Komatsu PC700LC -11 Hydraulic Excavator Shop Manual UENBM00433 PDF

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Komatsu PC700LC -11 Hydraulic Excavator Shop Manual UENBM00433 –  PDF DOWNLOAD

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Komatsu PC700LC -11 Hydraulic Excavator Shop Manual UENBM00433 –  PDF DOWNLOAD

Language : English
Pages : 2734
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC700LC -11 Hydraulic Excavator Shop Manual UENBM00433 –  PDF DOWNLOAD

• 80013 and up
• K70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 22
FOREWORD, SAFETY, BASIC INFORMATION . 28
HOW TO READ THE SHOP MANUAL . 28
SAFETY NOTICE FOR OPERATION . 30
PRECAUTIONS TO PREVENT FIRE . 38
ACTIONS IF FIRE OCCURS 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 42
PRECAUTIONS FOR DEF . 43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 43
PRECAUTIONS FOR ADDING 43
PRECAUTIONS FOR STORING . 43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 43
THE OTHER PRECAUTIONS . 43
STORE AdBlue/DEF 44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 58
PRACTICAL USE OF KOMTRAX 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 74
HOW TO READ ELECTRICAL WIRE CODE 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 79
STANDARD TIGHTENING TORQUE TABLE 82
CONVERSION TABLE 89
01 SPECIFICATIONS . 95
CONTENTS 96
ABBREVIATION LIST . 97
SPECIFICATIONS 103
SPECIFICATION DRAWING . 103
SPECIFICATION DRAWING: PC700LC-11 . 103
SPECIFICATION DRAWING: PC700LCSE-11 . 104
WORKING RANGE DRAWINGS 106
WORKING RANGE: PC700LC-11 . 106
WORKING RANGE: PC700LCSE-11 . 107
SPECIFICATIONS 108
SPECIFICATIONS: PC700LC-11 108
SPECIFICATIONS: PC700LCSE-11 110
WEIGHT TABLE 114
WEIGHT TABLE: PC700LC-11 114
WEIGHT TABLE: PC700LCSE-11 115
TABLE OF FUEL, COOLANT, AND LUBRICANTS 117
10 STRUCTURE AND FUNCTION . 119
CONTENTS 120
ABBREVIATION LIST . 123
UREA SCR SYSTEM . 129
LAYOUT DRAWING OF UREA SCR SYSTEM . 129
UREA SCR SYSTEM DIAGRAM . 134
FUNCTION OF UREA SCR SYSTEM . 135
FUNCTION OF AdBlue/DEF SYSTEM . 135
INDUCEMENT STRATEGY . 137
COMPONENT PARTS OF UREA SCR SYSTEM 145
AdBlue/DEF MIXING TUBE 145
SCR ASSEMBLY 145
AdBlue/DEF TANK . 148
AdBlue/DEF PUMP . 150
AdBlue/DEF INJECTOR . 151
AdBlue/DEF HOSE . 152
AdBlue/DEF TANK HEATING VALVE . 153
BOOT-UP SYSTEM 154
LAYOUT DRAWING OF BOOT-UP SYSTEM 154
SYSTEM OPERATING LAMP SYSTEM 155
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 155
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 155
BATTERY DISCONNECT SWITCH . 157
FUNCTION OF BATTERY DISCONNECT SWITCH . 157
ENGINE SYSTEM . 158
LAYOUT DRAWING OF ENGINE SYSTEM . 158
FUNCTION OF ENGINE SYSTEM . 159
ENGINE CONTROL SYSTEM . 160
ENGINE CONTROL SYSTEM DIAGRAM . 160
FUNCTION OF ENGINE CONTROL SYSTEM . 160
AUTO-DECELERATION SYSTEM 163
AUTO-DECELERATION SYSTEM DIAGRAM 163
FUNCTION OF AUTO-DECELERATION SYSTEM 163
OPERATION OF AUTO-DECELERATION SYSTEM . 164
AUTOMATIC LOW IDLE SYSTEM . 165
AUTOMATIC LOW IDLE SYSTEM DIAGRAM . 165
FUNCTION OF AUTOMATIC LOW IDLE SYSTEM . 165
OPERATION OF AUTOMATIC LOW IDLE SYSTEM 166
ENGINE AUTOMATIC WARM-UP SYSTEM . 167
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 167
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 168
OVERHEAT PREVENTION SYSTEM 170
OVERHEAT PREVENTION SYSTEM DIAGRAM 170
FUNCTION OF OVERHEAT PREVENTION SYSTEM 171
TURBOCHARGER PROTECTION SYSTEM 172
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 172
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 173
AUTOMATIC IDLE STOP SYSTEM 174
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 174
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 174
COMPONENT PARTS OF ENGINE SYSTEM 177
PTO . 177
VGT . 178
EGR SYSTEM 181
EGR VALVE . 183
EGR COOLER 185
KCCV SYSTEM . 186
KCCV VENTILATOR . 188
KDPF 190
COOLING SYSTEM 195
LAYOUT DRAWING OF COOLING SYSTEM 195
SPECIFICATIONS OF COOLING SYSTEM 196
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN . 197
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN . 197
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN . 198
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN . 199
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN . 199
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN . 199
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 201
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN 201
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 201
COMPONENT PARTS OF COOLING SYSTEM . 202
COOLING FAN PUMP 202
COOLING FAN MOTOR . 210
CONTROL SYSTEM 217
LAYOUT DRAWING OF CONTROL SYSTEM 217
MACHINE MONITOR SYSTEM 219
MACHINE MONITOR SYSTEM DIAGRAM 219
FUNCTION OF MACHINE MONITOR SYSTEM 219
KomVision SYSTEM 221
LAYOUT DRAWING OF KOMVISION SYSTEM 221
KomVision SYSTEM DIAGRAM 223
FUNCTION OF KomVision SYSTEM 223
KOMTRAX SYSTEM 225
KOMTRAX SYSTEM DIAGRAM 225
FUNCTION OF KOMTRAX SYSTEM 225
COMPONENT PARTS OF CONTROL SYSTEM . 226
MACHINE MONITOR . 226
KomVision CONTROLLER 239
KomVision CAMERA 243
KOMTRAX TERMINAL 243
PUMP CONTROLLER . 246
RESISTOR FOR TVC VALVE 250
CAN TERMINATING RESISTOR 250
ENGINE CONTROLLER . 252
FUEL CONTROL DIAL . 258
FUEL FEED PUMP 260
FUEL FEED PUMP SWITCH . 261
HYDRAULIC SYSTEM 262
LAYOUT DRAWING OF HYDRAULIC SYSTEM 262
OLSS 265
STRUCTURE OF OLSS . 265
FUNCTION OF OLSS 265
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 266
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 277
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 277
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 279
COMPONENT PARTS OF HYDRAULIC SYSTEM . 282
HYDRAULIC TANK 282
MAIN PUMP . 284
CONTROL VALVE . 311
VARIABLE BACK PRESSURE VALVE 331
WORK EQUIPMENT SYSTEM . 334
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 334
ONE-TOUCH POWER MAXIMIZING SYSTEM . 340
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 340
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 341
MACHINE PUSH-UP SYSTEM 342
MACHINE PUSH-UP SYSTEM DIAGRAM 342
FUNCTION OF MACHINE PUSH-UP SYSTEM 343
PPC LOCK SYSTEM . 344
PPC LOCK SYSTEM DIAGRAM . 344
FUNCTION OF PPC LOCK SYSTEM . 344
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 345
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 345
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 345
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 346
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 347
WORK EQUIPMENT AND SWING PPC VALVE 347
1ST-LINE ATTACHMENT PPC VALVE . 351
PPC SHUTTLE VALVE . 353
SOLENOID VALVE 354
ANTI-DROP VALVE FOR BOOM 356
ANTI-DROP VALVE FOR ARM . 360
PILOT CIRCUIT ACCUMULATOR . 365
SWING SYSTEM 366
LAYOUT DRAWING OF SWING SYSTEM 366
SWING CONTROL SYSTEM DIAGRAM 369
FUNCTION OF SWING CONTROL SYSTEM 370
COMPONENT PARTS OF SWING SYSTEM . 373
SWING MOTOR . 373
SWING MACHINERY . 384
SWING CIRCLE 385
TRAVEL SYSTEM . 387
LAYOUT DRAWING OF TRAVEL SYSTEM . 387
TRAVEL CONTROL SYSTEM DIAGRAM . 391
FUNCTION OF TRAVEL CONTROL SYSTEM . 392
COMPONENT PARTS OF TRAVEL SYSTEM 394
TRAVEL MOTOR 394
FINAL DRIVE . 404
TRAVEL PPC VALVE 405
CENTER SWIVEL JOINT . 410
UNDERCARRIAGE AND FRAME . 412
LAYOUT DRAWING OF UNDERCARRIAGE . 412
SPECIFICATIONS OF UNDERCARRIAGE . 412
WORK EQUIPMENT 413
STRUCTURE OF WORK EQUIPMENT . 413
FUNCTION OF WORK EQUIPMENT 414
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 415
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 415
BUCKET CLEARANCE ADJUSTMENT SHIM 416
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 416
CAB AND ITS ATTACHMENTS . 417
ROPS CAB 417
STRUCTURE OF ROPS CAB . 417
FUNCTION OF ROPS CAB 417
CAB MOUNT . 418
STRUCTURE OF CAB MOUNT 418
FUNCTION OF CAB MOUNT . 418
CAB TIPPING STOPPER . 419
STRUCTURE OF CAB TIPPING STOPPER 419
FUNCTION OF CAB TIPPING STOPPER . 419
20 STANDARD VALUE TABLE . 421
CONTENTS 422
ABBREVIATION LIST . 423
STANDARD VALUE TABLE FOR ENGINE . 429
STANDARD VALUE TABLE FOR ENGINE: PC700LC-11 . 429
STANDARD VALUE TABLE FOR MACHINE 434
STANDARD VALUE TABLE FOR MACHINE: PC700LC-11 434
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 451
30 TESTING AND ADJUSTING 455
CONTENTS 456
ABBREVIATION LIST . 459
RELATED INFORMATION ON TESTING AND ADJUSTING 465
TOOLS FOR TESTING AND ADJUSTING . 465
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 474
ENGINE AND COOLING SYSTEM . 476
TEST ENGINE SPEED . 476
METHOD FOR TESTING ENGINE SPEED . 476
TEST BOOST PRESSURE . 479
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 479
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL . 480
TEST EXHAUST GAS TEMPERATURE 481
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 481
TEST EXHAUST GAS COLOR 483
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 483
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 484
TEST AND ADJUST VALVE CLEARANCE . 486
METHOD FOR TESTING VALVE CLEARANCE 486
METHOD FOR ADJUSTING VALVE CLEARANCE 487
TEST COMPRESSION PRESSURE . 489
METHOD FOR TESTING COMPRESSION PRESSURE . 489
TEST BLOWBY PRESSURE 492
METHOD FOR TESTING BLOWBY PRESSURE 492
TEST ENGINE OIL PRESSURE 494
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR . 494
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 494
TEST EGR VALVE AND VGT OIL PRESSURE . 496
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 496
TEST FUEL PRESSURE 498
METHOD FOR TESTING FUEL PRESSURE 498
TEST FUEL RETURN RATE AND LEAKAGE . 500
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE . 500
BLEED AIR FROM FUEL SYSTEM 503
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 503
TEST FUEL CIRCUIT FOR LEAKAGE . 505
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 505
HANDLE CYLINDER CUT-OUT MODE OPERATION 507
HANDLE NO-INJECTION CRANKING OPERATION 508
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 509
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 509
CLEAN FUEL DOSER 510
METHOD FOR CLEANING FUEL DOSER 510
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 512
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 512
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 518
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 518
TEST SCR RELATED FUNCTIONS 519
TEST AdBlue/DEF PUMP RAISED PRESSURE 522
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 525
TEST AdBlue/DEF LINE HEATER RELAY 1 . 529
TEST AdBlue/DEF LINE HEATER RELAY 2 . 532
TEST AdBlue/DEF PUMP HEATER RELAY . 535
TEST AdBlue/DEF TANK HEATER VALVE . 538
TEST DENITRATION EFFICIENCY OF SCR 541
CLEAN AdBlue/DEF TANK . 545
METHOD FOR CLEANING AdBlue/DEF TANK . 545
POWER TRAIN . 549
TEST SWING CIRCLE BEARING CLEARANCE . 549
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 549
UNDERCARRIAGE AND FRAME . 550
TEST AND ADJUST TRACK TENSION . 550
METHOD FOR TESTING TRACK TENSION 550
METHOD FOR ADJUSTING TRACK TENSION 550
HYDRAULIC SYSTEM 552
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 552
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 552
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 557
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 557
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT . 557
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 559
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 562
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 570
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT . 574
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 574
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 575
TEST AND ADJUST PISTON PUMP CONTROL OIL PRESSURE 576
METHOD FOR TESTING TVC VALVE OUTLET PRESSURE 576
METHOD FOR TESTING CO AND NC VALVE OUTLET PRESSURE 577
METHOD FOR TESTING JET SENSOR OUTLET PRESSURE . 578
METHOD FOR ADJUSTING TVC VALVE 580
METHOD FOR ADJUSTING CO AND NC VALVE 581
METHOD FOR ADJUSTING JET SENSOR . 582
TEST SERVO PISTON STROKE 583
METHOD FOR TESTING SERVO PISTON STROKE 583
TEST OUTLET PRESSURE OF SOLENOID VALVE 585
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 585
OPERATING CONDITION OF SOLENOID VALVE . 586
TEST PPC VALVE OUTLET PRESSURE 589
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 589
TEST PPC SHUTTLE VALVE OUTLET PRESSURE 591
METHOD FOR TESTING PPC SHUTTLE VALVE OUTLET PRESSURE 591
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 595
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 595
TEST AND ADJUST TRAVEL DEVIATION 596
METHOD FOR TESTING TRAVEL DEVIATION . 596
METHOD FOR ADJUSTING TRAVEL DEVIATION . 596
TEST COOLING FAN SPEED 598
METHOD FOR TESTING COOLING FAN SPEED 598
TEST OIL PRESSURE IN FAN PUMP CIRCUIT . 599
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT . 599
TEST FAN PUMP EPC ELECTRIC CURRENT 600
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 600
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 601
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 601
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 602
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 602
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 602
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 603
TEST OIL LEAKAGE 604
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 604
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 605
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 605
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 606
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 606
METHOD FOR TESTING OIL LEAKAGE OF SWIVEL JOINT 607
BLEED AIR FROM HYDRAULIC CIRCUIT 609
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 610
CAB AND ITS ATTACHMENTS . 613
TEST CAB TIPPING STOPPER 613
METHOD FOR TESTING CAB TIPPING STOPPER 613
METHOD FOR ADJUSTING MIRRORS 614
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 614
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 615
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 616
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 617
ELECTRICAL SYSTEM . 619
SET AND OPERATE MACHINE MONITOR . 619
OPERATOR MODE . 622
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 622
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 622
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 623
CHECKING FUNCTION OF SERVICE METER 624
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 624
SERVICE MODE 626
METHOD FOR OPERATING SERVICE MODE . 626
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 629
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 635
ABNORMALITY RECORD MENU . 646
METHOD FOR CONFIRMING MAINTENANCE RECORD 651
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 652
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 656
DEFAULT MENU 657
DIAGNOSTIC TESTS MENU . 663
ADJUSTMENT MENU . 673
METHOD FOR PERFORMING NO-INJECTION CRANKING . 677
KOMTRAX SETTINGS MENU . 678
METHOD FOR DISPLAYING SERVICE MESSAGE . 680
METHOD FOR STARTING UP KOMTRAX TERMINAL . 682
ADJUST REARVIEW CAMERA ANGLE 687
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE . 687
ADJUST KomVision CAMERA ANGLE . 689
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
KomVision screen – Check 12 m visibility 708
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 711
HANDLE BATTERY DISCONNECT SWITCH 712
TEST DIODES . 713
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 713
METHOD FOR TESTING DIODE USING ANALOG TESTER 713
Pm CLINIC . 714
Pm CLINIC SERVICE . 714
Pm CLINIC CHECK SHEET: PC700LC-11 . 717
40 TROUBLESHOOTING 735
CONTENTS 736
ABBREVIATION LIST . 747
RELATED INFORMATION ON TROUBLESHOOTING 753
GENERAL TROUBLESHOOTING POINTS 753
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 754
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 766
CHECKS BEFORE TROUBLESHOOTING . 768
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 770
WALK-AROUND CHECK . 770
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 772
CHECK FUEL LEVEL AND TYPE . 772
CHECK IMPURE INGREDIENT IN FUEL . 773
CHECK FUEL PREFILTER 773
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 773
FUEL PREFILTER CARTRIDGE – REPLACE 774
CHECK MAIN FILTER . 775
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 776
CHECK COOLANT LEVEL (RESERVOIR TANK) 778
CHECK CLOGGING OF AIR CLEANER . 778
OUTER ELEMENT – CLEAN . 778
ELEMENTS – REPLACE 781
CHECK HYDRAULIC OIL LEVEL . 781
CHECK HYDRAULIC OIL STRAINER 783
CHECK HYDRAULIC FILTER 783
CHECK OIL LEVEL IN SWING MACHINERY CASE . 784
CHECK OIL LEVEL IN PTO CASE . 785
CHECK PTO LUBRICATION FILTER STRAINER . 785
CHECK OIL LEVEL IN FINAL DRIVE CASE . 786
BLEED AIR FROM FUEL SYSTEM 787
BLEED AIR FROM HYDRAULIC SYSTEM . 787
ELECTRICAL EQUIPMENT – CHECK METHOD . 787
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 793
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 793
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 793
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 793
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL . 794
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER . 794
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 794
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 798
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 801
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 805
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 807
CONNECTOR LIST AND LAYOUT . 810
CONNECTOR CONTACT IDENTIFICATION 824
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 864
FUSE LOCATION TABLE . 870
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 873
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 877
FAILURE CODES TABLE . 879
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 896
FAILURE CODE [879AKA] . 896
FAILURE CODE [879AKB] . 897
FAILURE CODE [879BKA] . 898
FAILURE CODE [879BKB] . 900
FAILURE CODE [879CKA] . 902
FAILURE CODE [879CKB] . 903
FAILURE CODE [879DKZ] . 904
FAILURE CODE [879EMC] . 906
FAILURE CODE [879FMC] . 907
FAILURE CODE [879GKX] . 908
FAILURE CODE [989L00] . 910
FAILURE CODE [989M00] . 911
FAILURE CODE [989N00] . 912
FAILURE CODE [A1U0N3] . 913
FAILURE CODE [A1U0N4] . 915
FAILURE CODE [A900FR] . 917
FAILURE CODE [A900N6] . 918
FAILURE CODE [A900NY] . 919
FAILURE CODE [AA10NX] . 920
FAILURE CODE [AB00KE] . 922
FAILURE CODE [AQ10N3] . 924
FAILURE CODE [AS00N3] . 926
FAILURE CODE [AS00R2] . 928
FAILURE CODE [AS00R3] . 929
FAILURE CODE [AS00R4] . 930
FAILURE CODE [AS00R5] . 931
FAILURE CODE [AS00R6] . 932
FAILURE CODE [AS00ZK] . 933
FAILURE CODE [AS10KM] . 934
FAILURE CODE [AS10NR] . 935
FAILURE CODE [AS10NT] . 936
FAILURE CODE [B@BAZG] . 937
FAILURE CODE [B@BAZK] . 938
FAILURE CODE [B@BCNS] . 940
FAILURE CODE [B@BCZK] . 941
FAILURE CODE [B@HANS] . 943
FAILURE CODE [CA115] 944
FAILURE CODE [CA122] 945
FAILURE CODE [CA123] 947
FAILURE CODE [CA131] 949
FAILURE CODE [CA132] 951
FAILURE CODE [CA135] 953
FAILURE CODE [CA141] 955
FAILURE CODE [CA144] 957
FAILURE CODE [CA145] 959
FAILURE CODE [CA153] 961
FAILURE CODE [CA154] 964
FAILURE CODE [CA187] 967
FAILURE CODE [CA221] 969
FAILURE CODE [CA222] 971
FAILURE CODE [CA227] 973
FAILURE CODE [CA234] 974
FAILURE CODE [CA238] 975
FAILURE CODE [CA239] 977
FAILURE CODE [CA249] 979
FAILURE CODE [CA256] 981
FAILURE CODE [CA271] 983
FAILURE CODE [CA272] 985
FAILURE CODE [CA273] 986
FAILURE CODE [CA274] 988
FAILURE CODE [CA322] 989
FAILURE CODE [CA323] 991
FAILURE CODE [CA324] 993
FAILURE CODE [CA325] 995
FAILURE CODE [CA331] 997
FAILURE CODE [CA332] 999
FAILURE CODE [CA343] 1001
FAILURE CODE [CA351] 1002
FAILURE CODE [CA352] 1003
FAILURE CODE [CA356] 1006
FAILURE CODE [CA357] 1008
FAILURE CODE [CA386] 1010
FAILURE CODE [CA441] 1011
FAILURE CODE [CA442] 1013
FAILURE CODE [CA449] 1014
FAILURE CODE [CA451] 1015
FAILURE CODE [CA452] 1017
FAILURE CODE [CA515] 1019
FAILURE CODE [CA516] 1021
FAILURE CODE [CA553] 1023
FAILURE CODE [CA555] 1024
FAILURE CODE [CA556] 1025
FAILURE CODE [CA559] 1026
FAILURE CODE [CA595] 1031
FAILURE CODE [CA687] 1032
FAILURE CODE [CA689] 1034
FAILURE CODE [CA691] 1036
FAILURE CODE [CA692] 1038
FAILURE CODE [CA697] 1040
FAILURE CODE [CA698] 1041
FAILURE CODE [CA731] 1042
FAILURE CODE [CA778] 1043
FAILURE CODE [CA1117] .1046
FAILURE CODE [CA1664] .1047
FAILURE CODE [CA1669] .1051
FAILURE CODE [CA1673] .1052
FAILURE CODE [CA1677] .1053
FAILURE CODE [CA1678] .1054
FAILURE CODE [CA1682] .1055
FAILURE CODE [CA1683] .1057
FAILURE CODE [CA1684] .1059
FAILURE CODE [CA1686] .1061
FAILURE CODE [CA1691] .1062
FAILURE CODE [CA1694] .1065
FAILURE CODE [CA1695] .1067
FAILURE CODE [CA1696] .1068
FAILURE CODE [CA1712] .1070
FAILURE CODE [CA1713] .1073
FAILURE CODE [CA1714] .1076
FAILURE CODE [CA1715] .1077
FAILURE CODE [CA1776] .1078
FAILURE CODE [CA1777] .1081
FAILURE CODE [CA1843] .1084
FAILURE CODE [CA1844] .1086
FAILURE CODE [CA1879] .1089
FAILURE CODE [CA1881] .1092
FAILURE CODE [CA1883] .1094
FAILURE CODE [CA1885] .1098
FAILURE CODE [CA1887] .1100
FAILURE CODE [CA1921] .1102
FAILURE CODE [CA1922] .1105
FAILURE CODE [CA1923] .1110
FAILURE CODE [CA1924] .1112
FAILURE CODE [CA1925] .1114
FAILURE CODE [CA1927] .1116
FAILURE CODE [CA1928] .1118
FAILURE CODE [CA1942] .1120
FAILURE CODE [CA1963] .1121
FAILURE CODE [CA1977] .1125
FAILURE CODE [CA1993] .1128
FAILURE CODE [CA2185] .1131
FAILURE CODE [CA2186] .1133
FAILURE CODE [CA2249] .1135
FAILURE CODE [CA2265] .1136
FAILURE CODE [CA2266] .1138
FAILURE CODE [CA2271] .1140
FAILURE CODE [CA2272] .1142
FAILURE CODE [CA2349] .1144
FAILURE CODE [CA2353] .1146
FAILURE CODE [CA2357] .1148
FAILURE CODE [CA2381] .1149
FAILURE CODE [CA2382] .1151
FAILURE CODE [CA2383] .1153
FAILURE CODE [CA2386] .1155
FAILURE CODE [CA2387] .1157
FAILURE CODE [CA2555] .1158
FAILURE CODE [CA2556] .1160
FAILURE CODE [CA2637] .1162
FAILURE CODE [CA2639] .1164
FAILURE CODE [CA2732] .1166
FAILURE CODE [CA2733] .1168
FAILURE CODE [CA2741] .1170
FAILURE CODE [CA2765] .1171
FAILURE CODE [CA2771] .1172
FAILURE CODE [CA2777] .1178
FAILURE CODE [CA2878] .1181
FAILURE CODE [CA2881] .1184
FAILURE CODE [CA2976] .1187
FAILURE CODE [CA3133] .1189
FAILURE CODE [CA3134] .1191
FAILURE CODE [CA3135] .1193
FAILURE CODE [CA3142] .1196
FAILURE CODE [CA3143] .1197
FAILURE CODE [CA3144] .1198
FAILURE CODE [CA3146] .1200
FAILURE CODE [CA3147] .1201
FAILURE CODE [CA3148] .1202
FAILURE CODE [CA3151] .1204
FAILURE CODE [CA3165] .1209
FAILURE CODE [CA3167] .1212
FAILURE CODE [CA3229] .1216
FAILURE CODE [CA3231] .1219
FAILURE CODE [CA3232] .1222
FAILURE CODE [CA3235] .1227
FAILURE CODE [CA3239] .1229
FAILURE CODE [CA3241] .1232
FAILURE CODE [CA3242] .1235
FAILURE CODE [CA3251] .1238
FAILURE CODE [CA3253] .1242
FAILURE CODE [CA3254] .1248
FAILURE CODE [CA3255] .1252
FAILURE CODE [CA3256] .1255
FAILURE CODE [CA3311] .1258
FAILURE CODE [CA3312] .1261
FAILURE CODE [CA3313] .1264
FAILURE CODE [CA3314] .1265
FAILURE CODE [CA3315] .1266
FAILURE CODE [CA3316] .1269
FAILURE CODE [CA3317] .1270
FAILURE CODE [CA3318] .1271
FAILURE CODE [CA3319] .1274
FAILURE CODE [CA3321] .1275
FAILURE CODE [CA3322] .1276
FAILURE CODE [CA3419] .1279
FAILURE CODE [CA3421] .1281
FAILURE CODE [CA3497] .1283
FAILURE CODE [CA3498] .1284
FAILURE CODE [CA3543] .1285
FAILURE CODE [CA3545] .1290
FAILURE CODE [CA3547] .1292
FAILURE CODE [CA3558] .1293
FAILURE CODE [CA3559] .1295
FAILURE CODE [CA3562] .1297
FAILURE CODE [CA3563] .1299
FAILURE CODE [CA3567] .1302
FAILURE CODE [CA3568] .1305
FAILURE CODE [CA3571] .1309
FAILURE CODE [CA3572] .1311
FAILURE CODE [CA3574] .1313
FAILURE CODE [CA3575] .1316
FAILURE CODE [CA3577] .1318
FAILURE CODE [CA3578] .1320
FAILURE CODE [CA3582] .1322
FAILURE CODE [CA3583] .1327
FAILURE CODE [CA3596] .1329
FAILURE CODE [CA3649] .1333
FAILURE CODE [CA3681] .1336
FAILURE CODE [CA3682] .1341
FAILURE CODE [CA3713] .1347
FAILURE CODE [CA3717] .1350
FAILURE CODE [CA3718] .1351
FAILURE CODE [CA3725] .1352
FAILURE CODE [CA3748] .1355
FAILURE CODE [CA3751] .1357
FAILURE CODE [CA3755] .1359
FAILURE CODE [CA3866] .1361
FAILURE CODE [CA3867] .1365
FAILURE CODE [CA3868] .1368
FAILURE CODE [CA3899] .1372
FAILURE CODE [CA3911] .1375
FAILURE CODE [CA3912] .1379
FAILURE CODE [CA3932] .1381
FAILURE CODE [CA3933] .1383
FAILURE CODE [CA3934] .1385
FAILURE CODE [CA3935] .1388
FAILURE CODE [CA3936] .1390
FAILURE CODE [CA4151] .1392
FAILURE CODE [CA4152] .1396
FAILURE CODE [CA4155] .1400
FAILURE CODE [CA4156] .1402
FAILURE CODE [CA4157] .1405
FAILURE CODE [CA4158] .1407
FAILURE CODE [CA4159] .1409
FAILURE CODE [CA4161] .1411
FAILURE CODE [CA4162] .1414
FAILURE CODE [CA4163] .1417
FAILURE CODE [CA4164] .1419
FAILURE CODE [CA4165] .1422
FAILURE CODE [CA4166] .1425
FAILURE CODE [CA4168] .1428
FAILURE CODE [CA4169] .1433
FAILURE CODE [CA4171] .1438
FAILURE CODE [CA4249] .1443
FAILURE CODE [CA4251] .1447
FAILURE CODE [CA4259] .1451
FAILURE CODE [CA4261] .1454
FAILURE CODE [CA4277] .1457
FAILURE CODE [CA4281] .1461
FAILURE CODE [CA4459] .1464
FAILURE CODE [CA4461] .1467
FAILURE CODE [CA4658] .1470
FAILURE CODE [CA4731] .1474
FAILURE CODE [CA4732] .1475
FAILURE CODE [CA4739] .1476
FAILURE CODE [CA4768] .1477
FAILURE CODE [CA4769] .1479
FAILURE CODE [CA4842] .1482
FAILURE CODE [CA4952] .1486
FAILURE CODE [CA5115] .1488
FAILURE CODE [CA5179] .1491
FAILURE CODE [CA5181] .1493
FAILURE CODE [CA5383] .1495
FAILURE CODE [D110KB] .1497
FAILURE CODE [D163KB] .1499
FAILURE CODE [D195KA] .1501
FAILURE CODE [D195KB] .1503
FAILURE CODE [D19JKZ] .1505
FAILURE CODE [D811MC] .1507
FAILURE CODE [D862KA] .1508
FAILURE CODE [D8ALKA] .1509
FAILURE CODE [D8ALKB] .1511
FAILURE CODE [D8AQKR] .1513
FAILURE CODE [DA20MC] .1517
FAILURE CODE [DA22KK] .1518
FAILURE CODE [DA25KP] .1520
FAILURE CODE [DA26KP] .1522
FAILURE CODE [DA29KQ] .1525
FAILURE CODE [DA2LKA] .1527
FAILURE CODE [DA2LKB] .1529
FAILURE CODE [DA2QKR] .1531
FAILURE CODE [DA2RKR] .1536
FAILURE CODE [DAF0KM] .1541
FAILURE CODE [DAF0MB] .1542
FAILURE CODE [DAF0MC] .1543
FAILURE CODE [DAF8KB] .1544
FAILURE CODE [DAF9KQ] .1546
FAILURE CODE [DAFGMC] .1547
FAILURE CODE [DAFLKA] .1548
FAILURE CODE [DAFLKB] .1550
FAILURE CODE [DAFQKR] .1552
FAILURE CODE [DAZ9KQ] .1556
FAILURE CODE [DAZQKR] .1557
FAILURE CODE [DB2QKR] .1561
FAILURE CODE [DB2RKR] .1566
FAILURE CODE [DBP0KM] .1571
FAILURE CODE [DBP0KT] .1572
FAILURE CODE [DBP5KB] .1573
FAILURE CODE [DBP5KY] .1576
FAILURE CODE [DBPQKR] .1579
FAILURE CODE [DDNRKA] .1584
FAILURE CODE [DDNRKY] .1586
FAILURE CODE [DDNS00] .1588
FAILURE CODE [DGE5KB] .1590
FAILURE CODE [DGH2KA] .1591
FAILURE CODE [DGH2KB] .1593
FAILURE CODE [DHA4KA] .1595
FAILURE CODE [DHAAMA] .1597
FAILURE CODE [DHACMA] .1599
FAILURE CODE [DHPAMA] .1601
FAILURE CODE [DHPBMA] .1603
FAILURE CODE [DHS3MA] .1605
FAILURE CODE [DHS4MA] .1608
FAILURE CODE [DHS8MA] .1611
FAILURE CODE [DHS9MA] .1614
FAILURE CODE [DHSAMA] .1617
FAILURE CODE [DHSBMA] .1620
FAILURE CODE [DHSCMA] .1623
FAILURE CODE [DHSDMA] .1626
FAILURE CODE [DHSFMA] .1629
FAILURE CODE [DHSGMA] .1632
FAILURE CODE [DHSHMA] .1635
FAILURE CODE [DHSJMA] .1638
FAILURE CODE [DHSVMA] .1641
FAILURE CODE [DKULKA] .1643
FAILURE CODE [DKULKB] .1645
FAILURE CODE [DKULKY] .1647
FAILURE CODE [DLM3KA] .1649
FAILURE CODE [DLM3KB] .1651
FAILURE CODE [DLM3MB] .1653
FAILURE CODE [DR10KA] .1654
FAILURE CODE [DR12KA] .1657
FAILURE CODE [DR20KA] .1659
FAILURE CODE [DR21KX] .1661
FAILURE CODE [DR30KA] .1663
FAILURE CODE [DR31KX] .1665
FAILURE CODE [DR40KA] .1667
FAILURE CODE [DUMBKA] .1669
FAILURE CODE [DUMBKB] .1671
FAILURE CODE [DV20KB] .1673
FAILURE CODE [DW43KA] .1674
FAILURE CODE [DW43KB] .1676
FAILURE CODE [DW43KY] .1678
FAILURE CODE [DW45KA] .1679
FAILURE CODE [DW45KB] .1682
FAILURE CODE [DW45KY] .1685
FAILURE CODE [DW48KA] .1687
FAILURE CODE [DW48KB] .1689
FAILURE CODE [DW48KY] .1691
FAILURE CODE [DW4CKY] .1692
FAILURE CODE [DW4XKA] .1694
FAILURE CODE [DW4XKB] .1696
FAILURE CODE [DW4XKY] .1698
FAILURE CODE [DW7BKA] .1699
FAILURE CODE [DW7BKB] .1701
FAILURE CODE [DW7BKY] .1703
FAILURE CODE [DWK0KA] .1704
FAILURE CODE [DWK0KB] .1706
FAILURE CODE [DWK0KY] .1708
FAILURE CODE [DWK2KA] .1709
FAILURE CODE [DWK2KB] .1711
FAILURE CODE [DWK2KY] .1713
FAILURE CODE [DWK8KA] .1714
FAILURE CODE [DWK8KB] .1716
FAILURE CODE [DWK8KY] .1718
FAILURE CODE [DX16KA] .1719
FAILURE CODE [DX16KB] .1721
FAILURE CODE [DXA2KA] .1722
FAILURE CODE [DXA2KB] .1725
FAILURE CODE [DXA3KA] .1727
FAILURE CODE [DXA3KB] .1730
FAILURE CODE [DY20KA] .1732
FAILURE CODE [DY20MA] .1734
FAILURE CODE [DY2CKB] .1736
FAILURE CODE [DY2DKB] .1738
FAILURE CODE [DY2EKB] .1740
FAILURE CODE [DY2FMA] .1742
FAILURE CODE [DY2GKM] .1744
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1746
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1746
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1752
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1755
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1757
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1759
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1762
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1763
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1764
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1765
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1766
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1767
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1768
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1769
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1770
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1771
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1772
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1774
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1775
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1776
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1777
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1779
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1780
E-23 FUNCTION SWITCH DOES NOT OPERATE .1781
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1782
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1783
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1784
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1785
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1786
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1787
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1788
E-31 ALARM BUZZER CANNOT BE CANCELED 1789
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1790
E-33 SERVICE MODE CANNOT BE SELECTED 1791
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1792
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1795
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1797
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1800
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1802
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1804
E-40 ALARM DOES NOT SOUND DURING TRAVEL .1805
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1807
E-42 HORN DOES NOT SOUND 1808
E-43 HORN DOES NOT STOP SOUNDING 1811
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1813
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1814
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1816
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1817
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1818
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1819
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1820
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1821
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1822
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1823
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1824
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1825
E-56 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1827
E-57 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 1828
E-58 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1830
E-59 STEP LIGHT DOES NOT LIGHT UP .1831
E-60 STEP LIGHT DOES NOT GO OUT .1833
E-61 BOOM SHOCKLESS FUNCTION CANNOT BE CANCELED .1835
E-62 BOOM SHOCKLESS FUNCTION DOES NOT WORK 1837
E-63 ELECTRIC GREASE GUN DOES NOT WORK 1838
E-64 ELECTRIC GREASE GUN DOES NOT STOP 1840
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1841
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1841
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1842
H-3 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1844
H-4 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1845
H-5 TRAVEL SPEED OR POWER IS LOW 1846
H-6 AUTO-DECELERATION FUNCTION CANNOT BE CANCELED .1847
H-7 SPEED OR POWER OF BOOM IS LOW .1848
H-8 ARM SPEED OR POWER IS LOW .1850
H-9 BUCKET SPEED OR POWER IS LOW 1851
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION .1852
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE .1853
H-12 HYDRAULIC DRIFT OF ARM IS LARGE 1854
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE .1855
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1856
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1857
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1858
H-17 MACHINE DOES NOT TRAVEL STRAIGHT .1859
H-18 SPEED OF BOOM AND BUCKET IS SLOW AT COMBINED OPERATION OF ARM, BOOM AND BUCKET .1860
H-19 SPEED OF BOOM, ARM, SWING AND TRAVEL IS SLOW AT COMBINED OPERATION OF BUCKET, BOOM AND ARM .1861
H-20 SWING SPEED IS SLOW AT COMBINED OPERATION OF ARM AND SWING .1862
H-21 TRAVEL DEVIATION IS LARGE AT START OF TRAVELING 1863
H-22 TRAVEL DEVIATION IS LARGE AT COMBINED OPERATION 1865
H-23 ONE OF TRACKS DOES NOT RUN .1866
H-24 TRAVEL SPEED DOES NOT CHANGE .1868
H-25 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1869
H-26 SWINGS ONLY IN ONE DIRECTION .1870
H-27 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1871
H-28 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1872
H-29 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1873
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1874
H-31 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1875
H-32 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1876
H-33 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1877
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1878
H-35 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1879
H-36 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1880
TROUBLESHOOTING OF ENGINE (S-MODE) 1881
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1881
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1882
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1883
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1884
S-4 ENGINE STARTABILITY IS POOR .1885
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1887
S-6 ENGINE STOPS DURING OPERATION .1889
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1891
S-8 ENGINE LACKS POWER 1892
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1894
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1896
S-11 OIL BECOMES CONTAMINATED QUICKLY .1897
S-1 FUEL CONSUMPTION IS EXCESSIVE .1898
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1899
S-14 OIL PRESSURE DROPS .1900
S-15 FUEL MIXES INTO ENGINE OIL .1902
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1903
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1904
S-18 UNUSUAL NOISE IS HEARD .1905
S-19 VIBRATION IS EXCESSIVE .1906
S-2 AIR CANNOT BE BLED FROM FUEL CIRCUIT 1907
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1908
S-22 ACTIVE REGENERATION TAKES TIME .1910
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1912
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1913
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1915
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1916
50 DISASSEMBLY AND ASSEMBLY .1917
CONTENTS 1918
ABBREVIATION LIST .1923
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1929
HOW TO READ THIS MANUAL .1929
COATING MATERIALS LIST 1931
SPECIAL TOOLS LIST 1935
SPECIAL TOOLS LIST 1952
SKETCHES OF SPECIAL TOOLS .1969
ENGINE AND COOLING SYSTEM .1976
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .1976
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1976
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1979
REMOVE AND INSTALL INJECTOR ASSEMBLY 1984
METHOD FOR REMOVING INJECTOR ASSEMBLY .1984
METHOD FOR INSTALLING INJECTOR ASSEMBLY .1989
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 1998
METHOD FOR REMOVING FUEL DOSER ASSEMBLY .1998
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY .1999
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2001
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2002
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2012
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2029
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2029
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2031
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2033
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2033
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2036
REMOVE AND INSTALL STARTER ASSEMBLY .2040
METHOD FOR REMOVING STARTER ASSEMBLY 2040
METHOD FOR INSTALLING STARTER ASSEMBLY 2040
REMOVE AND INSTALL ALTERNATOR BELT 2042
METHOD FOR REMOVING ALTERNATOR BELT .2042
METHOD FOR INSTALLING ALTERNATOR BELT .2043
REMOVE AND INSTALL RADIATOR ASSEMBLY 2045
METHOD FOR REMOVING RADIATOR ASSEMBLY .2045
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2048
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2052
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2052
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2055
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2059
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2059
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2061
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY .2064
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2064
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2073
REMOVE AND INSTALL ENGINE PTO AND HYDRAULIC ASSEMBLY 2082
METHOD FOR REMOVING ENGINE PTO AND HYDRAULIC ASSEMBLY .2082
METHOD FOR INSTALLING ENGINE PTO AND HYDRAULIC ASSEMBLY .2093
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2104
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2104
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2105
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2108
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2108
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2110
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2117
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2117
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2122
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2127
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2127
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2130
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2134
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2135
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2141
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2146
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2146
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2147
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2149
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2149
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2149
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2151
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2151
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2151
REMOVE AND INSTALL KDPF ASSEMBLY 2152
METHOD FOR REMOVING KDPF ASSEMBLY .2152
METHOD FOR INSTALLING KDPF ASSEMBLY .2156
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2165
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2166
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2170
REMOVE AND INSTALL SCR ASSEMBLY .2175
METHOD FOR REMOVING SCR ASSEMBLY 2175
METHOD FOR INSTALLING SCR ASSEMBLY 2177
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2181
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2182
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2188
REMOVE AND INSTALL KCCV ASSEMBLY 2200
METHOD FOR REMOVING KCCV ASSEMBLY .2200
METHOD FOR INSTALLING KCCV ASSEMBLY .2201
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2204
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2204
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2209
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2216
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2216
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2219
REMOVE AND INSTALL AdBlue/DEF PUMP 2223
METHOD FOR REMOVING AdBlue/DEF PUMP .2223
METHOD FOR INSTALLING AdBlue/DEF PUMP .2226
REMOVE AND INSTALL AdBlue/DEF HOSE 2229
METHOD FOR REMOVING AdBlue/DEF HOSE .2230
METHOD FOR INSTALLING AdBlue/DEF HOSE .2238
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2244
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2244
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2245
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2246
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2246
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2247
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2248
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2248
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2249
POWER TRAIN .2250
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY .2250
METHOD FOR DISASSEMBLING PTO ASSEMBLY .2250
METHOD FOR ASSEMBLING PTO ASSEMBLY 2251
REMOVE AND INSTALL PTO ASSEMBLY .2254
METHOD FOR REMOVING PTO ASSEMBLY 2254
METHOD FOR INSTALLING PTO ASSEMBLY 2255
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2258
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2258
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2259
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2260
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2261
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2266
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2275
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2275
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2276
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2278
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2278
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2282
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2287
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2287
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2288
UNDERCARRIAGE AND FRAME .2289
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 2289
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING .2289
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 2290
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2292
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY .2292
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY .2293
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2294
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY .2294
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY .2294
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD .2296
METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD .2298
METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD 2299
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2302
METHOD FOR SEPARATING TRACK ASSEMBLY 2302
METHOD FOR INSTALLING TRACK ASSEMBLY 2303
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2305
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2305
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2306
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2307
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2307
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2308
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2311
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2311
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2312
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2314
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2314
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2315
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2318
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2318
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2319
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2321
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2321
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2322
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2324
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2324
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2324
HYDRAULIC SYSTEM 2327
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2327
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2327
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2328
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2329
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2330
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2331
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2332
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2332
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2334
REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY 2337
METHOD FOR REMOVING HYDRAULIC PUMP ASSEMBLY .2337
METHOD FOR INSTALLING HYDRAULIC PUMP ASSEMBLY .2339
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2345
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2345
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2348
REMOVE AND INSTALL SWING MOTOR ASSEMBLY .2352
METHOD FOR REMOVING SWING MOTOR ASSEMBLY 2352
METHOD FOR INSTALLING SWING MOTOR ASSEMBLY 2353
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2354
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2354
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2355
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2357
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2357
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2358
DISASSEMBLE AND ASSEMBLE GREASE GUN ASSEMBLY 2360
METHOD FOR DISASSEMBLING GREASE GUN ASSEMBLY 2360
METHOD FOR ASSEMBLING GREASE GUN ASSEMBLY .2360
WORK EQUIPMENT 2361
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY .2361
METHOD FOR REMOVING BUCKET CYLINDER ASSEMBLY 2361
METHOD FOR INSTALLING BUCKET CYLINDER ASSEMBLY 2362
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY 2364
METHOD FOR REMOVING ARM CYLINDER ASSEMBLY .2364
METHOD FOR INSTALLING ARM CYLINDER ASSEMBLY .2365
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY .2367
METHOD FOR REMOVING BOOM CYLINDER ASSEMBLY 2367
METHOD FOR INSTALLING BOOM CYLINDER ASSEMBLY 2368
REMOVE AND INSTALL BUCKET ASSEMBLY 2370
METHOD FOR REMOVING BUCKET ASSEMBLY .2370
METHOD FOR INSTALLING BUCKET ASSEMBLY .2371
REMOVE AND INSTALL ARM ASSEMBLY .2372
METHOD FOR REMOVING ARM ASSEMBLY 2372
METHOD FOR INSTALLING ARM ASSEMBLY 2374
REMOVE AND INSTALL BOOM ASSEMBLY 2376
METHOD FOR REMOVING BOOM ASSEMBLY .2376
METHOD FOR INSTALLING BOOM ASSEMBLY .2377
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2379
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2379
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2381
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 2383
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2383
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2385
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM .2386
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM 2386
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM 2388
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY .2389
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY .2389
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY 2389
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2390
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2391
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2393
CAB AND ITS ATTACHMENTS .2398
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2398
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2398
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2405
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2414
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2416
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2416
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2426
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2426
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2429
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2435
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2435
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2438
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2443
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2443
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2448
REMOVE AND INSTALL OPERATOR’S SEAT 2455
METHOD FOR REMOVING OPERATOR’S SEAT .2455
METHOD FOR INSTALLING OPERATOR’S SEAT .2457
REMOVE AND INSTALL SEAT BELT 2460
METHOD FOR REMOVING SEAT BELT .2460
METHOD FOR INSTALLING SEAT BELT .2460
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2462
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2462
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2467
ELECTRICAL SYSTEM .2476
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2476
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2476
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2477
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2480
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2480
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2482
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2485
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2485
METHOD FOR INSTALLING KomVision CONTROLLER 2486
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2487
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2487
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2489
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2493
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2493
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2494
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2495
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2495
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2496
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2498
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2498
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2500
REMOVE AND INSTALL KomVision CAMERA .2502
METHOD FOR REMOVING KomVision CAMERA 2502
METHOD FOR INSTALLING KomVision CAMERA 2503
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2505
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2505
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2507
60 MAINTENANCE STANDARD .2509
CONTENTS 2510
ABBREVIATION LIST .2511
ENGINE AND COOLING SYSTEM .2517
MAINTENANCE STANDARD OF ENGINE MOUNT 2517
MAINTENANCE STANDARD FOR PTO 2519
MAINTENANCE STANDARD OF COOLING SYSTEM 2520
MAINTENANCE STANDARD OF COOLING FAN PUMP 2521
MAINTENANCE STANDARD OF SERVO VALVE .2522
MAINTENANCE STANDARD OF COOLING FAN MOTOR .2523
POWER TRAIN .2524
MAINTENANCE STANDARD OF SWING CIRCLE 2524
MAINTENANCE STANDARD OF SWING MACHINERY .2525
MAINTENANCE STANDARD OF FINAL DRIVE .2527
MAINTENANCE STANDARD OF SPROCKET 2529
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2530
UNDERCARRIAGE AND FRAME .2532
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2532
MAINTENANCE STANDARD OF IDLER .2534
MAINTENANCE STANDARD OF TRACK ROLLER 2536
MAINTENANCE STANDARD OF CARRIER ROLLER 2538
MAINTENANCE STANDARD OF TRACK SHOE 2539
MAINTENANCE STANDARD OF DOUBLE SHOE .2542
MAINTENANCE STANDARD OF TRIPLE SHOE .2543
HYDRAULIC SYSTEM 2544
MAINTENANCE STANDARD OF MAIN PUMP .2544
MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE .2546
MAINTENANCE STANDARD OF MAIN PUMP TVC VALVE .2548
MAINTENANCE STANDARD OF MAIN PUMP CO AND NC VALVE .2549
MAINTENANCE STANDARD OF SWING MOTOR .2550
MAINTENANCE STANDARD OF CONTROL VALVE .2551
MAINTENANCE STANDARD OF TRAVEL SHUTTLE VALVE OF CONTROL VALVE .2557
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE VALVE 2558
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2559
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .2561
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2563
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2566
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE .2569
MAINTENANCE STANDARD OF SOLENOID VALVE 2571
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2572
WORK EQUIPMENT 2573
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2573
DIMENSION OF ARM 2578
DIMENSIONS OF BUCKET 2580
MAINTENANCE STANDARD OF BOOM CYLINDER .2582
MAINTENANCE STANDARD OF ARM CYLINDER 2583
MAINTENANCE STANDARD OF BUCKET CYLINDER .2584
80 APPENDIX .2585
CONTENTS 2586
ABBREVIATION LIST .2588
AIR CONDITIONER SYSTEM 2594
PRECAUTIONS FOR REFRIGERANT .2594
AIR CONDITIONER COMPONENT .2595
SPECIFICATIONS OF AIR CONDITIONER .2597
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2598
OUTLINE OF REFRIGERATION CYCLE 2599
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2601
AIR CONDITIONER UNIT 2601
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2601
FUNCTION OF AIR CONDITIONER UNIT 2603
COMPONENT PARTS OF AIR CONDITIONER UNIT .2605
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2606
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2606
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2606
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2606
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2607
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2607
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2607
FUNCTION OF DUAL PRESSURE SWITCH 2608
AIR CONDITIONER CONTROLLER 2609
STRUCTURE OF AIR CONDITIONER CONTROLLER .2609
COMPRESSOR 2610
STRUCTURE OF COMPRESSOR .2610
SPECIFICATIONS OF COMPRESSOR 2610
FUNCTION OF COMPRESSOR 2610
CONDENSER .2611
STRUCTURE OF CONDENSER 2611
SPECIFICATIONS OF CONDENSER .2611
FUNCTION OF CONDENSER .2611
RECEIVER DRIER 2612
STRUCTURE OF RECEIVER DRIER .2612
SPECIFICATIONS OF RECEIVER DRIER 2612
FUNCTION OF RECEIVER DRIER 2612
SENSORS FOR AIR CONDITIONER SYSTEM 2613
STRUCTURE OF SUNLIGHT SENSOR 2613
FUNCTION OF SUNLIGHT SENSOR .2613
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2613
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2613
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2615
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2617
AIR CONDITIONER SYSTEM DIAGRAM 2619
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2620
FUNCTION OF AIR CONDITIONER CONTROLLER 2621
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2622
TESTING AIR LEAKAGE (DUCT) 2626
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2626
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2628
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2629
TEST VENT (MODE) CHANGEOVER .2630
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2630
TESTING FRESH/RECIRC AIR CHANGEOVER .2632
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2632
TEST SUNLIGHT SENSOR 2633
METHOD FOR TESTING SUNLIGHT SENSOR 2633
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2634
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2634
TEST RELAYS .2635
METHOD FOR TESTING RELAYS .2635
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2636
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2637
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2640
FAILURE CODE [879AKA] .2642
FAILURE CODE [879AKB] .2643
FAILURE CODE [879BKA] .2644
FAILURE CODE [879BKB] .2646
FAILURE CODE [879CKA] .2648
FAILURE CODE [879CKB] .2649
FAILURE CODE [879DKZ] .2650
FAILURE CODE [879EMC] .2652
FAILURE CODE [879FMC] .2653
FAILURE CODE [879GKX] .2654
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2656
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2658
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2661
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2663
TROUBLESHOOTING USING GAUGE PRESSURE 2665
CONNECTION OF SERVICE TOOL 2668
METHOD FOR CONNECTING SERVICE TOOL 2668
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2670
HANDLE COMPRESSOR OIL .2672
90 CIRCUIT DIAGRAMS .2675
CONTENTS 2676
ABBREVIATION LIST .2677
HYDRAULIC CIRCUIT DIAGRAM .2683
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2683
HYDRAULIC CIRCUIT DIAGRAM .2687
ELECTRICAL CIRCUIT DIAGRAM 2689
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2689
ELECTRICAL CIRCUIT DIAGRAM (1/12) .2693
ELECTRICAL CIRCUIT DIAGRAM (2/12) .2695
ELECTRICAL CIRCUIT DIAGRAM (3/12) .2697
ELECTRICAL CIRCUIT DIAGRAM (4/12) .2699
ELECTRICAL CIRCUIT DIAGRAM (5/12) .2701
ELECTRICAL CIRCUIT DIAGRAM (6/12) .2703
ELECTRICAL CIRCUIT DIAGRAM (7/12) .2705
ELECTRICAL CIRCUIT DIAGRAM (8/12) .2707
ELECTRICAL CIRCUIT DIAGRAM (9/12) .2709
ELECTRICAL CIRCUIT DIAGRAM (10/12) 2711
ELECTRICAL CIRCUIT DIAGRAM (11/12) 2713
ELECTRICAL CIRCUIT DIAGRAM (12/12) 2715
INDEX 2717

DESCRIPTION:

Komatsu PC700LC -11 Hydraulic Excavator Shop Manual UENBM00433 –  PDF DOWNLOAD

• 80013 and up
• K70001 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”.
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 29/12/24