Komatsu PC700LC -11 Hydraulic Excavator Shop Manual UENBM00430 PDF

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Komatsu PC700LC -11 Hydraulic Excavator Shop Manual UENBM00430 – PDF DOWNLOAD

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Komatsu PC700LC -11 Hydraulic Excavator Shop Manual UENBM00430 – PDF DOWNLOAD

Language : English
Pages : 2696
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC700LC -11 Hydraulic Excavator Shop Manual UENBM00430 – PDF DOWNLOAD

SERIAL NUMBERS

• 80013 and up
• K70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 21
FOREWORD, SAFETY, BASIC INFORMATION . 27
HOW TO READ THE SHOP MANUAL . 27
SAFETY NOTICE FOR OPERATION . 29
PRECAUTIONS TO PREVENT FIRE . 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 41
PRECAUTIONS FOR DEF . 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 42
PRECAUTIONS FOR ADDING 42
PRECAUTIONS FOR STORING . 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 42
THE OTHER PRECAUTIONS . 42
STORE AdBlue/DEF 43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 57
PRACTICAL USE OF KOMTRAX 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 73
HOW TO READ ELECTRICAL WIRE CODE 74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 78
STANDARD TIGHTENING TORQUE TABLE 81
CONVERSION TABLE 88
01 SPECIFICATIONS . 93
CONTENTS 94
ABBREVIATION LIST . 95
SPECIFICATIONS 101
SPECIFICATION DRAWING . 101
SPECIFICATION DRAWING: PC700LC-11 . 101
SPECIFICATION DRAWING: PC700LCSE-11 . 102
WORKING RANGE DRAWINGS 104
WORKING RANGE: PC700LC-11 . 104
WORKING RANGE: PC700LCSE-11 . 105
SPECIFICATIONS 106
SPECIFICATIONS: PC700LC-11 106
SPECIFICATIONS: PC700LCSE-11 108
WEIGHT TABLE 112
WEIGHT TABLE: PC700LC-11 112
WEIGHT TABLE: PC700LCSE-11 113
TABLE OF FUEL, COOLANT, AND LUBRICANTS 115
10 STRUCTURE AND FUNCTION . 117
CONTENTS 118
ABBREVIATION LIST . 121
UREA SCR SYSTEM . 127
LAYOUT DRAWING OF UREA SCR SYSTEM . 127
UREA SCR SYSTEM DIAGRAM . 132
FUNCTION OF UREA SCR SYSTEM . 133
FUNCTION OF AdBlue/DEF SYSTEM . 133
INDUCEMENT STRATEGY . 135
COMPONENT PARTS OF UREA SCR SYSTEM 143
AdBlue/DEF MIXING TUBE 143
SCR ASSEMBLY 143
AdBlue/DEF TANK . 146
AdBlue/DEF PUMP . 148
AdBlue/DEF INJECTOR . 149
AdBlue/DEF HOSE . 150
AdBlue/DEF TANK HEATING VALVE . 151
BOOT-UP SYSTEM 152
LAYOUT DRAWING OF BOOT-UP SYSTEM 152
SYSTEM OPERATING LAMP SYSTEM 153
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 153
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 153
BATTERY DISCONNECT SWITCH . 154
FUNCTION OF BATTERY DISCONNECT SWITCH . 154
ENGINE SYSTEM . 155
LAYOUT DRAWING OF ENGINE SYSTEM . 155
FUNCTION OF ENGINE SYSTEM . 156
ENGINE CONTROL SYSTEM . 157
ENGINE CONTROL SYSTEM DIAGRAM . 157
FUNCTION OF ENGINE CONTROL SYSTEM . 157
AUTO-DECELERATION SYSTEM 160
AUTO-DECELERATION SYSTEM DIAGRAM 160
FUNCTION OF AUTO-DECELERATION SYSTEM 160
OPERATION OF AUTO-DECELERATION SYSTEM . 161
AUTOMATIC LOW IDLE SYSTEM . 162
AUTOMATIC LOW IDLE SYSTEM DIAGRAM . 162
FUNCTION OF AUTOMATIC LOW IDLE SYSTEM . 162
OPERATION OF AUTOMATIC LOW IDLE SYSTEM 163
ENGINE AUTOMATIC WARM-UP SYSTEM . 164
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 164
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 165
OVERHEAT PREVENTION SYSTEM 167
OVERHEAT PREVENTION SYSTEM DIAGRAM 167
FUNCTION OF OVERHEAT PREVENTION SYSTEM 168
TURBOCHARGER PROTECTION SYSTEM 169
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 169
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 170
AUTOMATIC IDLE STOP SYSTEM 171
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 171
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 171
COMPONENT PARTS OF ENGINE SYSTEM 174
PTO . 174
VGT . 174
EGR SYSTEM 178
EGR VALVE . 180
EGR COOLER 182
KCCV SYSTEM . 183
KCCV VENTILATOR . 185
KDPF 187
COOLING SYSTEM 192
LAYOUT DRAWING OF COOLING SYSTEM 192
SPECIFICATIONS OF COOLING SYSTEM 193
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN . 194
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN . 194
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN . 195
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN . 196
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN . 196
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN . 196
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 198
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN 198
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 198
COMPONENT PARTS OF COOLING SYSTEM . 200
COOLING FAN PUMP 200
COOLING FAN MOTOR . 208
CONTROL SYSTEM 215
LAYOUT DRAWING OF CONTROL SYSTEM 215
MACHINE MONITOR SYSTEM 217
MACHINE MONITOR SYSTEM DIAGRAM 217
FUNCTION OF MACHINE MONITOR SYSTEM 217
KomVision SYSTEM 219
LAYOUT DRAWING OF KOMVISION SYSTEM 219
KomVision SYSTEM DIAGRAM 220
FUNCTION OF KomVision SYSTEM 221
KOMTRAX SYSTEM 223
KOMTRAX SYSTEM DIAGRAM 223
FUNCTION OF KOMTRAX SYSTEM 223
COMPONENT PARTS OF CONTROL SYSTEM . 224
MACHINE MONITOR . 224
KomVision CONTROLLER 237
KomVision CAMERA 241
KOMTRAX TERMINAL 241
PUMP CONTROLLER . 243
RESISTOR FOR TVC VALVE 247
CAN TERMINATING RESISTOR 248
ENGINE CONTROLLER . 249
FUEL CONTROL DIAL . 255
FUEL FEED PUMP 257
FUEL FEED PUMP SWITCH . 258
HYDRAULIC SYSTEM 259
LAYOUT DRAWING OF HYDRAULIC SYSTEM 259
OLSS 262
STRUCTURE OF OLSS . 262
FUNCTION OF OLSS 262
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 263
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 274
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 274
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 276
COMPONENT PARTS OF HYDRAULIC SYSTEM . 279
HYDRAULIC TANK 279
MAIN PUMP . 281
CONTROL VALVE . 308
VARIABLE BACK PRESSURE VALVE 328
WORK EQUIPMENT SYSTEM . 331
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 331
ONE-TOUCH POWER MAXIMIZING SYSTEM . 337
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 337
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 338
MACHINE PUSH-UP SYSTEM 339
MACHINE PUSH-UP SYSTEM DIAGRAM 339
FUNCTION OF MACHINE PUSH-UP SYSTEM 340
PPC LOCK SYSTEM . 341
PPC LOCK SYSTEM DIAGRAM . 341
FUNCTION OF PPC LOCK SYSTEM . 341
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 342
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 342
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 342
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 343
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 345
WORK EQUIPMENT AND SWING PPC VALVE 345
1ST-LINE ATTACHMENT PPC VALVE . 349
PPC SHUTTLE VALVE . 351
SOLENOID VALVE 352
ANTI-DROP VALVE FOR BOOM 354
ANTI-DROP VALVE FOR ARM . 358
PILOT CIRCUIT ACCUMULATOR . 363
SWING SYSTEM 364
LAYOUT DRAWING OF SWING SYSTEM 364
SWING CONTROL SYSTEM DIAGRAM 367
FUNCTION OF SWING CONTROL SYSTEM 368
COMPONENT PARTS OF SWING SYSTEM . 371
SWING MOTOR . 371
SWING MACHINERY . 382
SWING CIRCLE 383
TRAVEL SYSTEM . 385
LAYOUT DRAWING OF TRAVEL SYSTEM . 385
TRAVEL CONTROL SYSTEM DIAGRAM . 389
FUNCTION OF TRAVEL CONTROL SYSTEM . 390
COMPONENT PARTS OF TRAVEL SYSTEM 392
TRAVEL MOTOR 392
FINAL DRIVE . 402
TRAVEL PPC VALVE 403
CENTER SWIVEL JOINT . 408
UNDERCARRIAGE AND FRAME . 410
LAYOUT DRAWING OF UNDERCARRIAGE . 410
SPECIFICATIONS OF UNDERCARRIAGE . 410
WORK EQUIPMENT 411
STRUCTURE OF WORK EQUIPMENT . 411
FUNCTION OF WORK EQUIPMENT 412
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 413
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 413
BUCKET CLEARANCE ADJUSTMENT SHIM 414
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 414
CAB AND ITS ATTACHMENTS . 415
ROPS CAB 415
STRUCTURE OF ROPS CAB . 415
FUNCTION OF ROPS CAB 415
CAB MOUNT . 416
STRUCTURE OF CAB MOUNT 416
FUNCTION OF CAB MOUNT . 416
CAB TIPPING STOPPER . 417
STRUCTURE OF CAB TIPPING STOPPER 417
FUNCTION OF CAB TIPPING STOPPER . 417
20 STANDARD VALUE TABLE . 419
CONTENTS 420
ABBREVIATION LIST . 421
STANDARD VALUE TABLE FOR ENGINE . 427
STANDARD VALUE TABLE FOR ENGINE: PC700LC-11 . 427
STANDARD VALUE TABLE FOR MACHINE 432
STANDARD VALUE TABLE FOR MACHINE: PC700LC-11 432
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 449
30 TESTING AND ADJUSTING 453
CONTENTS 454
ABBREVIATION LIST . 457
RELATED INFORMATION ON TESTING AND ADJUSTING 463
TOOLS FOR TESTING AND ADJUSTING . 463
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 472
ENGINE AND COOLING SYSTEM . 473
TEST ENGINE SPEED . 473
METHOD FOR TESTING ENGINE SPEED . 473
TEST BOOST PRESSURE . 476
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 476
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL . 477
TEST EXHAUST GAS TEMPERATURE 479
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 479
TEST EXHAUST GAS COLOR 481
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 481
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 482
TEST AND ADJUST VALVE CLEARANCE . 484
METHOD FOR TESTING VALVE CLEARANCE 484
METHOD FOR ADJUSTING VALVE CLEARANCE 485
TEST COMPRESSION PRESSURE . 487
METHOD FOR TESTING COMPRESSION PRESSURE . 487
TEST BLOWBY PRESSURE 490
METHOD FOR TESTING BLOWBY PRESSURE 490
TEST ENGINE OIL PRESSURE 492
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR . 492
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 492
TEST EGR VALVE AND VGT OIL PRESSURE . 494
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 494
TEST FUEL PRESSURE 496
METHOD FOR TESTING FUEL PRESSURE 496
TEST FUEL RETURN RATE AND LEAKAGE . 498
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE . 498
BLEED AIR FROM FUEL SYSTEM 501
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 501
TEST FUEL CIRCUIT FOR LEAKAGE . 503
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 503
HANDLE CYLINDER CUT-OUT MODE OPERATION 505
HANDLE NO-INJECTION CRANKING OPERATION 506
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 507
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 507
CLEAN FUEL DOSER 508
METHOD FOR CLEANING FUEL DOSER 508
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 510
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 510
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 516
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 516
TEST SCR RELATED FUNCTIONS 517
TEST AdBlue/DEF PUMP RAISED PRESSURE 520
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 523
TEST AdBlue/DEF LINE HEATER RELAY 1 . 527
TEST AdBlue/DEF LINE HEATER RELAY 2 . 530
TEST AdBlue/DEF PUMP HEATER RELAY . 533
TEST AdBlue/DEF TANK HEATER VALVE . 536
TEST DENITRATION EFFICIENCY OF SCR 539
CLEAN AdBlue/DEF TANK . 543
METHOD FOR CLEANING AdBlue/DEF TANK . 543
POWER TRAIN . 547
TEST SWING CIRCLE BEARING CLEARANCE . 547
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 547
UNDERCARRIAGE AND FRAME . 548
TEST AND ADJUST TRACK TENSION . 548
METHOD FOR TESTING TRACK TENSION 548
METHOD FOR ADJUSTING TRACK TENSION 548
HYDRAULIC SYSTEM 550
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 550
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 550
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 559
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT . 559
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 560
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 563
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 572
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT . 575
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 575
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 576
TEST AND ADJUST PISTON PUMP CONTROL OIL PRESSURE 577
METHOD FOR TESTING TVC VALVE OUTLET PRESSURE 577
METHOD FOR TESTING CO AND NC VALVE OUTLET PRESSURE 578
METHOD FOR TESTING JET SENSOR OUTLET PRESSURE . 579
METHOD FOR ADJUSTING TVC VALVE 581
METHOD FOR ADJUSTING CO AND NC VALVE 582
METHOD FOR ADJUSTING JET SENSOR . 583
TEST SERVO PISTON STROKE 584
METHOD FOR TESTING SERVO PISTON STROKE 584
TEST OUTLET PRESSURE OF SOLENOID VALVE 586
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 586
OPERATING CONDITION OF SOLENOID VALVE . 587
TEST PPC VALVE OUTLET PRESSURE 590
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 590
TEST PPC SHUTTLE VALVE OUTLET PRESSURE 592
METHOD FOR TESTING PPC SHUTTLE VALVE OUTLET PRESSURE 592
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 596
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 596
TEST AND ADJUST TRAVEL DEVIATION 597
METHOD FOR TESTING TRAVEL DEVIATION . 597
METHOD FOR ADJUSTING TRAVEL DEVIATION . 597
TEST COOLING FAN SPEED 599
METHOD FOR TESTING COOLING FAN SPEED 599
TEST OIL PRESSURE IN FAN PUMP CIRCUIT . 600
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT . 600
TEST FAN PUMP EPC ELECTRIC CURRENT 601
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 601
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 602
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 602
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 603
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 603
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 603
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 604
TEST OIL LEAKAGE 605
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 605
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 606
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 606
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 607
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 607
METHOD FOR TESTING OIL LEAKAGE OF SWIVEL JOINT 608
BLEED AIR FROM HYDRAULIC CIRCUIT 610
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 611
CAB AND ITS ATTACHMENTS . 614
TEST CAB TIPPING STOPPER 614
METHOD FOR TESTING CAB TIPPING STOPPER 614
METHOD FOR ADJUSTING MIRRORS 615
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 615
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 616
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 617
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 618
ELECTRICAL SYSTEM . 620
SET AND OPERATE MACHINE MONITOR . 620
OPERATOR MODE . 623
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 623
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 623
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 624
CHECKING FUNCTION OF SERVICE METER 625
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 625
SERVICE MODE 627
METHOD FOR OPERATING SERVICE MODE . 627
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 630
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 636
ABNORMALITY RECORD MENU . 647
METHOD FOR CONFIRMING MAINTENANCE RECORD 652
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 653
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 657
DEFAULT MENU 658
DIAGNOSTIC TESTS MENU . 664
ADJUSTMENT MENU . 674
METHOD FOR PERFORMING NO-INJECTION CRANKING . 678
KOMTRAX SETTINGS MENU . 679
METHOD FOR DISPLAYING SERVICE MESSAGE . 681
METHOD FOR STARTING UP KOMTRAX TERMINAL . 683
ADJUST REARVIEW CAMERA ANGLE 688
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE . 688
ADJUST KomVision CAMERA ANGLE . 690
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 690
ADJUST KomVision RELATED ITEMS 692
SETTING OF KomVision (MAIN SETTING) . 692
SETTING OF KomVision (CAMERA SETTING) . 694
SETTING OF KomVision (CAMERA CALIBRATION) . 694
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 706
HANDLE BATTERY DISCONNECT SWITCH 707
TEST DIODES . 708
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 708
METHOD FOR TESTING DIODE USING ANALOG TESTER 708
Pm CLINIC . 709
Pm CLINIC SERVICE . 709
Pm CLINIC CHECK SHEET: PC700LC-11 . 712
40 TROUBLESHOOTING 729
CONTENTS 730
ABBREVIATION LIST . 741
RELATED INFORMATION ON TROUBLESHOOTING 747
GENERAL TROUBLESHOOTING POINTS 747
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 749
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 761
CHECKS BEFORE TROUBLESHOOTING . 763
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 765
WALK-AROUND CHECK . 765
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 767
CHECK FUEL LEVEL AND TYPE . 767
CHECK IMPURE INGREDIENT IN FUEL . 768
CHECK FUEL PREFILTER 768
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 768
FUEL PREFILTER CARTRIDGE – REPLACE 769
CHECK MAIN FILTER . 770
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 771
CHECK COOLANT LEVEL (RESERVOIR TANK) 773
CHECK CLOGGING OF AIR CLEANER . 773
OUTER ELEMENT – CLEAN . 773
ELEMENTS – REPLACE 776
CHECK HYDRAULIC OIL LEVEL . 776
CHECK HYDRAULIC OIL STRAINER 778
CHECK HYDRAULIC FILTER 778
CHECK OIL LEVEL IN SWING MACHINERY CASE . 779
CHECK OIL LEVEL IN PTO CASE . 780
CHECK PTO LUBRICATION FILTER STRAINER . 780
CHECK OIL LEVEL IN FINAL DRIVE CASE . 781
BLEED AIR FROM FUEL SYSTEM 781
BLEED AIR FROM HYDRAULIC SYSTEM . 782
ELECTRICAL EQUIPMENT – CHECK METHOD . 782
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 788
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 788
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 788
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 788
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL . 789
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK . 789
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 793
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 796
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 800
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 802
CONNECTOR LIST AND LAYOUT . 805
CONNECTOR CONTACT IDENTIFICATION 819
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 859
FUSE LOCATION TABLE . 865
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 868
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 872
FAILURE CODES TABLE . 874
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 891
FAILURE CODE [879AKA] . 891
FAILURE CODE [879AKB] . 892
FAILURE CODE [879BKA] . 893
FAILURE CODE [879BKB] . 895
FAILURE CODE [879CKA] . 897
FAILURE CODE [879CKB] . 898
FAILURE CODE [879DKZ] . 899
FAILURE CODE [879EMC] . 901
FAILURE CODE [879FMC] . 902
FAILURE CODE [879GKX] . 903
FAILURE CODE [989L00] . 905
FAILURE CODE [989M00] . 906
FAILURE CODE [989N00] . 907
FAILURE CODE [A1U0N3] . 908
FAILURE CODE [A1U0N4] . 910
FAILURE CODE [A900FR] . 912
FAILURE CODE [A900N6] . 913
FAILURE CODE [A900NY] . 914
FAILURE CODE [AA10NX] . 915
FAILURE CODE [AB00KE] . 917
FAILURE CODE [AQ10N3] . 919
FAILURE CODE [AS00N3] . 921
FAILURE CODE [AS00R2] . 923
FAILURE CODE [AS00R3] . 924
FAILURE CODE [AS00R4] . 925
FAILURE CODE [AS00R5] . 926
FAILURE CODE [AS00R6] . 927
FAILURE CODE [AS00ZK] . 928
FAILURE CODE [AS10KM] . 929
FAILURE CODE [AS10NR] . 930
FAILURE CODE [AS10NT] . 931
FAILURE CODE [B@BAZG] . 932
FAILURE CODE [B@BAZK] . 933
FAILURE CODE [B@BCNS] . 935
FAILURE CODE [B@BCZK] . 936
FAILURE CODE [B@HANS] . 938
FAILURE CODE [CA115] 939
FAILURE CODE [CA122] 940
FAILURE CODE [CA123] 942
FAILURE CODE [CA131] 944
FAILURE CODE [CA132] 946
FAILURE CODE [CA135] 948
FAILURE CODE [CA141] 950
FAILURE CODE [CA144] 952
FAILURE CODE [CA145] 954
FAILURE CODE [CA153] 956
FAILURE CODE [CA154] 959
FAILURE CODE [CA187] 962
FAILURE CODE [CA221] 964
FAILURE CODE [CA222] 966
FAILURE CODE [CA227] 968
FAILURE CODE [CA234] 969
FAILURE CODE [CA238] 970
FAILURE CODE [CA239] 972
FAILURE CODE [CA249] 974
FAILURE CODE [CA256] 976
FAILURE CODE [CA271] 978
FAILURE CODE [CA272] 980
FAILURE CODE [CA273] 981
FAILURE CODE [CA274] 983
FAILURE CODE [CA322] 984
FAILURE CODE [CA323] 986
FAILURE CODE [CA324] 988
FAILURE CODE [CA325] 990
FAILURE CODE [CA331] 992
FAILURE CODE [CA332] 994
FAILURE CODE [CA343] 996
FAILURE CODE [CA351] 997
FAILURE CODE [CA352] 998
FAILURE CODE [CA356] 1001
FAILURE CODE [CA357] 1003
FAILURE CODE [CA386] 1005
FAILURE CODE [CA441] 1006
FAILURE CODE [CA442] 1008
FAILURE CODE [CA449] 1009
FAILURE CODE [CA451] 1010
FAILURE CODE [CA452] 1012
FAILURE CODE [CA515] 1014
FAILURE CODE [CA516] 1016
FAILURE CODE [CA553] 1018
FAILURE CODE [CA555] 1019
FAILURE CODE [CA556] 1020
FAILURE CODE [CA559] 1021
FAILURE CODE [CA595] 1026
FAILURE CODE [CA687] 1027
FAILURE CODE [CA689] 1029
FAILURE CODE [CA691] 1031
FAILURE CODE [CA692] 1033
FAILURE CODE [CA697] 1035
FAILURE CODE [CA698] 1036
FAILURE CODE [CA731] 1037
FAILURE CODE [CA778] 1038
FAILURE CODE [CA1117] .1041
FAILURE CODE [CA1664] .1042
FAILURE CODE [CA1669] .1046
FAILURE CODE [CA1673] .1047
FAILURE CODE [CA1677] .1048
FAILURE CODE [CA1678] .1049
FAILURE CODE [CA1682] .1050
FAILURE CODE [CA1683] .1052
FAILURE CODE [CA1684] .1054
FAILURE CODE [CA1686] .1056
FAILURE CODE [CA1691] .1057
FAILURE CODE [CA1694] .1060
FAILURE CODE [CA1695] .1062
FAILURE CODE [CA1696] .1063
FAILURE CODE [CA1712] .1065
FAILURE CODE [CA1713] .1068
FAILURE CODE [CA1714] .1070
FAILURE CODE [CA1715] .1071
FAILURE CODE [CA1776] .1072
FAILURE CODE [CA1777] .1075
FAILURE CODE [CA1843] .1078
FAILURE CODE [CA1844] .1080
FAILURE CODE [CA1879] .1083
FAILURE CODE [CA1881] .1086
FAILURE CODE [CA1883] .1088
FAILURE CODE [CA1885] .1092
FAILURE CODE [CA1887] .1094
FAILURE CODE [CA1921] .1096
FAILURE CODE [CA1922] .1099
FAILURE CODE [CA1923] .1105
FAILURE CODE [CA1924] .1107
FAILURE CODE [CA1925] .1109
FAILURE CODE [CA1927] .1111
FAILURE CODE [CA1928] .1113
FAILURE CODE [CA1942] .1115
FAILURE CODE [CA1963] .1116
FAILURE CODE [CA1977] .1120
FAILURE CODE [CA1993] .1123
FAILURE CODE [CA2185] .1126
FAILURE CODE [CA2186] .1128
FAILURE CODE [CA2249] .1130
FAILURE CODE [CA2265] .1131
FAILURE CODE [CA2266] .1133
FAILURE CODE [CA2271] .1135
FAILURE CODE [CA2272] .1137
FAILURE CODE [CA2349] .1139
FAILURE CODE [CA2353] .1141
FAILURE CODE [CA2357] .1143
FAILURE CODE [CA2381] .1144
FAILURE CODE [CA2382] .1146
FAILURE CODE [CA2383] .1148
FAILURE CODE [CA2386] .1150
FAILURE CODE [CA2387] .1152
FAILURE CODE [CA2555] .1153
FAILURE CODE [CA2556] .1155
FAILURE CODE [CA2637] .1157
FAILURE CODE [CA2639] .1159
FAILURE CODE [CA2732] .1161
FAILURE CODE [CA2733] .1163
FAILURE CODE [CA2741] .1165
FAILURE CODE [CA2765] .1166
FAILURE CODE [CA2771] .1167
FAILURE CODE [CA2777] .1173
FAILURE CODE [CA2878] .1176
FAILURE CODE [CA2881] .1179
FAILURE CODE [CA2976] .1182
FAILURE CODE [CA3133] .1184
FAILURE CODE [CA3134] .1186
FAILURE CODE [CA3135] .1188
FAILURE CODE [CA3142] .1191
FAILURE CODE [CA3143] .1192
FAILURE CODE [CA3144] .1193
FAILURE CODE [CA3146] .1195
FAILURE CODE [CA3147] .1196
FAILURE CODE [CA3148] .1197
FAILURE CODE [CA3151] .1199
FAILURE CODE [CA3165] .1204
FAILURE CODE [CA3167] .1206
FAILURE CODE [CA3229] .1210
FAILURE CODE [CA3231] .1213
FAILURE CODE [CA3232] .1216
FAILURE CODE [CA3235] .1221
FAILURE CODE [CA3239] .1223
FAILURE CODE [CA3241] .1226
FAILURE CODE [CA3242] .1229
FAILURE CODE [CA3251] .1232
FAILURE CODE [CA3253] .1236
FAILURE CODE [CA3254] .1242
FAILURE CODE [CA3255] .1246
FAILURE CODE [CA3256] .1249
FAILURE CODE [CA3311] .1252
FAILURE CODE [CA3312] .1255
FAILURE CODE [CA3313] .1258
FAILURE CODE [CA3314] .1259
FAILURE CODE [CA3315] .1260
FAILURE CODE [CA3316] .1263
FAILURE CODE [CA3317] .1264
FAILURE CODE [CA3318] .1265
FAILURE CODE [CA3319] .1268
FAILURE CODE [CA3321] .1269
FAILURE CODE [CA3322] .1270
FAILURE CODE [CA3419] .1273
FAILURE CODE [CA3421] .1275
FAILURE CODE [CA3497] .1277
FAILURE CODE [CA3498] .1278
FAILURE CODE [CA3543] .1279
FAILURE CODE [CA3545] .1284
FAILURE CODE [CA3547] .1286
FAILURE CODE [CA3558] .1287
FAILURE CODE [CA3559] .1289
FAILURE CODE [CA3562] .1291
FAILURE CODE [CA3563] .1293
FAILURE CODE [CA3567] .1296
FAILURE CODE [CA3568] .1299
FAILURE CODE [CA3571] .1303
FAILURE CODE [CA3572] .1305
FAILURE CODE [CA3574] .1307
FAILURE CODE [CA3575] .1310
FAILURE CODE [CA3577] .1312
FAILURE CODE [CA3578] .1314
FAILURE CODE [CA3582] .1316
FAILURE CODE [CA3583] .1321
FAILURE CODE [CA3596] .1323
FAILURE CODE [CA3649] .1327
FAILURE CODE [CA3681] .1330
FAILURE CODE [CA3682] .1335
FAILURE CODE [CA3713] .1341
FAILURE CODE [CA3717] .1344
FAILURE CODE [CA3718] .1345
FAILURE CODE [CA3725] .1346
FAILURE CODE [CA3748] .1349
FAILURE CODE [CA3751] .1351
FAILURE CODE [CA3755] .1353
FAILURE CODE [CA3866] .1355
FAILURE CODE [CA3867] .1359
FAILURE CODE [CA3868] .1362
FAILURE CODE [CA3899] .1366
FAILURE CODE [CA3911] .1369
FAILURE CODE [CA3912] .1373
FAILURE CODE [CA3932] .1375
FAILURE CODE [CA3933] .1377
FAILURE CODE [CA3934] .1379
FAILURE CODE [CA3935] .1382
FAILURE CODE [CA3936] .1384
FAILURE CODE [CA4151] .1386
FAILURE CODE [CA4152] .1390
FAILURE CODE [CA4155] .1394
FAILURE CODE [CA4156] .1396
FAILURE CODE [CA4157] .1399
FAILURE CODE [CA4158] .1401
FAILURE CODE [CA4159] .1403
FAILURE CODE [CA4161] .1405
FAILURE CODE [CA4162] .1408
FAILURE CODE [CA4163] .1411
FAILURE CODE [CA4164] .1413
FAILURE CODE [CA4165] .1416
FAILURE CODE [CA4166] .1419
FAILURE CODE [CA4168] .1422
FAILURE CODE [CA4169] .1427
FAILURE CODE [CA4171] .1432
FAILURE CODE [CA4249] .1437
FAILURE CODE [CA4251] .1441
FAILURE CODE [CA4259] .1445
FAILURE CODE [CA4261] .1448
FAILURE CODE [CA4277] .1451
FAILURE CODE [CA4281] .1454
FAILURE CODE [CA4459] .1457
FAILURE CODE [CA4461] .1460
FAILURE CODE [CA4658] .1463
FAILURE CODE [CA4731] .1467
FAILURE CODE [CA4732] .1468
FAILURE CODE [CA4739] .1469
FAILURE CODE [CA4768] .1470
FAILURE CODE [CA4769] .1472
FAILURE CODE [CA4842] .1475
FAILURE CODE [CA4952] .1478
FAILURE CODE [CA5115] .1480
FAILURE CODE [CA5179] .1483
FAILURE CODE [CA5181] .1485
FAILURE CODE [CA5383] .1487
FAILURE CODE [D110KB] .1489
FAILURE CODE [D163KB] .1491
FAILURE CODE [D195KA] .1493
FAILURE CODE [D195KB] .1495
FAILURE CODE [D19JKZ] .1497
FAILURE CODE [D811MC] .1499
FAILURE CODE [D862KA] .1500
FAILURE CODE [D8ALKA] .1501
FAILURE CODE [D8ALKB] .1503
FAILURE CODE [D8AQKR] .1505
FAILURE CODE [DA20MC] .1509
FAILURE CODE [DA22KK] .1510
FAILURE CODE [DA25KP] .1512
FAILURE CODE [DA26KP] .1514
FAILURE CODE [DA29KQ] .1517
FAILURE CODE [DA2LKA] .1519
FAILURE CODE [DA2LKB] .1521
FAILURE CODE [DA2QKR] .1523
FAILURE CODE [DA2RKR] .1528
FAILURE CODE [DAF0KM] .1533
FAILURE CODE [DAF0MB] .1534
FAILURE CODE [DAF0MC] .1535
FAILURE CODE [DAF8KB] .1536
FAILURE CODE [DAF9KQ] .1538
FAILURE CODE [DAFGMC] .1539
FAILURE CODE [DAFLKA] .1540
FAILURE CODE [DAFLKB] .1542
FAILURE CODE [DAFQKR] .1544
FAILURE CODE [DAZ9KQ] .1548
FAILURE CODE [DAZQKR] .1549
FAILURE CODE [DB2QKR] .1553
FAILURE CODE [DB2RKR] .1558
FAILURE CODE [DBP0KM] .1563
FAILURE CODE [DBP0KT] .1564
FAILURE CODE [DBPQKR] .1565
FAILURE CODE [DDNRKA] .1570
FAILURE CODE [DDNRKY] .1572
FAILURE CODE [DDNS00] .1574
FAILURE CODE [DGE5KB] .1576
FAILURE CODE [DGH2KA] .1577
FAILURE CODE [DGH2KB] .1579
FAILURE CODE [DHA4KA] .1581
FAILURE CODE [DHAAMA] .1583
FAILURE CODE [DHACMA] .1585
FAILURE CODE [DHPAMA] .1587
FAILURE CODE [DHPBMA] .1589
FAILURE CODE [DHS3MA] .1591
FAILURE CODE [DHS4MA] .1594
FAILURE CODE [DHS8MA] .1597
FAILURE CODE [DHS9MA] .1600
FAILURE CODE [DHSAMA] .1603
FAILURE CODE [DHSBMA] .1606
FAILURE CODE [DHSCMA] .1609
FAILURE CODE [DHSDMA] .1612
FAILURE CODE [DHSFMA] .1615
FAILURE CODE [DHSGMA] .1618
FAILURE CODE [DHSHMA] .1621
FAILURE CODE [DHSJMA] .1624
FAILURE CODE [DHSVMA] .1627
FAILURE CODE [DKULKA] .1629
FAILURE CODE [DKULKB] .1631
FAILURE CODE [DKULKY] .1633
FAILURE CODE [DLM3KA] .1635
FAILURE CODE [DLM3KB] .1637
FAILURE CODE [DLM3MB] .1639
FAILURE CODE [DR10KA] .1640
FAILURE CODE [DR21KX] .1643
FAILURE CODE [DR31KX] .1645
FAILURE CODE [DUMBKA] .1647
FAILURE CODE [DUMBKB] .1649
FAILURE CODE [DV20KB] .1651
FAILURE CODE [DW43KA] .1652
FAILURE CODE [DW43KB] .1654
FAILURE CODE [DW43KY] .1656
FAILURE CODE [DW45KA] .1657
FAILURE CODE [DW45KB] .1660
FAILURE CODE [DW45KY] .1663
FAILURE CODE [DW48KA] .1665
FAILURE CODE [DW48KB] .1667
FAILURE CODE [DW48KY] .1669
FAILURE CODE [DW4CKY] .1670
FAILURE CODE [DW4XKA] .1672
FAILURE CODE [DW4XKB] .1674
FAILURE CODE [DW4XKY] .1676
FAILURE CODE [DW7BKA] .1677
FAILURE CODE [DW7BKB] .1679
FAILURE CODE [DW7BKY] .1681
FAILURE CODE [DWK0KA] .1682
FAILURE CODE [DWK0KB] .1684
FAILURE CODE [DWK0KY] .1686
FAILURE CODE [DWK2KA] .1687
FAILURE CODE [DWK2KB] .1689
FAILURE CODE [DWK2KY] .1691
FAILURE CODE [DWK8KA] .1692
FAILURE CODE [DWK8KB] .1694
FAILURE CODE [DWK8KY] .1696
FAILURE CODE [DX16KA] .1697
FAILURE CODE [DX16KB] .1699
FAILURE CODE [DXA2KA] .1700
FAILURE CODE [DXA2KB] .1703
FAILURE CODE [DXA3KA] .1705
FAILURE CODE [DXA3KB] .1708
FAILURE CODE [DY20KA] .1710
FAILURE CODE [DY20MA] .1712
FAILURE CODE [DY2CKB] .1714
FAILURE CODE [DY2DKB] .1716
FAILURE CODE [DY2EKB] .1718
FAILURE CODE [DY2FMA] .1720
FAILURE CODE [DY2GKM] .1722
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1724
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1724
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1730
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1733
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1735
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1737
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1740
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1741
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1742
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1743
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1744
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1745
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1746
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1747
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1748
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1749
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1750
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1752
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1753
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1754
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1755
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1757
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1758
E-23 FUNCTION SWITCH DOES NOT OPERATE .1759
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1760
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1761
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1762
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1763
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1764
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1765
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1766
E-31 ALARM BUZZER CANNOT BE CANCELED 1767
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1768
E-33 SERVICE MODE CANNOT BE SELECTED 1769
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1770
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1773
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1775
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1778
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1780
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1782
E-40 ALARM DOES NOT SOUND DURING TRAVEL .1783
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1785
E-42 HORN DOES NOT SOUND 1786
E-43 HORN DOES NOT STOP SOUNDING 1789
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1791
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1792
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1794
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1795
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1796
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1797
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1798
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1799
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1800
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1801
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1802
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1803
E-56 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1805
E-57 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 1806
E-58 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1808
E-59 STEP LIGHT DOES NOT LIGHT UP .1809
E-60 STEP LIGHT DOES NOT GO OUT .1811
E-61 BOOM SHOCKLESS FUNCTION CANNOT BE CANCELED .1813
E-62 BOOM SHOCKLESS FUNCTION DOES NOT WORK 1815
E-63 ELECTRIC GREASE GUN DOES NOT WORK 1816
E-64 ELECTRIC GREASE GUN DOES NOT STOP 1818
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1819
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1819
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1820
H-3 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1822
H-4 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1823
H-5 TRAVEL SPEED OR POWER IS LOW 1824
H-6 AUTO-DECELERATION FUNCTION CANNOT BE CANCELED .1825
H-7 SPEED OR POWER OF BOOM IS LOW .1826
H-8 ARM SPEED OR POWER IS LOW .1828
H-9 BUCKET SPEED OR POWER IS LOW 1829
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION .1830
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE .1831
H-12 HYDRAULIC DRIFT OF ARM IS LARGE 1832
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE .1833
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1834
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1835
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1836
H-17 MACHINE DOES NOT TRAVEL STRAIGHT .1837
H-18 SPEED OF BOOM AND BUCKET IS SLOW AT COMBINED OPERATION OF ARM, BOOM AND BUCKET .1838
H-19 SPEED OF BOOM, ARM, SWING AND TRAVEL IS SLOW AT COMBINED OPERATION OF BUCKET, BOOM AND ARM .1839
H-20 SWING SPEED IS SLOW AT COMBINED OPERATION OF ARM AND SWING .1840
H-21 TRAVEL DEVIATION IS LARGE AT START OF TRAVELING 1841
H-22 TRAVEL DEVIATION IS LARGE AT COMBINED OPERATION 1843
H-23 ONE OF TRACKS DOES NOT RUN .1844
H-24 TRAVEL SPEED DOES NOT CHANGE .1846
H-25 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1847
H-26 SWINGS ONLY IN ONE DIRECTION .1848
H-27 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1849
H-28 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1850
H-29 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1851
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1852
H-31 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1853
H-32 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1854
H-33 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1855
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1856
H-35 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1857
H-36 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1858
TROUBLESHOOTING OF ENGINE (S-MODE) 1859
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1859
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1860
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1861
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1862
S-4 ENGINE STARTABILITY IS POOR .1863
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1865
S-6 ENGINE STOPS DURING OPERATION .1867
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1869
S-8 ENGINE LACKS POWER 1870
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1872
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1874
S-11 OIL BECOMES CONTAMINATED QUICKLY .1875
S-12 FUEL CONSUMPTION IS EXCESSIVE 1876
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1877
S-14 OIL PRESSURE DROPS .1878
S-15 FUEL MIXES INTO ENGINE OIL .1880
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1881
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1882
S-18 UNUSUAL NOISE IS HEARD .1884
S-19 VIBRATION IS EXCESSIVE .1885
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1886
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1887
S-22 ACTIVE REGENERATION TAKES TIME .1889
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1891
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1892
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1894
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1895
50 DISASSEMBLY AND ASSEMBLY .1897
CONTENTS 1898
ABBREVIATION LIST .1903
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1909
HOW TO READ THIS MANUAL .1909
COATING MATERIALS LIST 1911
SPECIAL TOOLS LIST 1916
SPECIAL TOOLS LIST 1933
SKETCHES OF SPECIAL TOOLS .1950
ENGINE AND COOLING SYSTEM .1957
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .1957
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1957
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1959
REMOVE AND INSTALL INJECTOR ASSEMBLY 1964
METHOD FOR REMOVING INJECTOR ASSEMBLY .1964
METHOD FOR INSTALLING INJECTOR ASSEMBLY .1969
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 1978
METHOD FOR REMOVING FUEL DOSER ASSEMBLY .1978
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY .1979
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .1981
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1982
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1992
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2009
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2009
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2011
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2013
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2013
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2016
REMOVE AND INSTALL STARTER ASSEMBLY .2020
METHOD FOR REMOVING STARTER ASSEMBLY 2020
METHOD FOR INSTALLING STARTER ASSEMBLY 2020
REMOVE AND INSTALL ALTERNATOR BELT 2022
METHOD FOR REMOVING ALTERNATOR BELT .2022
METHOD FOR INSTALLING ALTERNATOR BELT .2023
REMOVE AND INSTALL RADIATOR ASSEMBLY 2025
METHOD FOR REMOVING RADIATOR ASSEMBLY .2025
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2028
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2032
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2032
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2035
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2039
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2039
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2041
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY .2044
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2044
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2053
REMOVE AND INSTALL ENGINE PTO AND HYDRAULIC ASSEMBLY 2062
METHOD FOR REMOVING ENGINE PTO AND HYDRAULIC ASSEMBLY .2062
METHOD FOR INSTALLING ENGINE PTO AND HYDRAULIC ASSEMBLY .2073
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2084
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2084
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2085
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2088
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2088
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2090
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2097
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2097
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2101
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2107
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2107
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2110
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2114
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2115
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2121
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2126
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2126
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2127
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2129
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2129
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2129
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2131
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2131
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2131
REMOVE AND INSTALL KDPF ASSEMBLY 2132
METHOD FOR REMOVING KDPF ASSEMBLY .2132
METHOD FOR INSTALLING KDPF ASSEMBLY .2136
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2140
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2141
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2145
REMOVE AND INSTALL SCR ASSEMBLY .2150
METHOD FOR REMOVING SCR ASSEMBLY 2150
METHOD FOR INSTALLING SCR ASSEMBLY 2152
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2156
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2157
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2163
REMOVE AND INSTALL KCCV ASSEMBLY 2171
METHOD FOR REMOVING KCCV ASSEMBLY .2171
METHOD FOR INSTALLING KCCV ASSEMBLY .2172
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2174
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2174
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2179
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2186
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2186
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2189
REMOVE AND INSTALL AdBlue/DEF PUMP 2193
METHOD FOR REMOVING AdBlue/DEF PUMP .2193
METHOD FOR INSTALLING AdBlue/DEF PUMP .2196
REMOVE AND INSTALL AdBlue/DEF HOSE 2199
METHOD FOR REMOVING AdBlue/DEF HOSE .2200
METHOD FOR INSTALLING AdBlue/DEF HOSE .2208
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2214
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2214
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2215
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2216
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2216
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2217
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2218
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2218
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2219
POWER TRAIN .2220
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY .2220
METHOD FOR DISASSEMBLING PTO ASSEMBLY .2220
METHOD FOR ASSEMBLING PTO ASSEMBLY 2221
REMOVE AND INSTALL PTO ASSEMBLY .2224
METHOD FOR REMOVING PTO ASSEMBLY 2224
METHOD FOR INSTALLING PTO ASSEMBLY 2225
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2228
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2228
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2229
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2230
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2231
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2236
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2245
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2245
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2246
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2248
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2248
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2252
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2257
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2257
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2258
UNDERCARRIAGE AND FRAME .2259
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 2259
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING .2259
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 2260
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2262
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY .2262
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY .2263
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2264
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY .2264
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY .2264
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD .2266
METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD .2268
METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD 2269
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2272
METHOD FOR SEPARATING TRACK ASSEMBLY 2272
METHOD FOR INSTALLING TRACK ASSEMBLY 2273
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2275
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2275
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2276
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2277
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2277
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2278
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2281
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2281
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2282
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2284
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2284
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2285
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2288
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2288
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2289
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2291
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2291
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2292
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2294
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2294
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2294
HYDRAULIC SYSTEM 2296
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2296
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2296
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2296
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2298
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2299
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2300
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2301
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2301
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2303
REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY 2306
METHOD FOR REMOVING HYDRAULIC PUMP ASSEMBLY .2306
METHOD FOR INSTALLING HYDRAULIC PUMP ASSEMBLY .2308
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2314
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2314
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2317
REMOVE AND INSTALL SWING MOTOR ASSEMBLY .2321
METHOD FOR REMOVING SWING MOTOR ASSEMBLY 2321
METHOD FOR INSTALLING SWING MOTOR ASSEMBLY 2322
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2323
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2323
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2324
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2326
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2326
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2327
DISASSEMBLE AND ASSEMBLE GREASE GUN ASSEMBLY 2329
METHOD FOR DISASSEMBLING GREASE GUN ASSEMBLY 2329
METHOD FOR ASSEMBLING GREASE GUN ASSEMBLY .2329
WORK EQUIPMENT 2330
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY .2330
METHOD FOR REMOVING BUCKET CYLINDER ASSEMBLY 2330
METHOD FOR INSTALLING BUCKET CYLINDER ASSEMBLY 2331
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY 2333
METHOD FOR REMOVING ARM CYLINDER ASSEMBLY .2333
METHOD FOR INSTALLING ARM CYLINDER ASSEMBLY .2334
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY .2336
METHOD FOR REMOVING BOOM CYLINDER ASSEMBLY 2336
METHOD FOR INSTALLING BOOM CYLINDER ASSEMBLY 2337
REMOVE AND INSTALL BUCKET ASSEMBLY 2339
METHOD FOR REMOVING BUCKET ASSEMBLY .2339
METHOD FOR INSTALLING BUCKET ASSEMBLY .2340
REMOVE AND INSTALL ARM ASSEMBLY .2341
METHOD FOR REMOVING ARM ASSEMBLY 2341
METHOD FOR INSTALLING ARM ASSEMBLY 2343
REMOVE AND INSTALL BOOM ASSEMBLY 2345
METHOD FOR REMOVING BOOM ASSEMBLY .2345
METHOD FOR INSTALLING BOOM ASSEMBLY .2346
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2348
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2348
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2350
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 2352
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2352
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2354
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM .2355
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM 2355
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM 2357
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY .2358
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY .2358
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY 2358
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2359
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2360
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2362
CAB AND ITS ATTACHMENTS .2367
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2367
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2367
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2374
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2381
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2383
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2383
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2394
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2394
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2397
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2403
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2403
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2406
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2411
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2411
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2415
REMOVE AND INSTALL OPERATOR’S SEAT 2421
METHOD FOR REMOVING OPERATOR’S SEAT .2421
METHOD FOR INSTALLING OPERATOR’S SEAT .2423
REMOVE AND INSTALL SEAT BELT 2426
METHOD FOR REMOVING SEAT BELT .2426
METHOD FOR INSTALLING SEAT BELT .2426
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2428
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2428
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2433
ELECTRICAL SYSTEM .2441
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2441
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2441
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2442
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2445
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2445
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2447
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2450
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2450
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2452
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2456
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2456
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2457
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2458
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2458
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2459
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2461
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2461
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2463
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2465
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2465
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2466
60 MAINTENANCE STANDARD .2469
CONTENTS 2470
ABBREVIATION LIST .2471
ENGINE AND COOLING SYSTEM .2477
MAINTENANCE STANDARD OF ENGINE MOUNT 2477
MAINTENANCE STANDARD FOR PTO 2479
MAINTENANCE STANDARD OF COOLING SYSTEM 2480
MAINTENANCE STANDARD OF COOLING FAN PUMP 2481
MAINTENANCE STANDARD OF SERVO VALVE .2482
MAINTENANCE STANDARD OF COOLING FAN MOTOR .2483
POWER TRAIN .2484
MAINTENANCE STANDARD OF SWING CIRCLE 2484
MAINTENANCE STANDARD OF SWING MACHINERY .2485
MAINTENANCE STANDARD OF FINAL DRIVE .2487
MAINTENANCE STANDARD OF SPROCKET 2489
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2490
UNDERCARRIAGE AND FRAME .2492
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2492
MAINTENANCE STANDARD OF IDLER .2494
MAINTENANCE STANDARD OF TRACK ROLLER 2496
MAINTENANCE STANDARD OF CARRIER ROLLER 2498
MAINTENANCE STANDARD OF TRACK SHOE 2499
MAINTENANCE STANDARD OF DOUBLE SHOE .2502
MAINTENANCE STANDARD OF TRIPLE SHOE .2503
HYDRAULIC SYSTEM 2504
MAINTENANCE STANDARD OF MAIN PUMP .2504
MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE .2506
MAINTENANCE STANDARD OF MAIN PUMP TVC VALVE .2508
MAINTENANCE STANDARD OF MAIN PUMP CO AND NC VALVE .2509
MAINTENANCE STANDARD OF SWING MOTOR .2510
MAINTENANCE STANDARD OF CONTROL VALVE .2511
MAINTENANCE STANDARD OF TRAVEL SHUTTLE VALVE OF CONTROL VALVE .2518
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE VALVE 2519
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2520
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .2522
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2524
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2527
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE .2530
MAINTENANCE STANDARD OF SOLENOID VALVE 2532
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2533
WORK EQUIPMENT 2534
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2534
DIMENSION OF ARM 2539
DIMENSIONS OF BUCKET 2541
MAINTENANCE STANDARD OF BOOM CYLINDER .2543
MAINTENANCE STANDARD OF ARM CYLINDER 2544
MAINTENANCE STANDARD OF BUCKET CYLINDER .2545
80 APPENDIX .2547
CONTENTS 2548
ABBREVIATION LIST .2550
AIR CONDITIONER SYSTEM 2556
PRECAUTIONS FOR REFRIGERANT .2556
AIR CONDITIONER COMPONENT .2557
SPECIFICATIONS OF AIR CONDITIONER .2559
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2560
OUTLINE OF REFRIGERATION CYCLE 2561
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2563
AIR CONDITIONER UNIT 2563
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2563
FUNCTION OF AIR CONDITIONER UNIT 2565
COMPONENT PARTS OF AIR CONDITIONER UNIT .2567
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2568
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2568
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2568
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2568
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2569
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2569
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2569
FUNCTION OF DUAL PRESSURE SWITCH 2570
AIR CONDITIONER CONTROLLER 2571
STRUCTURE OF AIR CONDITIONER CONTROLLER .2571
COMPRESSOR 2572
STRUCTURE OF COMPRESSOR .2572
SPECIFICATIONS OF COMPRESSOR 2572
FUNCTION OF COMPRESSOR 2572
CONDENSER .2573
STRUCTURE OF CONDENSER 2573
SPECIFICATIONS OF CONDENSER .2573
FUNCTION OF CONDENSER .2573
RECEIVER DRIER 2574
STRUCTURE OF RECEIVER DRIER .2574
SPECIFICATIONS OF RECEIVER DRIER 2574
FUNCTION OF RECEIVER DRIER 2574
SENSORS FOR AIR CONDITIONER SYSTEM 2575
STRUCTURE OF SUNLIGHT SENSOR 2575
FUNCTION OF SUNLIGHT SENSOR .2575
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2575
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2575
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2577
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2579
AIR CONDITIONER SYSTEM DIAGRAM 2581
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2582
FUNCTION OF AIR CONDITIONER CONTROLLER 2583
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2584
TESTING AIR LEAKAGE (DUCT) 2586
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2586
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2588
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2589
TEST VENT (MODE) CHANGEOVER .2590
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2590
TESTING FRESH/RECIRC AIR CHANGEOVER .2592
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2592
TEST SUNLIGHT SENSOR 2593
METHOD FOR TESTING SUNLIGHT SENSOR 2593
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2594
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2594
TEST RELAYS .2596
METHOD FOR TESTING RELAYS .2596
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2597
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2599
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2602
FAILURE CODE [879AKA] .2604
FAILURE CODE [879AKB] .2605
FAILURE CODE [879BKA] .2606
FAILURE CODE [879BKB] .2608
FAILURE CODE [879CKA] .2610
FAILURE CODE [879CKB] .2611
FAILURE CODE [879DKZ] .2612
FAILURE CODE [879EMC] .2614
FAILURE CODE [879FMC] .2615
FAILURE CODE [879GKX] .2616
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2618
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2620
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2623
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2625
TROUBLESHOOTING USING GAUGE PRESSURE 2627
CONNECTION OF SERVICE TOOL 2630
METHOD FOR CONNECTING SERVICE TOOL 2630
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2632
HANDLE COMPRESSOR OIL .2634
90 CIRCUIT DIAGRAMS .2637
CONTENTS 2638
ABBREVIATION LIST .2639
HYDRAULIC CIRCUIT DIAGRAM .2645
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2645
HYDRAULIC CIRCUIT DIAGRAM .2649
ELECTRICAL CIRCUIT DIAGRAM 2651
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2651
ELECTRICAL CIRCUIT DIAGRAM (1/12) .2655
ELECTRICAL CIRCUIT DIAGRAM (2/12) .2657
ELECTRICAL CIRCUIT DIAGRAM (3/12) .2659
ELECTRICAL CIRCUIT DIAGRAM (4/12) .2661
ELECTRICAL CIRCUIT DIAGRAM (5/12) .2663
ELECTRICAL CIRCUIT DIAGRAM (6/12) .2665
ELECTRICAL CIRCUIT DIAGRAM (7/12) .2667
ELECTRICAL CIRCUIT DIAGRAM (8/12) .2669
ELECTRICAL CIRCUIT DIAGRAM (9/12) .2671
ELECTRICAL CIRCUIT DIAGRAM (10/12) 2673
ELECTRICAL CIRCUIT DIAGRAM (11/12) 2675
ELECTRICAL CIRCUIT DIAGRAM (12/12) 2677
INDEX .2679

DESCRIPTION:

Komatsu PC700LC -11 Hydraulic Excavator Shop Manual UENBM00430 – PDF DOWNLOAD

SERIAL NUMBERS

• 80013 and up
• K70001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE 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.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

G.B 31/12/24