882-02 – PDF DOWNLOAD

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 26
FOREWORD, SAFETY, BASIC INFORMATION 29
HOW TO READ THE SHOP MANUAL 29
SAFETY NOTICE FOR OPERATION 31
PRECAUTIONS TO PREVENT FIRE 39
ACTIONS IF FIRE OCCURS 41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 42
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION 43
PRECAUTIONS FOR DEF 44
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 44
PRECAUTIONS FOR ADDING 44
PRECAUTIONS FOR STORING 44
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 44
THE OTHER PRECAUTIONS 44
STORE AdBlue/DEF 45
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 46
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS 49
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
SPECIFICATIONS 97
SPECIFICATION DRAWING 97
SPECIFICATION DRAWING: PC210LCI-11 97
WORKING RANGE DRAWINGS 99
WORKING RANGE: PC210LCI-11 99
SPECIFICATIONS 100
SPECIFICATIONS: PC210LCI-11 100
WEIGHT TABLE 103
WEIGHT TABLE: PC210LCI-11 103
TABLE OF FUEL, COOLANT, AND LUBRICANTS 105
10 STRUCTURE AND FUNCTION 107
CONTENTS 108
NOx CONTROL SYSTEM 112
FUNCTION OF NOx CONTROL SYSTEM 112
UREA SCR SYSTEM 113
LAYOUT DRAWING OF UREA SCR SYSTEM 114
UREA SCR SYSTEM DIAGRAM 119
FUNCTION OF UREA SCR SYSTEM 120
FUNCTION OF AdBlue/DEF SYSTEM 120
INDUCEMENT STRATEGY 122
COMPONENT PARTS OF UREA SCR SYSTEM 130
AdBlue/DEF MIXING TUBE 130
SCR ASSEMBLY 130
AdBlue/DEF TANK 133
AdBlue/DEF PUMP 135
AdBlue/DEF INJECTOR 136
AdBlue/DEF HOSE 137
AdBlue/DEF TANK HEATING VALVE 138
BOOT-UP SYSTEM 139
LAYOUT DRAWING OF BOOT-UP SYSTEM 139
SYSTEM OPERATING LAMP SYSTEM 141
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 141
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 141
BATTERY DISCONNECT SWITCH 143
FUNCTION OF BATTERY DISCONNECT SWITCH 143
ENGINE SYSTEM 144
LAYOUT DRAWING OF ENGINE SYSTEM 144
SPECIFICATIONS OF ENGINE SYSTEM 145
FUNCTION OF ENGINE SYSTEM 145
ENGINE CONTROL SYSTEM 146
ENGINE CONTROL SYSTEM DIAGRAM 146
FUNCTION OF ENGINE CONTROL SYSTEM 147
AUTO-DECELERATION SYSTEM 149
AUTO-DECELERATION SYSTEM DIAGRAM 149
FUNCTION OF AUTO-DECELERATION SYSTEM 149
OPERATION OF AUTO-DECELERATION SYSTEM 150
ENGINE AUTOMATIC WARM-UP SYSTEM 151
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 151
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 152
OVERHEAT PREVENTION SYSTEM 153
OVERHEAT PREVENTION SYSTEM DIAGRAM 153
FUNCTION OF OVERHEAT PREVENTION SYSTEM 154
TURBOCHARGER PROTECTION SYSTEM 156
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 156
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 157
AUTOMATIC IDLE STOP SYSTEM 158
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 158
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 158
COMPONENT PARTS OF ENGINE SYSTEM 161
VGT 161
EGR SYSTEM 165
EGR VALVE 167
EGR COOLER 169
KCCV SYSTEM 170
KCCV VENTILATOR 172
KDPF 174
COOLING SYSTEM 179
LAYOUT DRAWING OF COOLING SYSTEM 179
SPECIFICATIONS OF COOLING SYSTEM 180
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 181
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 181
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 182
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 183
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 183
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 183
COMPONENT PARTS OF COOLING SYSTEM 185
FAN CLUTCH 185
CONTROL SYSTEM 186
LAYOUT DRAWING OF CONTROL SYSTEM PARTS 186
MACHINE MONITOR SYSTEM 189
MACHINE MONITOR SYSTEM DIAGRAM 189
FUNCTION OF MACHINE MONITOR SYSTEM 189
KomVision SYSTEM 191
LAYOUT DRAWING OF KOMVISION SYSTEM 191
KomVision SYSTEM DIAGRAM 193
FUNCTION OF KomVision SYSTEM 193
KOMTRAX SYSTEM 195
KOMTRAX SYSTEM DIAGRAM 195
FUNCTION OF KOMTRAX SYSTEM 195
PPC LEVERS 196
LH PPC LEVER 196
RH PPC LEVER 197
AUTOMATIC GREASE SYSTEM 198
OUTLINE OF AUTO GREASE SYSTEM 198
COMPONENT PARTS OF CONTROL SYSTEM 210
MACHINE MONITOR 210
KomVision CONTROLLER 224
KomVision CAMERA 228
GATEWAY FUNCTION CONTROLLER 229
COMMUNICATION TERMINAL 232
PUMP CONTROLLER 234
RESISTOR FOR PC-EPC VALVE 238
CAN TERMINATING RESISTOR 238
ENGINE CONTROLLER 240
FUEL CONTROL DIAL 246
FUEL FEED PUMP 248
FUEL FEED PUMP SWITCH 249
HYDRAULIC SYSTEM 250
LAYOUT DRAWING OF HYDRAULIC SYSTEM 250
CLSS 256
STRUCTURE OF CLSS 256
OPERATION OF UNLOAD VALVE AND LS PRESSURE 258
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 259
PRESSURE COMPENSATION CONTROL 275
ENGINE AND PUMP COMBINED CONTROL SYSTEM 279
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 279
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 280
PUMP AND VALVE CONTROL SYSTEM 285
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 285
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 286
COMPONENT PARTS OF HYDRAULIC SYSTEM 288
HYDRAULIC TANK 288
MAIN PUMP 290
CONTROL VALVE 312
WORK EQUIPMENT SYSTEM 367
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 367
STRUCTURE OF VALVE CONTROL 372
BUCKET CONTROL SYSTEM 374
OPERATION OF BUCKET CONTROL SYSTEM 374
ONE-TOUCH POWER MAXIMIZING SYSTEM 375
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 375
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 376
PPC LOCK SYSTEM 377
PPC LOCK SYSTEM DIAGRAM 377
FUNCTION OF PPC LOCK SYSTEM 377
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 378
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 378
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 378
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 379
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 380
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 380
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 381
TOOL CONTROL SYSTEM 382
TOOL CONTROL SYSTEM DIAGRAM 382
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 384
WORK EQUIPMENT AND SWING PPC VALVE 384
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 390
2ND-LINE ATTACHMENT PPC VALVE 396
SOLENOID VALVE 398
ANTI-DROP VALVE FOR BOOM 401
ANTI-DROP VALVE FOR ARM 405
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 409
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 411
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE 414
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE 416
ATTACHMENT BYPASS SOLENOID VALVE 419
PILOT CIRCUIT ACCUMULATOR 421
ATTACHMENT CIRCUIT ACCUMULATOR 422
ICT SYSTEM 423
LAYOUT DRAWING OF ICT SYSTEM 423
ICT CONTROL SYSTEM DIAGRAM 426
BUCKET EDGE POSITION DETECTION SYSTEM 427
BUCKET EDGE POSITION DETECTION SYSTEM DIAGRAM 427
FUNCTION OF BUCKET EDGE POSITION DETECTION SYSTEM 427
OPERATION OF BUCKET EDGE POSITION DETECTION SYSTEM 427
THE INTELLIGENT MACHINE CONTROL SYSTEM 429
FUNCTION OF INTELLIGENT MACHINE CONTROL SYSTEM 429
AUTO GRADE ASSIST CONTROL 430
BUCKET ANGLE HOLD CONTROL 436
AUTO STOP CONTROL 438
TILT AUTOMATIC CONTROL (MACHINES WITH AUTO TILT BUCKET) 452
CUSHION SYSTEM FOR ARM IN END 455
CUSHION SYSTEM FOR ARM IN END DIAGRAM 455
FUNCTION OF CUSHION SYSTEM FOR ARM IN END 455
OPERATION OF CUSHION SYSTEM FOR ARM IN END 455
BOOM SECONDARY DRIVE SWITCH 457
CONTROL FUNCTION WHEN BOOM SECONDARY DRIVE SWITCH IS TURNED TO ON POSITION 457
COMPONENT PARTS OF ICT SYSTEM 458
ICT SENSOR CONTROLLER 458
WORK EQUIPMENT CONTROLLER 462
CONTROL BOX 466
GNSS RECEIVER 469
GNSS ANTENNA 470
IMU SENSOR 471
INTELLIGENT MACHINE CONTROL EPC VALVE 473
STROKE SENSOR FOR BOOM CYLINDER 476
STROKE SENSOR FOR ARM CYLINDER 477
STROKE AND RESET SENSOR FOR BUCKET CYLINDER 479
RESET SENSOR FOR BOOM CYLINDER 481
RESET SENSOR FOR ARM CYLINDER 482
BOOM SPOOL STROKE SENSOR 483
ARM SPOOL STROKE SENSOR 484
SWING SYSTEM 486
LAYOUT DRAWING OF SWING SYSTEM 486
SWING CONTROL SYSTEM DIAGRAM 489
FUNCTION OF SWING CONTROL SYSTEM 489
COMPONENT PARTS OF SWING SYSTEM 493
SWING MOTOR 493
SWING MACHINERY 505
SWING CIRCLE 506
TRAVEL SYSTEM 508
LAYOUT DRAWING OF TRAVEL SYSTEM 508
TRAVEL CONTROL SYSTEM DIAGRAM 512
FUNCTION OF TRAVEL CONTROL SYSTEM 512
COMPONENT PARTS OF TRAVEL SYSTEM 514
TRAVEL MOTOR 514
FINAL DRIVE 526
TRAVEL PPC VALVE 528
CENTER SWIVEL JOINT 533
UNDERCARRIAGE AND FRAME 535
LAYOUT DRAWING OF UNDERCARRIAGE 535
SPECIFICATIONS OF UNDERCARRIAGE 536
WORK EQUIPMENT 537
STRUCTURE OF WORK EQUIPMENT 537
FUNCTION OF WORK EQUIPMENT 538
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 539
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 539
BUCKET CLEARANCE ADJUSTMENT SHIM 540
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 540
CAB AND ITS ATTACHMENTS 541
ROPS CAB 541
STRUCTURE OF ROPS CAB 541
FUNCTION OF ROPS CAB 541
CAB MOUNT 542
STRUCTURE OF CAB MOUNT 542
FUNCTION OF CAB MOUNT 542
CAB TIPPING STOPPER 543
STRUCTURE OF CAB TIPPING STOPPER 543
FUNCTION OF CAB TIPPING STOPPER 543
20 STANDARD VALUE TABLE 545
CONTENTS 546
STANDARD VALUE TABLE FOR ENGINE 547
STANDARD VALUE TABLE FOR ENGINE:PC210LCI-11 547
STANDARD VALUE TABLE FOR MACHINE 551
STANDARD VALUE TABLE FOR MACHINE:PC210LCI-11 551
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 574
30 TESTING AND ADJUSTING 579
CONTENTS 580
RELATED INFORMATION ON TESTING AND ADJUSTING 584
TOOLS FOR TESTING AND ADJUSTING 584
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 594
ENGINE AND COOLING SYSTEM 596
TEST ENGINE SPEED 596
METHOD FOR TESTING ENGINE SPEED 596
TEST BOOST PRESSURE 599
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 599
METHOD FOR TESTING BOOST PRESSURE 600
TEST EXHAUST GAS COLOR 601
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 601
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 602
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 604
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 604
TEST AND ADJUST VALVE CLEARANCE 606
METHOD FOR TESTING VALVE CLEARANCE 606
METHOD FOR ADJUSTING VALVE CLEARANCE 607
TEST COMPRESSION PRESSURE 609
METHOD FOR TESTING COMPRESSION PRESSURE 609
TEST BLOWBY PRESSURE 614
METHOD FOR TESTING BLOWBY PRESSURE 614
TEST ENGINE OIL PRESSURE 616
METHOD FOR TESTING ENGINE OIL PRESSURE 616
TEST EGR VALVE AND VGT OIL PRESSURE 617
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 617
TEST FUEL PRESSURE 619
METHOD FOR TESTING FUEL PRESSURE 620
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 625
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 626
BLEEDING AIR FROM FUEL SYSTEM 632
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 632
TEST FUEL CIRCUIT FOR LEAKAGE 633
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 633
HANDLE CYLINDER CUT-OUT MODE OPERATION 635
HANDLE NO-INJECTION CRANKING OPERATION 636
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 637
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 637
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 637
TEST COOLING FAN SPEED 639
METHOD FOR TESTING COOLING FAN SPEED 639
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 640
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 640
TEST SCR RELATED FUNCTIONS 641
TEST AdBlue/DEF PUMP RAISED PRESSURE 644
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 647
TEST AdBlue/DEF LINE HEATER RELAY 1 651
TEST AdBlue/DEF LINE HEATER RELAY 2 654
TEST AdBlue/DEF PUMP HEATER RELAY 656
TEST AdBlue/DEF TANK HEATER VALVE 659
TEST DENITRATION EFFICIENCY OF SCR 662
CLEAN AdBlue/DEF TANK 666
METHOD FOR CLEANING AdBlue/DEF TANK 666
CLEAN AdBlue/DEF PUMP 670
METHOD FOR CLEAN AdBlue/DEF PUMP 670
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 677
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 677
POWER TRAIN 679
TEST SWING CIRCLE BEARING CLEARANCE 679
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 679
UNDERCARRIAGE AND FRAME 680
TEST AND ADJUST TRACK TENSION 680
METHOD FOR TESTING TRACK TENSION 680
METHOD FOR ADJUSTING TRACK TENSION 680
HYDRAULIC SYSTEM 682
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 682
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 682
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 682
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 686
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 687
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 688
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 689
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 695
TEST OIL PRESSURE OF CONTROL CIRCUIT 698
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 698
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 700
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 700
TEST PC-EPC VALVE OUTLET PRESSURE 701
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 702
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 704
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 704
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL 705
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 708
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 709
METHOD FOR ADJUSTING LS VALVE 710
TEST OUTLET PRESSURE OF SOLENOID VALVE 711
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 711
OPERATING CONDITION OF SOLENOID VALVE 712
TEST PPC VALVE OUTLET PRESSURE 715
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 715
TEST ATTACHMENT CIRCUIT OIL PRESSURE 717
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 717
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 718
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 718
TEST PUMP SWASH PLATE SENSOR 719
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 719
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 720
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 720
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 720
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 721
TEST OIL LEAKAGE 722
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 722
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 722
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 723
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 724
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 724
BLEED AIR FROM HYDRAULIC CIRCUIT 725
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 727
WORK EQUIPMENT 729
TEST AND CHARGE ACCUMULATOR (MANUFACTURED BY NOK) NITROGEN GAS PRESSURE FOR ATTACHMENT (LOW PRESSURE SIDE) 729
TEST ACCUMULATOR (MANUFACTURED BY NOK) NITROGEN GAS PRESSURE FOR ATTACHMENT (LOW PRESSURE SIDE) 729
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH PRESSURE SIDE) 733
TEST ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH PRESSURE SIDE) 733
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ATTACHMENT PIPING 737
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ATTACHMENT PIPING 737
CAB AND ITS ATTACHMENTS 744
TEST CAB TIPPING STOPPER 744
METHOD FOR TESTING CAB TIPPING STOPPER 744
METHOD FOR ADJUSTING MIRRORS 745
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 745
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 746
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 747
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 748
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 749
ELECTRICAL SYSTEM 751
SET AND OPERATE MACHINE MONITOR 751
OPERATOR MODE 755
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 755
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 755
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 756
CHECKING FUNCTION OF SERVICE METER 757
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 757
SERVICE MODE 759
OPERATE SERVICE MODE 759
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 763
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 770
ABNORMALITY RECORD MENU 783
METHOD FOR CONFIRMING MAINTENANCE RECORD 788
METHOD FOR OPERATING MAINTENANCE MODE SETTING 789
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 793
DEFAULT MENU 794
DIAGNOSTIC TESTS MENU 805
ADJUSTMENT MENU 816
METHOD FOR PERFORMING NO-INJECTION CRANKING 855
KOMTRAX SETTINGS MENU 856
METHOD FOR DISPLAYING SERVICE MESSAGE 858
METHOD FOR STARTING UP KOMTRAX SYSTEM 860
ADJUST REARVIEW CAMERA ANGLE 865
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 865
ADJUST KomVision CAMERA ANGLE 868
METHOD FOR ADJUSTING KomVision CAMERA ANGLE 869
ADJUST KomVision RELATED ITEMS 873
SETTING OF KomVision (MAIN SETTING) 873
SETTING OF KomVision (CAMERA SETTING) 875
SETTING OF KomVision (CAMERA CALIBRATION) 877
KomVision screen – Check 12 m visibility 890
SET REGION OF Bluetooth(R) COMPATIBLE RADIO 893
SET REGION OF Bluetooth(R) COMPATIBLE RADIO 893
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 895
HANDLE BATTERY DISCONNECT SWITCH 896
TEST DIODES 897
METHOD FOR TESTING DIODE USING DIGITAL TESTER 897
METHOD FOR TESTING DIODE USING ANALOG TESTER 897
ICT SYSTEM 898
SET AND OPERATE CONTROL BOX 898
METHOD FOR SETTING THE STARTING SWITCH INTERLOCK FUNCTION OF THE CONTROL BOX 900
METHOD FOR SELECTING EXCAVATOR MODEL AND IN THE CONTROL BOX 903
SET GNSS RECEIVER TYPE 907
SET HEADING MODE 910
SWITCH GRADE TRANSITIONS FINENESS ON CONTROL BOX 914
MONITORING AND LOGGING FUNCTION ON CONTROL BOX 917
SET TILT AUTOMATIC CONTROL FUNCTION 922
CALIBRATE INTELLIGENT MACHINE CONTROL 926
PPC Pressure Sensor Calibration 928
Control Map Calibration 1009
METHOD FOR TESTING THE INTELLIGENT MACHINE CONTROL SYSTEM 1177
CALIBRATE IMU SENSOR FOR YAW ANGLE 1183
IMU SENSOR CALIBRATION 1190
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION OF IMU SENSOR 1202
WORK EQUIPMENT CYLINDER CALIBRATION 1202
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION OF WORK EQUIPMENT CYLINDER 1215
GENERAL CALIBRATION OF BUCKET BLADE EDGE POSITION, BOOM DIMENSIONS, ARM DIMENSIONS, BUCKET LINK DIMENSIONS, AND GNSS ANTENNA POSITION WITH TOTAL STATION 1217
CALIBRATION OF BOOM DIMENSIONS AND ARM DIMENSIONS WITH TOTAL STATION 1269
CALIBRATION OF BUCKET LINK DIMENSIONS WITH TOTAL STATION 1289
CALIBRATION OF GNSS ANTENNA WITH TOTAL STATION 1326
INPUT RANGE OF THE MEASURED VALUES IN CALIBRATION WITH TOTAL STATION 1350
VERIFY THE INPUT VALUES IN CALIBRATION WITH TOTAL STATION 1352
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION WITH TOTAL STATION 1352
CALIBRATION OF GNSS ANTENNA WITHOUT TOTAL STATION 1353
CALIBRATION OF BUCKET BLADE EDGE POSITION WITHOUT TOTAL STATION 1357
INPUT RANGE OF THE MEASURED VALUES IN CALIBRATION WITHOUT TOTAL STATION 1367
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION WITHOUT TOTAL STATION 1367
Pm CLINIC 1369
Pm CLINIC SERVICE 1369
Pm CLINIC CHECK SHEET:PC210LCI-11 1370
40 TROUBLESHOOTING 1381
CONTENTS 1382
RELATED INFORMATION ON TROUBLESHOOTING 1397
GENERAL TROUBLESHOOTING POINTS 1397
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEM 1398
TABLE OF FAILURE CODES THAT IS SUBJECT TO INDUCEMENT 1405
SEQUENCE OF EVENTS IN TROUBLESHOOTING 1406
CHECKS BEFORE TROUBLESHOOTING 1408
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 1410
WALK-AROUND CHECK 1410
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 1412
CHECK FUEL LEVEL AND TYPE 1412
CHECK IMPURE INGREDIENT IN FUEL 1412
CHECK FUEL PREFILTER 1413
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 1413
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 1414
CHECK MAIN FILTER 1415
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 1417
CHECK COOLANT LEVEL (RESERVOIR TANK) 1418
CHECK CLOGGING OF AIR CLEANER 1418
OUTER ELEMENT – CLEAN 1419
ELEMENTS – REPLACE 1421
CHECK HYDRAULIC OIL LEVEL 1422
CHECK HYDRAULIC OIL STRAINER 1423
CHECK HYDRAULIC FILTER 1424
CHECK OIL LEVEL IN SWING MACHINERY CASE 1425
CHECK OIL LEVEL IN DAMPER CASE 1426
CHECK OIL LEVEL IN FINAL DRIVE CASE 1426
BLEED AIR FROM FUEL SYSTEM 1427
BLEED AIR FROM HYDRAULIC SYSTEM 1427
ELECTRICAL EQUIPMENT – CHECK METHOD 1427
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 1435
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 1435
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 1435
PREPARATION FOR TROUBLESHOOTING OF ICT SENSOR CONTROLLER 1436
PREPARATION FOR TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER 1437
PREPARATION FOR TROUBLESHOOTING OF GATEWAY CONTROLLER 1438
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER 1441
PREPARATION FOR TROUBLESHOOTING OF CONTROL BOX 1442
PREPARATION FOR TROUBLESHOOTING OF GNSS RECIVER 1442
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 1442
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1446
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 1449
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1454
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 1456
CONNECTOR LIST AND LAYOUT 1459
CONNECTOR CONTACT IDENTIFICATION 1482
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1522
FUSE LOCATION TABLE 1528
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1532
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1536
FAILURE CODE TABLE 1538
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1564
FAILURE CODE [6AZ0ZG] 1564
FAILURE CODE [879AKA] 1566
FAILURE CODE [879AKB] 1567
FAILURE CODE [879BKA] 1568
FAILURE CODE [879BKB] 1570
FAILURE CODE [879CKA] 1572
FAILURE CODE [879CKB] 1573
FAILURE CODE [879DKZ] 1574
FAILURE CODE [879EMC] 1576
FAILURE CODE [879FMC] 1577
FAILURE CODE [879GKX] 1578
FAILURE CODE [989L00] 1580
FAILURE CODE [989M00] 1581
FAILURE CODE [989N00] 1582
FAILURE CODE [A1U0N3] 1583
FAILURE CODE [A1U0N4] 1585
FAILURE CODE [A900FR] 1587
FAILURE CODE [A900N6] 1588
FAILURE CODE [A900NY] 1589
FAILURE CODE [AA10NX] 1590
FAILURE CODE [AB00KE] 1592
FAILURE CODE [AQ10N3] 1595
FAILURE CODE [AS00N3] 1596
FAILURE CODE [AS00R2] 1598
FAILURE CODE [AS00R3] 1599
FAILURE CODE [AS00R4] 1600
FAILURE CODE [AS00R5] 1601
FAILURE CODE [AS00R6] 1602
FAILURE CODE [AS00ZK] 1603
FAILURE CODE [AS10KM] 1604
FAILURE CODE [AS10NR] 1605
FAILURE CODE [AS10NT] 1606
FAILURE CODE [B@BAZG] 1607
FAILURE CODE [B@BAZK] 1608
FAILURE CODE [B@BCNS] 1610
FAILURE CODE [B@BCQA] 1611
FAILURE CODE [B@BCZK] 1613
FAILURE CODE [B@HANS] 1615
FAILURE CODE [CA115] 1616
FAILURE CODE [CA122] 1617
FAILURE CODE [CA123] 1619
FAILURE CODE [CA131] 1621
FAILURE CODE [CA132] 1623
FAILURE CODE [CA144] 1625
FAILURE CODE [CA145] 1627
FAILURE CODE [CA153] 1629
FAILURE CODE [CA154] 1632
FAILURE CODE [CA187] 1634
FAILURE CODE [CA221] 1636
FAILURE CODE [CA222] 1638
FAILURE CODE [CA227] 1640
FAILURE CODE [CA234] 1641
FAILURE CODE [CA238] 1642
FAILURE CODE [CA239] 1644
FAILURE CODE [CA249] 1646
FAILURE CODE [CA256] 1648
FAILURE CODE [CA271] 1650
FAILURE CODE [CA272] 1652
FAILURE CODE [CA322] 1654
FAILURE CODE [CA323] 1656
FAILURE CODE [CA324] 1658
FAILURE CODE [CA325] 1660
FAILURE CODE [CA331] 1662
FAILURE CODE [CA332] 1664
FAILURE CODE [CA343] 1666
FAILURE CODE [CA351] 1667
FAILURE CODE [CA352] 1668
FAILURE CODE [CA356] 1671
FAILURE CODE [CA357] 1673
FAILURE CODE [CA386] 1675
FAILURE CODE [CA428] 1676
FAILURE CODE [CA429] 1678
FAILURE CODE [CA435] 1680
FAILURE CODE [CA441] 1682
FAILURE CODE [CA442] 1684
FAILURE CODE [CA449] 1685
FAILURE CODE [CA451] 1686
FAILURE CODE [CA452] 1688
FAILURE CODE [CA488] 1690
FAILURE CODE [CA515] 1691
FAILURE CODE [CA516] 1693
FAILURE CODE [CA553] 1695
FAILURE CODE [CA555] 1696
FAILURE CODE [CA556] 1697
FAILURE CODE [CA559] 1698
FAILURE CODE [CA595] 1701
FAILURE CODE [CA687] 1702
FAILURE CODE [CA689] 1704
FAILURE CODE [CA691] 1707
FAILURE CODE [CA692] 1709
FAILURE CODE [CA697] 1711
FAILURE CODE [CA698] 1712
FAILURE CODE [CA731] 1713
FAILURE CODE [CA778] 1715
FAILURE CODE [CA1117] 1720
FAILURE CODE [CA1664] 1721
FAILURE CODE [CA1669] 1723
FAILURE CODE [CA1673] 1724
FAILURE CODE [CA1677] 1725
FAILURE CODE [CA1678] 1726
FAILURE CODE [CA1682] 1727
FAILURE CODE [CA1683] 1730
FAILURE CODE [CA1684] 1732
FAILURE CODE [CA1686] 1734
FAILURE CODE [CA1691] 1735
FAILURE CODE [CA1694] 1738
FAILURE CODE [CA1695] 1741
FAILURE CODE [CA1696] 1742
FAILURE CODE [CA1712] 1744
FAILURE CODE [CA1713] 1747
FAILURE CODE [CA1714] 1749
FAILURE CODE [CA1715] 1750
FAILURE CODE [CA1776] 1751
FAILURE CODE [CA1777] 1754
FAILURE CODE [CA1843] 1757
FAILURE CODE [CA1844] 1759
FAILURE CODE [CA1879] 1762
FAILURE CODE [CA1881] 1764
FAILURE CODE [CA1883] 1766
FAILURE CODE [CA1885] 1769
FAILURE CODE [CA1887] 1771
FAILURE CODE [CA1921] 1773
FAILURE CODE [CA1922] 1776
FAILURE CODE [CA1942] 1781
FAILURE CODE [CA1993] 1782
FAILURE CODE [CA2185] 1785
FAILURE CODE [CA2186] 1786
FAILURE CODE [CA2249] 1788
FAILURE CODE [CA2271] 1789
FAILURE CODE [CA2272] 1792
FAILURE CODE [CA2288] 1795
FAILURE CODE [CA2311] 1796
FAILURE CODE [CA2349] 1797
FAILURE CODE [CA2353] 1800
FAILURE CODE [CA2357] 1802
FAILURE CODE [CA2381] 1803
FAILURE CODE [CA2382] 1806
FAILURE CODE [CA2383] 1809
FAILURE CODE [CA2386] 1812
FAILURE CODE [CA2387] 1814
TROUBLESHOOTING FLOWCHART 1818
FAILURE CODE [CA2555] 1819
FAILURE CODE [CA2556] 1822
FAILURE CODE [CA2637] 1825
FAILURE CODE [CA2639] 1827
FAILURE CODE [CA2771] 1830
FAILURE CODE [CA2777] 1836
FAILURE CODE [CA2976] 1839
FAILURE CODE [CA3133] 1841
FAILURE CODE [CA3134] 1844
FAILURE CODE [CA3135] 1846
FAILURE CODE [CA3142] 1849
FAILURE CODE [CA3143] 1850
FAILURE CODE [CA3144] 1851
FAILURE CODE [CA3146] 1853
FAILURE CODE [CA3147] 1854
FAILURE CODE [CA3148] 1855
FAILURE CODE [CA3151] 1857
FAILURE CODE [CA3165] 1863
FAILURE CODE [CA3229] 1865
FAILURE CODE [CA3231] 1867
FAILURE CODE [CA3232] 1869
FAILURE CODE [CA3235] 1873
FAILURE CODE [CA3239] 1875
FAILURE CODE [CA3241] 1878
FAILURE CODE [CA3242] 1881
FAILURE CODE [CA3251] 1884
FAILURE CODE [CA3253] 1886
FAILURE CODE [CA3254] 1889
FAILURE CODE [CA3255] 1892
FAILURE CODE [CA3256] 1896
FAILURE CODE [CA3311] 1898
FAILURE CODE [CA3312] 1900
FAILURE CODE [CA3313] 1903
FAILURE CODE [CA3314] 1904
FAILURE CODE [CA3315] 1905
FAILURE CODE [CA3316] 1907
FAILURE CODE [CA3317] 1908
FAILURE CODE [CA3318] 1909
FAILURE CODE [CA3319] 1911
FAILURE CODE [CA3321] 1912
FAILURE CODE [CA3322] 1914
FAILURE CODE [CA3419] 1916
FAILURE CODE [CA3421] 1918
FAILURE CODE [CA3497] 1920
FAILURE CODE [CA3498] 1921
FAILURE CODE [CA3543] 1922
FAILURE CODE [CA3545] 1929
FAILURE CODE [CA3547] 1931
FAILURE CODE [CA3558] 1932
FAILURE CODE [CA3559] 1934
FAILURE CODE [CA3562] 1936
FAILURE CODE [CA3563] 1938
FAILURE CODE [CA3567] 1941
FAILURE CODE [CA3568] 1944
FAILURE CODE [CA3571] 1948
FAILURE CODE [CA3572] 1950
FAILURE CODE [CA3574] 1952
FAILURE CODE [CA3575] 1954
FAILURE CODE [CA3577] 1956
FAILURE CODE [CA3578] 1958
FAILURE CODE [CA3582] 1960
FAILURE CODE [CA3583] 1966
FAILURE CODE [CA3596] 1968
FAILURE CODE [CA3649] 1970
FAILURE CODE [CA3681] 1972
FAILURE CODE [CA3682] 1977
FAILURE CODE [CA3713] 1983
FAILURE CODE [CA3717] 1986
FAILURE CODE [CA3718] 1987
FAILURE CODE [CA3725] 1988
FAILURE CODE [CA3741] 1991
FAILURE CODE [CA3748] 1992
FAILURE CODE [CA3751] 1994
FAILURE CODE [CA3755] 1996
FAILURE CODE [CA3866] 1998
FAILURE CODE [CA3867] 2002
FAILURE CODE [CA3868] 2005
FAILURE CODE [CA3899] 2009
FAILURE CODE [CA3911] 2011
FAILURE CODE [CA3912] 2015
FAILURE CODE [CA3932] 2017
FAILURE CODE [CA3933] 2019
FAILURE CODE [CA3934] 2021
FAILURE CODE [CA3935] 2024
FAILURE CODE [CA3936] 2026
FAILURE CODE [CA4151] 2028
FAILURE CODE [CA4152] 2032
FAILURE CODE [CA4155] 2036
FAILURE CODE [CA4156] 2038
FAILURE CODE [CA4157] 2041
FAILURE CODE [CA4158] 2043
FAILURE CODE [CA4159] 2044
FAILURE CODE [CA4161] 2045
FAILURE CODE [CA4162] 2048
FAILURE CODE [CA4163] 2051
FAILURE CODE [CA4164] 2052
FAILURE CODE [CA4165] 2054
FAILURE CODE [CA4166] 2056
FAILURE CODE [CA4168] 2057
FAILURE CODE [CA4169] 2060
FAILURE CODE [CA4171] 2062
FAILURE CODE [CA4249] 2065
FAILURE CODE [CA4251] 2067
FAILURE CODE [CA4259] 2069
FAILURE CODE [CA4261] 2072
FAILURE CODE [CA4277] 2075
FAILURE CODE [CA4281] 2079
FAILURE CODE [CA4459] 2082
FAILURE CODE [CA4461] 2085
FAILURE CODE [CA4658] 2088
FAILURE CODE [CA4731] 2092
FAILURE CODE [CA4732] 2093
FAILURE CODE [CA4739] 2094
FAILURE CODE [CA4768] 2095
FAILURE CODE [CA4769] 2097
FAILURE CODE [CA4842] 2100
FAILURE CODE [CA4952] 2104
FAILURE CODE [CA5115] 2106
FAILURE CODE [CA5179] 2109
FAILURE CODE [CA5181] 2111
FAILURE CODE [CA5383] 2113
FAILURE CODE [D110KB] 2115
FAILURE CODE [D19JKZ] 2117
FAILURE CODE [D1M3KA] 2120
FAILURE CODE [D1M3KB] 2122
FAILURE CODE [D1M3KY] 2124
FAILURE CODE [D1M3MA] 2126
FAILURE CODE [D1M4KA] 2127
FAILURE CODE [D1M4KB] 2129
FAILURE CODE [D1M4KY] 2131
FAILURE CODE [D1M5KA] 2132
FAILURE CODE [D1M5KB] 2134
FAILURE CODE [D1M5KY] 2136
FAILURE CODE [D1M5MA] 2138
FAILURE CODE [D811MC] 2139
FAILURE CODE [D862KA] 2140
FAILURE CODE [D8ALKA] 2142
FAILURE CODE [D8ALKB] 2145
FAILURE CODE [D8AQKR] 2148
FAILURE CODE [D8G1KT] 2156
FAILURE CODE [D8G6KT] 2157
FAILURE CODE [DA20MC] 2158
FAILURE CODE [DA22KK] 2159
FAILURE CODE [DA25KP] 2162
FAILURE CODE [DA26KP] 2166
FAILURE CODE [DA29KQ] 2168
FAILURE CODE [DA2LKA] 2171
FAILURE CODE [DA2LKB] 2175
FAILURE CODE [DA2QKR] 2178
FAILURE CODE [DA2RKR] 2188
FAILURE CODE [DAF0KM] 2197
FAILURE CODE [DAF0MB] 2198
FAILURE CODE [DAF0MC] 2199
FAILURE CODE [DAF8KB] 2200
FAILURE CODE [DAF9KQ] 2202
FAILURE CODE [DAFGMC] 2203
FAILURE CODE [DAFLKA] 2204
FAILURE CODE [DAFLKB] 2208
FAILURE CODE [DAFQKR] 2211
FAILURE CODE [DAZ9KQ] 2220
FAILURE CODE [DAZQKR] 2221
FAILURE CODE [DB2QKR] 2229
FAILURE CODE [DB2RKR] 2238
FAILURE CODE [DB90MC] 2246
FAILURE CODE [DB92KK] 2247
FAILURE CODE [DB95KP] 2249
FAILURE CODE [DB96KP] 2253
FAILURE CODE [DB99KQ] 2257
FAILURE CODE [DB9LKA] 2260
FAILURE CODE [DB9LKB] 2264
FAILURE CODE [DB9QKR] 2267
FAILURE CODE [DB9RKR] 2277
FAILURE CODE [DBP0KM] 2286
FAILURE CODE [DBP0KT] 2287
FAILURE CODE [DBP5KB] 2288
FAILURE CODE [DBP5KY] 2291
FAILURE CODE [DBPQKR] 2294
FAILURE CODE [DBR0MC] 2303
FAILURE CODE [DBR2KK] 2304
FAILURE CODE [DBR5KP] 2307
FAILURE CODE [DBR6KP] 2309
FAILURE CODE [DBR9KQ] 2311
FAILURE CODE [DBRLKA] 2314
FAILURE CODE [DBRLKB] 2318
FAILURE CODE [DBRQKR] 2321
FAILURE CODE [DBRRKR] 2330
FAILURE CODE [DBRSKB] 2339
FAILURE CODE [DBRTKB] 2341
FAILURE CODE [DBUSKR] 2343
FAILURE CODE [DD20MA] 2347
FAILURE CODE [DDNRKA] 2350
FAILURE CODE [DDNRKY] 2352
FAILURE CODE [DDNS00] 2354
FAILURE CODE [DFB1KZ] 2356
FAILURE CODE [DFB2KZ] 2358
FAILURE CODE [DFB3L8] 2360
FAILURE CODE [DFB4L8] 2362
FAILURE CODE [DFB5KZ] 2364
FAILURE CODE [DFB6KZ] 2366
FAILURE CODE [DGH2KA] 2368
FAILURE CODE [DGH2KB] 2370
FAILURE CODE [DHA4KA] 2372
FAILURE CODE [DHAAMA] 2374
FAILURE CODE [DHACMA] 2376
FAILURE CODE [DHPAMA] 2378
FAILURE CODE [DHPBMA] 2380
FAILURE CODE [DHS3MA] 2382
FAILURE CODE [DHS4MA] 2385
FAILURE CODE [DHS8MA] 2388
FAILURE CODE [DHS9MA] 2391
FAILURE CODE [DHSAMA] 2394
FAILURE CODE [DHSBMA] 2397
FAILURE CODE [DHSCMA] 2400
FAILURE CODE [DHSDMA] 2403
FAILURE CODE [DHSFMA] 2406
FAILURE CODE [DHSGMA] 2409
FAILURE CODE [DHSHMA] 2412
FAILURE CODE [DHSJMA] 2415
FAILURE CODE [DHUXMA] 2418
FAILURE CODE [DHUYMA] 2420
FAILURE CODE [DHZAMA] 2422
FAILURE CODE [DHZCL8] 2426
FAILURE CODE [DK80KM] 2427
FAILURE CODE [DK80KR] 2428
FAILURE CODE [DK80KT] 2433
FAILURE CODE [DK8DKB] 2434
FAILURE CODE [DK8CKT] 2436
FAILURE CODE [DK8CKR] 2437
FAILURE CODE [DKG1KM] 2441
FAILURE CODE [DKG1L8] 2442
FAILURE CODE [DKR0MA] 2443
FAILURE CODE [DKR1MA] 2445
FAILURE CODE [DKT0KM] 2447
FAILURE CODE [DKT0L8] 2448
FAILURE CODE [DKT1KA] 2449
FAILURE CODE [DKT1KB] 2451
FAILURE CODE [DKT2KA] 2453
FAILURE CODE [DKT2KB] 2455
FAILURE CODE [DKT4KM] 2457
FAILURE CODE [DKT4L8] 2458
FAILURE CODE [DKT5KA] 2459
FAILURE CODE [DKT5KB] 2461
FAILURE CODE [DKT6KA] 2463
FAILURE CODE [DKT6KB] 2465
FAILURE CODE [DKT8KA] 2467
FAILURE CODE [DKT8KB] 2469
FAILURE CODE [DKT9KA] 2471
FAILURE CODE [DKT9KB] 2473
FAILURE CODE [DKTAKA] 2475
FAILURE CODE [DKTAKB] 2477
FAILURE CODE [DKTAMB] 2479
FAILURE CODE [DKTBKX] 2480
FAILURE CODE [DKTBMC] 2482
FAILURE CODE [DKTEMB] 2483
FAILURE CODE [DKTFKX] 2485
FAILURE CODE [DKTFMC] 2487
FAILURE CODE [DKTJMB] 2488
FAILURE CODE [DKTUL8] 2490
FAILURE CODE [DKTVKA] 2491
FAILURE CODE [DKTVKB] 2493
FAILURE CODE [DKTWKA] 2494
FAILURE CODE [DKTWKB] 2496
FAILURE CODE [DKU1MA] 2497
FAILURE CODE [DKU2MA] 2498
FAILURE CODE [DKUGKA] 2499
FAILURE CODE [DKUGKB] 2501
FAILURE CODE [DKUGKY] 2503
FAILURE CODE [DKUHKA] 2505
FAILURE CODE [DKUHKB] 2507
FAILURE CODE [DKUHKY] 2509
FAILURE CODE [DKULKA] 2511
FAILURE CODE [DKULKB] 2513
FAILURE CODE [DKULKY] 2515
FAILURE CODE [DKV0KA] 2517
FAILURE CODE [DKV0KY] 2520
FAILURE CODE [DKV1KA] 2522
FAILURE CODE [DKV1KY] 2524
FAILURE CODE [DKV2KA] 2526
FAILURE CODE [DKV2KY] 2528
FAILURE CODE [DKV3KA] 2530
FAILURE CODE [DKV3KY] 2532
FAILURE CODE [DKV4MA] 2534
FAILURE CODE [DKV5MA] 2537
FAILURE CODE [DKV6MA] 2540
FAILURE CODE [DKV7MA] 2543
FAILURE CODE [DKV8MA] 2546
FAILURE CODE [DKV9MA] 2549
FAILURE CODE [DKVAMA] 2552
FAILURE CODE [DKVBKA] 2555
FAILURE CODE [DKVBKB] 2557
FAILURE CODE [DKVBKY] 2559
FAILURE CODE [DKVCKA] 2561
FAILURE CODE [DKVCKB] 2563
FAILURE CODE [DKVCKY] 2565
FAILURE CODE [DKVDKA] 2567
FAILURE CODE [DKVDKB] 2569
FAILURE CODE [DKVDKY] 2571
FAILURE CODE [DKVDMA] 2573
FAILURE CODE [DKVLMA] 2575
FAILURE CODE [DKVMMA] 2578
FAILURE CODE [DKVNKX] 2581
FAILURE CODE [DKVNL8] 2582
FAILURE CODE [DKVKKX] 2583
FAILURE CODE [DKVKL8] 2584
FAILURE CODE [DKVPMA] 2585
FAILURE CODE [DKVQMA] 2588
FAILURE CODE [DLM5KA] 2591
FAILURE CODE [DLM5MB] 2593
FAILURE CODE [DR10KA] 2595
FAILURE CODE [DR12KA] 2598
FAILURE CODE [DR20KA] 2600
FAILURE CODE [DR21KX] 2602
FAILURE CODE [DR30KA] 2604
FAILURE CODE [DR31KX] 2606
FAILURE CODE [DR40KA] 2608
FAILURE CODE [DUMBKA] 2610
FAILURE CODE [DUMBKB] 2614
FAILURE CODE [DV20KB] 2617
FAILURE CODE [DW43KA] 2619
FAILURE CODE [DW43KB] 2621
FAILURE CODE [DW43KY] 2623
FAILURE CODE [DW45KA] 2625
FAILURE CODE [DW45KB] 2628
FAILURE CODE [DW45KY] 2631
FAILURE CODE [DW4CKY] 2633
FAILURE CODE [DW4FKA] 2635
FAILURE CODE [DW4FKB] 2638
FAILURE CODE [DW4FKY] 2640
FAILURE CODE [DW4GKA] 2642
FAILURE CODE [DW4GKB] 2645
FAILURE CODE [DW4GKY] 2647
FAILURE CODE [DW4SKA] 2649
FAILURE CODE [DW4SKB] 2651
FAILURE CODE [DW4SKY] 2653
FAILURE CODE [DW91KA] 2655
FAILURE CODE [DW91KB] 2657
FAILURE CODE [DW91KY] 2659
FAILURE CODE [DWA2KA] 2661
FAILURE CODE [DWA2KB] 2663
FAILURE CODE [DWA2KY] 2665
FAILURE CODE [DWK0KA] 2667
FAILURE CODE [DWK0KB] 2669
FAILURE CODE [DWK0KY] 2671
FAILURE CODE [DWK2KA] 2673
FAILURE CODE [DWK2KB] 2675
FAILURE CODE [DWK2KY] 2677
FAILURE CODE [DWK8KA] 2679
FAILURE CODE [DWK8KB] 2681
FAILURE CODE [DWK8KY] 2683
FAILURE CODE [DWN5KA] 2685
FAILURE CODE [DWN5KB] 2687
FAILURE CODE [DWN5KY] 2689
FAILURE CODE [DWPUKA] 2691
FAILURE CODE [DWPUKB] 2693
FAILURE CODE [DWPUKY] 2695
FAILURE CODE [DXA8KA] 2696
FAILURE CODE [DXA8KB] 2698
FAILURE CODE [DXA9KA] 2700
FAILURE CODE [DXA9KB] 2702
FAILURE CODE [DXE0KA] 2704
FAILURE CODE [DXE0KB] 2705
FAILURE CODE [DXE4KA] 2707
FAILURE CODE [DXE4KB] 2709
FAILURE CODE [DXE4KY] 2711
FAILURE CODE [DXE5KA] 2713
FAILURE CODE [DXE5KB] 2715
FAILURE CODE [DXE6KA] 2717
FAILURE CODE [DXE6KB] 2719
FAILURE CODE [DXE7KA] 2721
FAILURE CODE [DXE7KB] 2723
FAILURE CODE [DXE7KY] 2725
FAILURE CODE [DXE8KA] 2727
FAILURE CODE [DXE8KB] 2729
FAILURE CODE [DXE8KY] 2731
FAILURE CODE [DXE9KA] 2733
FAILURE CODE [DXE9KB] 2735
FAILURE CODE [DXE9KY] 2737
FAILURE CODE [DXEAKA] 2739
FAILURE CODE [DXEAKB] 2741
FAILURE CODE [DXEAKY] 2743
FAILURE CODE [DXEKKA] 2745
FAILURE CODE [DXEKKB] 2747
FAILURE CODE [DXEKKY] 2749
FAILURE CODE [DXELKA] 2750
FAILURE CODE [DXELKB] 2752
FAILURE CODE [DXELKY] 2754
FAILURE CODE [DXRWKA] 2755
FAILURE CODE [DXRWKB] 2757
FAILURE CODE [DXRWKY] 2759
FAILURE CODE [DXRXKA] 2761
FAILURE CODE [DXRXKB] 2763
FAILURE CODE [DXRXKY] 2765
FAILURE CODE [DXRYKA] 2767
FAILURE CODE [DXRYKB] 2769
FAILURE CODE [DXRYKY] 2771
FAILURE CODE [DY20KA] 2773
FAILURE CODE [DY20MA] 2775
FAILURE CODE [DY2CKB] 2777
FAILURE CODE [DY2DKB] 2780
FAILURE CODE [DY2EKB] 2782
FAILURE CODE [F311KA] 2784
FAILURE CODE [F311KB] 2786
FAILURE CODE [F312KA] 2788
FAILURE CODE [F312KB] 2790
FAILURE CODE [F313KA] 2792
FAILURE CODE [F313KB] 2794
FAILURE CODE [F314KA] 2797
FAILURE CODE [F314KB] 2799
FAILURE CODE [F315KB] 2801
FAILURE CODE [F315KY] 2803
FAILURE CODE [F316KB] 2805
FAILURE CODE [F316KY] 2807
FAILURE CODE [F318KB] 2809
FAILURE CODE [F318KY] 2812
FAILURE CODE [F31AKB] 2814
FAILURE CODE [F31AKY] 2816
FAILURE CODE [F31BKB] 2818
FAILURE CODE [F31BKY] 2820
FAILURE CODE [F31CKB] 2822
FAILURE CODE [F31CKY] 2824
FAILURE CODE [F31DKB] 2826
FAILURE CODE [F31DKY] 2828
FAILURE CODE [F31EKB] 2830
FAILURE CODE [F31EKY] 2832
FAILURE CODE [F7FQKR] 2834
FAILURE CODE [F7G0MC] 2843
FAILURE CODE [H16SL8] 2844
FAILURE CODE [H17SL8] 2846
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2848
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2848
MANUAL PREHEATING SYSTEM DOES NOT WORK 2854
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2857
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2859
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 2861
WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 2864
WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 2865
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2866
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2867
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 2868
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2869
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2870
WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2871
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2872
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2873
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2874
FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2875
DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 2877
ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2878
DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 2879
HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2880
DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 2882
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 2883
FUNCTION SWITCH DOES NOT OPERATE 2884
AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 2885
WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 2886
AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 2887
WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 2888
WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 2889
WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 2890
WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 2891
ALARM BUZZER CANNOT BE CANCELED 2893
SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 2894
SERVICE MODE CANNOT BE SELECTED 2895
ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 2896
ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 2899
BUCKET DOES NOT MOVE WITH AUTO TILT FUNCTION 2901
WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 2902
WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 2905
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 2907
ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 2910
ALARM DOES NOT SOUND DURING TRAVEL 2911
ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 2913
HORN DOES NOT SOUND 2914
HORN DOES NOT STOP SOUNDING 2917
WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 2919
WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 2920
WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 2922
BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2923
BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2924
ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2925
ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2926
BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2927
BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2928
SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2929
TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2930
SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2931
ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED 2933
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2934
CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not connected!] AND [Slope sensor not connected!] 2935
CONTROL BOX DISPLAYS THE MESSAGE [GPS receiver not connected!] 2938
CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link ] 2941
CONTROL BOX DISPLAYS THE MESSAGE [Tilt Bucket Sensor Offline!] 2942
CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites ] 2943
CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!] 2944
CONTROL BOX DISPLAYS THE MESSAGE [Sensors are invalid] 2947
CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize ] 2950
CONTROL BOX DISPLAYS THE MESSAGE [Initializing ] 2951
CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization ] 2952
CONTROL BOX DISPLAYS THE MESSAGE [Low precisions ] 2953
CONTROL BOX DISPLAYS [Out of design area ] 2954
CONTROL BOX DISPLAYS THE MESSAGE [Avoidance Area Breach!] 2955
CONTROL BOX SHOWS THE MESSAGE [CPU LOAD IS INCREASED] 2956
CONTROL BOX CAN NOT BE TURNED ON 2957
CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN 2958
CONTROL BOX DOES NOT DISPLAY HYDRAULIC EXCAVATOR IMAGE 2959
CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE 2960
CONTROL BOX TOUCH PANEL DOES NOT RESPOND 2961
CONTROL BOX TOUCH PANEL IS INACCURATE 2962
WHEN CHECKING AND ADJUSTING THE BUCKET EDGE POSITION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE 2963
SEMI-AUTO MODE IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED 2965
AUTO GRADE ASSIST CONTROL DOES NOT OPERATE WHILE SEMI-AUTO MODE IS DISPLAYED 2966
AUTO STOP CONTROL DOES NOT OPERATE WHILE SEMI-AUTO MODE IS DISPLAYED 2967
“SEMI-AUTOMATIC MODE” IS SHOWN BUT THE WORK MODE ICON IS NOT SHOWN 2968
BUCKET ANGLE HOLD CONTROL DOES NOT OPERATE 2969
BLADE EDGE POSITION ON DESIGN SURFACE IS NOT ACCURATE WHEN AUTO GRADE ASSIST FUNCTION IS ON 2970
BLADE EDGE STOP POSITION IS NOT ACCURATE FOR DESIGN SURFACE WHEN AUTO STOP CONTROL FUNCTION IS ON 2972
FACING ANGLE COMPASS DOES NOT BECOME PERPENDICULAR TO TARGET 2974
NG OCCURS VERY OFTEN IN IMU CALIBRATION DIAGNOSIS 2975
CUSHION FOR BOOM RAISE END DOES NOT WORK OR IS WEAK 2976
CUSHION FOR ARM IN END DOES NOT WORK OR IS WEAK 2977
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2980
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2980
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 2981
FAILURE MODE AND CAUSE TABLE 2983
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 2992
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 2993
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2996
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 2997
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2998
H-6 SPEED OR POWER OF BOOM IS LOW 3000
H-7 ARM SPEED OR POWER IS LOW 3004
H-8 BUCKET SPEED OR POWER IS LOW 3009
H-9 BUCKET DOES NOT MOVE IN SINGLE OPERATION WITH AUTO TILT FUNCTION 3012
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 3013
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE 3014
H-12 HYDRAULIC DRIFT OF ARM IS LARGE 3016
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE 3018
H-14 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 3019
H-15 TIME LAG OF WORK EQUIPMENT IS LARGE 3020
H-16 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 3021
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED 3022
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 3023
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 3024
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 3025
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 3026
H-22 MACHINE DOES NOT TRAVEL STRAIGHT 3027
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 3029
H-24 TRAVEL SPEED IS LOW 3032
H-25 ONE OF TRACKS DOES NOT RUN 3034
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 3035
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 3036
H-28 SWINGS ONLY IN ONE DIRECTION 3037
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 3038
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 3039
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 3040
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 3041
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 3042
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 3043
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 3044
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 3045
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 3046
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN 3047
TROUBLESHOOTING OF ENGINE (S-MODE) 3048
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 3048
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 3049
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 3050
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 3051
S-4 ENGINE STARTABILITY IS POOR 3053
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 3055
S-6 ENGINE STOPS DURING OPERATION 3057
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 3059
S-8 ENGINE LACKS POWER 3060
S-9 KDPF GETS CLOGGED IN A SHORT TIME 3062
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 3064
S-11 OIL BECOMES CONTAMINATED QUICKLY 3065
S-12 FUEL CONSUMPTION IS EXCESSIVE 3066
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 3067
S-14 OIL PRESSURE DROPS 3068
S-15 FUEL MIXES INTO ENGINE OIL 3070
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 3071
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 3072
S-18 UNUSUAL NOISE IS HEARD 3073
S-19 VIBRATION IS EXCESSIVE 3074
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 3075
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 3076
S-22 ACTIVE REGENERATION TAKES TIME 3078
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 3079
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 3080
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 3082
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 3083
50 DISASSEMBLY AND ASSEMBLY 3085
CONTENTS 3086
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 3092
HOW TO READ THIS MANUAL 3092
COATING MATERIALS LIST 3094
SPECIAL TOOLS LIST 3098
SKETCHES OF SPECIAL TOOLS 3110
ENGINE AND COOLING SYSTEM 3116
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 3116
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 3116
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 3119
REMOVE AND INSTALL INJECTOR ASSEMBLY 3122
METHOD FOR REMOVING INJECTOR ASSEMBLY 3122
METHOD FOR INSTALLING INJECTOR ASSEMBLY 3127
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 3135
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 3136
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 3145
REMOVE AND INSTALL EGR VALVE ASSEMBLY 3161
METHOD FOR REMOVING EGR VALVE ASSEMBLY 3161
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 3162
REMOVE AND INSTALL EGR COOLER ASSEMBLY 3164
METHOD FOR REMOVING EGR COOLER ASSEMBLY 3164
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 3168
REMOVE AND INSTALL STARTER ASSEMBLY 3173
METHOD FOR REMOVING STARTER ASSEMBLY 3173
METHOD FOR INSTALLING STARTER ASSEMBLY 3174
REMOVE AND INSTALL ALTERNATOR BELT 3177
METHOD FOR REMOVING ALTERNATOR BELT 3177
METHOD FOR INSTALLING ALTERNATOR BELT 3179
REMOVE AND INSTALL RADIATOR ASSEMBLY 3182
METHOD FOR REMOVING RADIATOR ASSEMBLY 3182
METHOD FOR INSTALLING RADIATOR ASSEMBLY 3184
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 3187
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 3187
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 3190
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 3193
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 3193
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 3195
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 3197
REMOVE FAN CLUTCH ASSEMBLY 3197
INSTALL FAN CLUTCH ASSEMBLY 3202
REMOVE AND INSTALL FAN 3206
METHOD FOR INSTALLING FAN 3206
METHOD FOR REMOVING FAN 3206
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 3207
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY 3207
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY 3216
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 3228
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 3228
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 3231
REMOVE AND INSTALL ENGINE REAR OIL SEAL 3235
METHOD FOR REMOVING ENGINE REAR OIL SEAL 3235
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 3236
REMOVE AND INSTALL FUEL COOLER ASSEMBLY 3239
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 3239
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 3239
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 3241
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 3241
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 3243
REMOVE AND INSTALL FUEL TANK ASSEMBLY 3248
METHOD FOR REMOVING FUEL TANK ASSEMBLY 3248
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 3252
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 3258
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 3258
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 3264
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 3270
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 3270
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 3276
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 3282
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 3282
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 3282
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 3289
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 3289
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 3289
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 3290
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 3290
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 3292
REMOVE AND INSTALL KDPF ASSEMBLY 3295
METHOD FOR REMOVING KDPF ASSEMBLY 3295
METHOD FOR INSTALLING KDPF ASSEMBLY 3297
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 3299
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 3300
METHOD FOR ASSEMBLING KDPF ASSEMBLY 3303
REMOVE AND INSTALL SCR ASSEMBLY 3308
METHOD FOR REMOVING SCR ASSEMBLY 3308
METHOD FOR INSTALLING SCR ASSEMBLY 3310
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 3312
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 3312
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 3319
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET 3325
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 3325
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 3332
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 3339
REMOVE BELLOWS PIPE ASSEMBLY 3339
INSTALL BELLOWS PIPE ASSEMBLY 3341
REMOVE AND INSTALL KCCV ASSEMBLY 3345
METHOD FOR REMOVING KCCV ASSEMBLY 3345
METHOD FOR INSTALLING KCCV ASSEMBLY 3347
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 3352
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 3352
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 3358
REMOVE AND INSTALL AdBlue/DEF INJECTOR 3364
METHOD FOR REMOVING AdBlue/DEF INJECTOR 3364
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 3367
REMOVE AND INSTALL AdBlue/DEF PUMP 3370
METHOD FOR REMOVING AdBlue/DEF PUMP 3370
METHOD FOR INSTALLING AdBlue/DEF PUMP 3373
REMOVE AND INSTALL AdBlue/DEF HOSE 3376
METHOD FOR REMOVING AdBlue/DEF HOSE 3376
METHOD FOR INSTALLING AdBlue/DEF HOSE 3384
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 3390
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 3390
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 3391
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 3393
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 3393
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 3395
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 3398
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 3398
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 3399
POWER TRAIN 3400
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 3400
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 3400
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 3401
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 3403
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 3403
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 3407
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 3416
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 3416
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 3418
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 3422
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 3422
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 3426
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 3433
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 3433
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 3434
UNDERCARRIAGE AND FRAME 3435
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 3435
METHOD FOR SEPARATING TRACK ASSEMBLY 3435
METHOD FOR INSTALLING TRACK ASSEMBLY 3437
REMOVE AND INSTALL SPROCKET 3440
METHOD FOR REMOVING SPROCKET 3440
METHOD FOR INSTALLING SPROCKET 3440
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 3442
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 3442
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 3443
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 3444
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 3444
METHOD FOR ASSEMBLING IDLER ASSEMBLY 3445
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 3449
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 3450
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 3450
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 3452
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 3453
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 3454
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 3456
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 3456
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 3458
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 3460
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 3460
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 3462
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 3465
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 3465
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 3468
HYDRAULIC SYSTEM 3472
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 3472
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 3472
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 3474
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 3477
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 3477
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 3478
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 3480
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 3480
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 3483
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 3488
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 3488
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 3491
REMOVE AND INSTALL JUNCTION BLOCK ASSEMBLY FOR INTELLIGENT MACHINE CONTROL 3495
REMOVE JUNCTION BLOCK ASSEMBLY FOR INTELLIGENT MACHINE CONTROL 3495
INSTALL JUNCTION BLOCK ASSEMBLY FOR INTELLIGENT MACHINE CONTROL 3499
REMOVE AND INSTALL PRESSURE SENSOR FOR INTELLIGENT MACHINE CONTROL 3504
METHOD FOR REMOVING PRESSURE SENSOR FOR INTELLIGENT MACHINE CONTROL 3504
METHOD FOR INSTALLING PRESSURE SENSOR FOR INTELLIGENT MACHINE CONTROL 3506
REMOVE AND INSTALL BOOM SPOOL STROKE SENSOR 3508
METHOD FOR REMOVING BOOM SPOOL STROKE SENSOR 3508
METHOD FOR INSTALLING BOOM SPOOL STROKE SENSOR 3508
REMOVE AND INSTALL ARM SPOOL STROKE SENSOR 3510
METHOD FOR REMOVING ARM SPOOL STROKE SENSOR 3510
METHOD FOR INSTALLING ARM SPOOL STROKE SENSOR 3510
REMOVE AND INSTALL JUNCTION BLOCK BYPASS ADAPTER FOR INTELLIGENT MACHINE CONTROL 3512
METHOD FOR REMOVING JUNCTION BLOCK BYPASS ADAPTER FOR INTELLIGENT MACHINE CONTROL 3512
METHOD FOR REMOVING JUNCTION BLOCK BYPASS ADAPTER FOR INTELLIGENT MACHINE CONTROL 3514
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 3516
REMOVE CONTROL VALVE ASSEMBLY 3516
INSTALL CONTROL VALVE ASSEMBLY 3524
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 3533
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 3533
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 3534
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 3538
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 3538
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 3538
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 3540
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 3540
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 3541
WORK EQUIPMENT 3543
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 3543
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 3543
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 3548
DISASSEMBLE AND ASSEMBLE STROKE SENSING BOOM CYLINDER ASSEMBLY 3555
METHOD FOR DISASSEMBLING STROKE SENSING BOOM CYLINDER ASSEMBLY 3556
METHOD FOR ASSEMBLING STROKE SENSING BOOM CYLINDER ASSEMBLY 3561
DISASSEMBLE AND ASSEMBLE STROKE SENSING ARM CYLINDER ASSEMBLY 3568
METHOD FOR DISASSEMBLING STROKE SENSING ARM CYLINDER ASSEMBLY 3569
METHOD FOR ASSEMBLING STROKE SENSING ARM CYLINDER ASSEMBLY 3574
DISASSEMBLE AND ASSEMBLE STROKE SENSING BUCKET CYLINDER ASSEMBLY 3582
METHOD FOR DISASSEMBLING STROKE SENSING BUCKET CYLINDER ASSEMBLY 3583
METHOD FOR ASSEMBLING STROKE SENSING BUCKET CYLINDER ASSEMBLY 3588
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3598
CAB AND ITS ATTACHMENTS 3604
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 3604
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 3604
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 3615
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 3627
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 3629
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 3629
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 3639
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 3639
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 3642
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 3648
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 3648
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 3655
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 3664
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 3664
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 3672
REMOVE AND INSTALL OPERATOR’S SEAT 3680
METHOD FOR REMOVING OPERATOR’S SEAT 3680
METHOD FOR INSTALLING OPERATOR’S SEAT 3682
REMOVE AND INSTALL SEAT BELT 3686
METHOD FOR REMOVING SEAT BELT 3686
METHOD FOR INSTALLING SEAT BELT 3686
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 3688
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 3688
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 3694
ELECTRICAL SYSTEM 3703
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3703
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 3703
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 3704
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 3706
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 3706
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 3710
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3716
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY 3716
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY 3718
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 3721
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY 3721
METHOD FOR INSTALLING KomVision CONTROLLER 3722
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3724
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 3724
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 3727
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 3731
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR 3731
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR 3732
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3733
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 3733
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 3733
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3735
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 3735
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 3736
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 3737
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 3737
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 3739
REMOVE AND INSTALL KomVision CAMERA 3742
METHOD FOR REMOVING KomVision CAMERA 3742
METHOD FOR INSTALLING KomVision CAMERA 3745
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 3748
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3748
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3751
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 3755
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 3755
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 3759
REMOVE AND INSTALL COMMUNICATION TERMINAL 3765
METHOD FOR REMOVING COMMUNICATION TERMINAL 3765
METHOD FOR INSTALLING COMMUNICATION TERMINAL 3766
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 3769
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS 3769
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS 3779
REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY 3791
METHOD FOR REMOVING ICT SENSOR CONTROLLER ASSEMBLY 3791
METHOD FOR INSTALLING ICT SENSOR CONTROLLER ASSEMBLY 3793
REMOVE AND INSTALL JUNCTION HARNESS OF CONTROL BOX 3797
METHOD FOR REMOVING JUNCTION HARNESS OF CONTROL BOX 3797
METHOD FOR INSTALLING JUNCTION HARNESS OF CONTROL BOX 3799
REMOVE AND INSTALL CONTROL BOX HARNESS 3802
METHOD FOR REMOVING CONTROL BOX HARNESS 3802
METHOD FOR INSTALLING CONTROL BOX HARNESS 3802
REMOVE AND INSTALL GNSS RECEIVER 3803
METHOD FOR REMOVING GNSS RECEIVER 3803
METHOD FOR INSTALLING GNSS RECEIVER 3803
REMOVE AND INSTALL GNSS RECEIVER ANTENNA 3805
METHOD FOR REMOVING GNSS RECEIVER ANTENNA 3805
METHOD FOR INSTALLING GNSS RECEIVER ANTENNA 3806
REMOVE AND INSTALL NETWORK MODEM ANTENNA 3808
REMOVE NETWORK MODEM ANTENNA 3808
INSTALL NETWORK MODEM ANTENNA 3808
REMOVE AND INSTALL GNSS ANTENNA 3810
METHOD FOR REMOVING GNSS ANTENNA 3810
METHOD FOR INSTALLING GNSS ANTENNA 3811
REMOVE AND INSTALL IMU SENSOR 3812
METHOD FOR REMOVING IMU SENSOR 3812
METHOD FOR INSTALLING IMU SENSOR 3812
60 MAINTENANCE STANDARD 3813
CONTENTS 3814
ENGINE AND COOLING SYSTEM 3815
MAINTENANCE STANDARD OF ENGINE MOUNT 3815
MAINTENANCE STANDARD OF COOLING SYSTEM 3816
POWER TRAIN 3818
MAINTENANCE STANDARD OF SWING CIRCLE 3818
MAINTENANCE STANDARD OF SWING MACHINERY 3819
MAINTENANCE STANDARD OF FINAL DRIVE 3821
MAINTENANCE STANDARD OF SPROCKET 3823
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 3824
UNDERCARRIAGE AND FRAME 3826
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 3826
MAINTENANCE STANDARD OF IDLER 3828
MAINTENANCE STANDARD OF TRACK ROLLER 3830
MAINTENANCE STANDARD OF CARRIER ROLLER 3831
MAINTENANCE STANDARD OF TRACK SHOE 3832
MAINTENANCE STANDARD OF TRIPLE SHOE 3835
MAINTENANCE STANDARD OF SWAMP SHOE 3836
MAINTENANCE STANDARD OF ROAD LINER 3837
HYDRAULIC SYSTEM 3838
MAINTENANCE STANDARD OF HYDRAULIC TANK 3838
MAINTENANCE STANDARD OF MAIN PUMP 3839
MAINTENANCE STANDARD OF LS-EPC VALVE 3840
MAINTENANCE STANDARD OF PC-EPC VALVE 3841
MAINTENANCE STANDARD OF SWING MOTOR 3842
MAINTENANCE STANDARD OF TRAVEL MOTOR 3845
MAINTENANCE STANDARD OF CONTROL VALVE 3848
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 3858
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 3861
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 3864
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 3866
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE 3867
MAINTENANCE STANDARD OF SOLENOID VALVE 3869
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 3870
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 3871
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 3872
WORK EQUIPMENT 3873
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 3873
DIMENSION OF ARM 3878
DIMENSIONS OF BUCKET 3880
MAINTENANCE STANDARD OF BOOM CYLINDER 3882
MAINTENANCE STANDARD OF STROKE SENSING BOOM CYLINDER 3883
MAINTENANCE STANDARD OF STROKE SENSING ARM CYLINDER 3885
MAINTENANCE STANDARD OF STROKE SENSING BUCKET CYLINDER 3887
MAINTENANCE STANDARD OF STROKE SENSOR FOR BOOM CYLINDER 3889
MAINTENANCE STANDARD OF STROKE SENSOR FOR ARM CYLINDER 3890
MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BUCKET CYLINDER 3891
80 APPENDIX 3893
CONTENTS 3894
AIR CONDITIONER SYSTEM 3896
PRECAUTIONS FOR REFRIGERANT 3896
AIR CONDITIONER COMPONENT 3897
SPECIFICATIONS OF AIR CONDITIONER 3899
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3900
OUTLINE OF REFRIGERATION CYCLE 3901
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3903
AIR CONDITIONER UNIT 3903
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3903
FUNCTION OF AIR CONDITIONER UNIT 3905
COMPONENT PARTS OF AIR CONDITIONER UNIT 3907
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3908
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3908
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3908
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3908
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3909
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3909
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3909
FUNCTION OF DUAL PRESSURE SWITCH 3910
AIR CONDITIONER CONTROLLER 3911
STRUCTURE OF AIR CONDITIONER CONTROLLER 3911
COMPRESSOR 3912
STRUCTURE OF COMPRESSOR 3912
SPECIFICATIONS OF COMPRESSOR 3912
FUNCTION OF COMPRESSOR 3912
CONDENSER 3913
STRUCTURE OF CONDENSER 3913
SPECIFICATIONS OF CONDENSER 3913
FUNCTION OF CONDENSER 3913
SENSORS FOR AIR CONDITIONER SYSTEM 3915
STRUCTURE OF SUNLIGHT SENSOR 3915
FUNCTION OF SUNLIGHT SENSOR 3915
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 3915
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3915
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3917
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3919
AIR CONDITIONER SYSTEM DIAGRAM 3921
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3922
FUNCTION OF AIR CONDITIONER CONTROLLER 3923
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3924
TESTING AIR LEAKAGE (DUCT) 3928
METHOD FOR TESTING AIR LEAKAGE (DUCT) 3928
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3929
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3930
TEST VENT (MODE) CHANGEOVER 3931
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3931
TESTING FRESH/RECIRC AIR CHANGEOVER 3932
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3932
TEST SUNLIGHT SENSOR 3933
METHOD FOR TESTING SUNLIGHT SENSOR 3933
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3934
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3934
TEST RELAYS 3935
METHOD FOR TESTING RELAYS 3935
AIR CONDITIONER TROUBLESHOOTING CHART 1 3936
AIR CONDITIONER TROUBLESHOOTING CHART 2 3937
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3940
FAILURE CODE [879AKA] 3942
FAILURE CODE [879AKB] 3943
FAILURE CODE [879BKA] 3944
FAILURE CODE [879BKB] 3946
FAILURE CODE [879CKA] 3948
FAILURE CODE [879CKB] 3949
FAILURE CODE [879DKZ] 3950
FAILURE CODE [879EMC] 3952
FAILURE CODE [879FMC] 3953
FAILURE CODE [879GKX] 3954
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3956
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3958
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3961
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3963
TROUBLESHOOTING USING GAUGE PRESSURE 3965
CONNECTION OF SERVICE TOOL 3968
METHOD FOR CONNECTING SERVICE TOOL 3968
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3970
HANDLE COMPRESSOR OIL 3972
METHOD FOR REPLACING DESICCANT 3974
90 CIRCUIT DIAGRAMS 3977
CONTENTS 3978
HOW TO READ THE CODES FOR ELECTRIC CABLE 3979
HYDRAULIC CIRCUIT DIAGRAM 3983
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3983
HYDRAULIC CIRCUIT DIAGRAM (1/3) 3987
HYDRAULIC CIRCUIT DIAGRAM (2/3) 3989
HYDRAULIC CIRCUIT DIAGRAM (3/3) 3991
ELECTRICAL CIRCUIT DIAGRAM 3993
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3993
ELECTRICAL CIRCUIT DIAGRAM (1/14) 3997
ELECTRICAL CIRCUIT DIAGRAM (2/14) 3999
ELECTRICAL CIRCUIT DIAGRAM (3/14) 4001
ELECTRICAL CIRCUIT DIAGRAM (4/14) 4003
ELECTRICAL CIRCUIT DIAGRAM (5/14) 4005
ELECTRICAL CIRCUIT DIAGRAM (6/14) 4007
ELECTRICAL CIRCUIT DIAGRAM (7/14) 4009
ELECTRICAL CIRCUIT DIAGRAM (8/14) 4011
ELECTRICAL CIRCUIT DIAGRAM (9/14) 4013
ELECTRICAL CIRCUIT DIAGRAM (10/14) 4015
ELECTRICAL CIRCUIT DIAGRAM (11/14) 4017
ELECTRICAL CIRCUIT DIAGRAM (12/14) 4019
ELECTRICAL CIRCUIT DIAGRAM (13/14) 4021
ELECTRICAL CIRCUIT DIAGRAM (14/14) 4023
INDEX 4025

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