Komatsu PC700LC-11E0 Hydraulic Excavator Shop Manual UENBM00511 PDF

Description

Komatsu PC700LC-11E0 Hydraulic Excavator Shop Manual UENBM00511 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC700LC-11E0 Hydraulic Excavator Shop Manual UENBM00511 – PDF DOWNLOAD

Language : English
Pages : 2720
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC700LC-11E0 Hydraulic Excavator Shop Manual UENBM00511 – PDF DOWNLOAD

• SERIAL NUMBERS K75001 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-11E0 . 103
SPECIFICATION DRAWING: PC700LCSE-11E0 . 104
WORKING RANGE DRAWINGS 106
WORKING RANGE: PC700LC-11E0 . 106
WORKING RANGE: PC700LCSE-11E0 . 107
SPECIFICATIONS 108
SPECIFICATIONS: PC700LC-11E0 108
SPECIFICATIONS: PC700LCSE-11E0 110
WEIGHT TABLE 114
WEIGHT TABLE: PC700LC-11E0 114
WEIGHT TABLE: PC700LCSE-11E0 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-11E0 . 429
STANDARD VALUE TABLE FOR MACHINE 434
STANDARD VALUE TABLE FOR MACHINE: PC700LC-11E0 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 FROM HYDRAULIC CIRCUIT 552
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 561
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT . 561
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 562
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 565
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 573
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT . 577
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 577
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 578
TEST AND ADJUST PISTON PUMP CONTROL OIL PRESSURE 579
METHOD FOR TESTING TVC VALVE OUTLET PRESSURE 579
METHOD FOR TESTING CO AND NC VALVE OUTLET PRESSURE 580
METHOD FOR TESTING JET SENSOR OUTLET PRESSURE . 581
METHOD FOR ADJUSTING TVC VALVE 583
METHOD FOR ADJUSTING CO AND NC VALVE 584
METHOD FOR ADJUSTING JET SENSOR . 585
TEST SERVO PISTON STROKE 586
METHOD FOR TESTING SERVO PISTON STROKE 586
TEST OUTLET PRESSURE OF SOLENOID VALVE 588
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 588
OPERATING CONDITION OF SOLENOID VALVE . 589
TEST PPC VALVE OUTLET PRESSURE 592
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 592
TEST PPC SHUTTLE VALVE OUTLET PRESSURE 594
METHOD FOR TESTING PPC SHUTTLE VALVE OUTLET PRESSURE 594
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 598
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 598
TEST AND ADJUST TRAVEL DEVIATION 599
METHOD FOR TESTING TRAVEL DEVIATION . 599
METHOD FOR ADJUSTING TRAVEL DEVIATION . 599
TEST COOLING FAN SPEED 601
METHOD FOR TESTING COOLING FAN SPEED 601
TEST OIL PRESSURE IN FAN PUMP CIRCUIT . 602
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT . 602
TEST FAN PUMP EPC ELECTRIC CURRENT 603
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 603
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 604
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 604
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 605
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 605
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 605
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 606
TEST OIL LEAKAGE 607
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 607
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 608
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 608
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 609
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 609
METHOD FOR TESTING OIL LEAKAGE OF SWIVEL JOINT 610
BLEED AIR FROM HYDRAULIC CIRCUIT 612
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 613
CAB AND ITS ATTACHMENTS . 616
TEST CAB TIPPING STOPPER 616
METHOD FOR TESTING CAB TIPPING STOPPER 616
METHOD FOR ADJUSTING MIRRORS 617
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 617
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 618
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 619
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 620
ELECTRICAL SYSTEM . 622
SET AND OPERATE MACHINE MONITOR . 622
OPERATOR MODE . 625
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 625
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 625
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 626
CHECKING FUNCTION OF SERVICE METER 627
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 627
SERVICE MODE 629
METHOD FOR OPERATING SERVICE MODE . 629
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 632
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 638
ABNORMALITY RECORD MENU . 649
METHOD FOR CONFIRMING MAINTENANCE RECORD 654
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 655
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 659
DEFAULT MENU 660
DIAGNOSTIC TESTS MENU . 666
ADJUSTMENT MENU . 676
METHOD FOR PERFORMING NO-INJECTION CRANKING . 680
KOMTRAX SETTINGS MENU . 681
METHOD FOR DISPLAYING SERVICE MESSAGE . 683
METHOD FOR STARTING UP KOMTRAX TERMINAL . 685
ADJUST REARVIEW CAMERA ANGLE 690
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE . 690
ADJUST KomVision CAMERA ANGLE . 692
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 693
ADJUST KomVision RELATED ITEMS 695
SETTING OF KomVision (MAIN SETTING) . 695
SETTING OF KomVision (CAMERA SETTING) . 697
SETTING OF KomVision (CAMERA CALIBRATION) . 697
KomVision screen – Check 12 m visibility 711
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 714
HANDLE BATTERY DISCONNECT SWITCH 715
TEST DIODES . 716
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 716
METHOD FOR TESTING DIODE USING ANALOG TESTER 716
Pm CLINIC . 717
Pm CLINIC SERVICE . 717
Pm CLINIC CHECK SHEET: PC700LC-11E0 . 720
40 TROUBLESHOOTING 737
CONTENTS 738
ABBREVIATION LIST . 749
RELATED INFORMATION ON TROUBLESHOOTING 755
GENERAL TROUBLESHOOTING POINTS 755
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 756
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 768
CHECKS BEFORE TROUBLESHOOTING . 770
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 772
WALK-AROUND CHECK . 772
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 774
CHECK FUEL LEVEL AND TYPE . 774
CHECK IMPURE INGREDIENT IN FUEL . 775
CHECK FUEL PREFILTER 775
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 775
FUEL PREFILTER CARTRIDGE – REPLACE 776
CHECK MAIN FILTER . 777
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 778
CHECK COOLANT LEVEL (RESERVOIR TANK) 780
CHECK CLOGGING OF AIR CLEANER . 780
OUTER ELEMENT – CLEAN . 780
ELEMENTS – REPLACE 783
CHECK HYDRAULIC OIL LEVEL . 783
CHECK HYDRAULIC OIL STRAINER 785
CHECK HYDRAULIC FILTER 785
CHECK OIL LEVEL IN SWING MACHINERY CASE . 786
CHECK OIL LEVEL IN PTO CASE . 787
CHECK PTO LUBRICATION FILTER STRAINER . 787
CHECK OIL LEVEL IN FINAL DRIVE CASE . 788
BLEED AIR FROM FUEL SYSTEM 789
BLEED AIR FROM HYDRAULIC SYSTEM . 789
ELECTRICAL EQUIPMENT – CHECK METHOD . 789
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 795
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 795
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 795
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 795
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL . 796
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER . 796
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 796
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 800
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 803
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 807
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 809
CONNECTOR LIST AND LAYOUT . 812
CONNECTOR CONTACT IDENTIFICATION 826
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 866
FUSE LOCATION TABLE . 872
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 875
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 879
FAILURE CODES TABLE . 881
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 898
FAILURE CODE [879AKA] . 898
FAILURE CODE [879AKB] . 899
FAILURE CODE [879BKA] . 900
FAILURE CODE [879BKB] . 902
FAILURE CODE [879CKA] . 904
FAILURE CODE [879CKB] . 905
FAILURE CODE [879DKZ] . 906
FAILURE CODE [879EMC] . 908
FAILURE CODE [879FMC] . 909
FAILURE CODE [879GKX] . 910
FAILURE CODE [989L00] . 912
FAILURE CODE [989M00] . 913
FAILURE CODE [989N00] . 914
FAILURE CODE [A1U0N3] . 915
FAILURE CODE [A1U0N4] . 917
FAILURE CODE [A900FR] . 919
FAILURE CODE [A900N6] . 920
FAILURE CODE [A900NY] . 921
FAILURE CODE [AA10NX] . 922
FAILURE CODE [AB00KE] . 924
FAILURE CODE [AQ10N3] . 926
FAILURE CODE [AS00N3] . 928
FAILURE CODE [AS00R2] . 930
FAILURE CODE [AS00R3] . 931
FAILURE CODE [AS00R4] . 932
FAILURE CODE [AS00R5] . 933
FAILURE CODE [AS00R6] . 934
FAILURE CODE [AS00ZK] . 935
FAILURE CODE [AS10KM] . 936
FAILURE CODE [AS10NR] . 937
FAILURE CODE [AS10NT] . 938
FAILURE CODE [B@BAZG] . 939
FAILURE CODE [B@BAZK] . 940
FAILURE CODE [B@BCNS] . 942
FAILURE CODE [B@BCZK] . 943
FAILURE CODE [B@HANS] . 945
FAILURE CODE [CA115] 946
FAILURE CODE [CA122] 947
FAILURE CODE [CA123] 949
FAILURE CODE [CA131] 951
FAILURE CODE [CA132] 953
FAILURE CODE [CA135] 955
FAILURE CODE [CA141] 957
FAILURE CODE [CA144] 959
FAILURE CODE [CA145] 961
FAILURE CODE [CA153] 963
FAILURE CODE [CA154] 966
FAILURE CODE [CA187] 969
FAILURE CODE [CA221] 971
FAILURE CODE [CA222] 973
FAILURE CODE [CA227] 975
FAILURE CODE [CA234] 976
FAILURE CODE [CA238] 977
FAILURE CODE [CA239] 979
FAILURE CODE [CA249] 981
FAILURE CODE [CA256] 983
FAILURE CODE [CA271] 985
FAILURE CODE [CA272] 987
FAILURE CODE [CA273] 988
FAILURE CODE [CA274] 990
FAILURE CODE [CA322] 991
FAILURE CODE [CA323] 993
FAILURE CODE [CA324] 995
FAILURE CODE [CA325] 997
FAILURE CODE [CA331] 999
FAILURE CODE [CA332] 1001
FAILURE CODE [CA343] 1003
FAILURE CODE [CA351] 1004
FAILURE CODE [CA352] 1005
FAILURE CODE [CA356] 1008
FAILURE CODE [CA357] 1010
FAILURE CODE [CA386] 1012
FAILURE CODE [CA441] 1013
FAILURE CODE [CA442] 1015
FAILURE CODE [CA449] 1016
FAILURE CODE [CA451] 1017
FAILURE CODE [CA452] 1019
FAILURE CODE [CA515] 1021
FAILURE CODE [CA516] 1023
FAILURE CODE [CA553] 1025
FAILURE CODE [CA555] 1026
FAILURE CODE [CA556] 1027
FAILURE CODE [CA559] 1028
FAILURE CODE [CA595] 1033
FAILURE CODE [CA687] 1034
FAILURE CODE [CA689] 1036
FAILURE CODE [CA691] 1038
FAILURE CODE [CA692] 1040
FAILURE CODE [CA697] 1042
FAILURE CODE [CA698] 1043
FAILURE CODE [CA731] 1044
FAILURE CODE [CA778] 1045
FAILURE CODE [CA1117] .1048
FAILURE CODE [CA1664] .1049
FAILURE CODE [CA1669] .1053
FAILURE CODE [CA1673] .1054
FAILURE CODE [CA1677] .1055
FAILURE CODE [CA1678] .1056
FAILURE CODE [CA1682] .1057
FAILURE CODE [CA1683] .1059
FAILURE CODE [CA1684] .1061
FAILURE CODE [CA1686] .1063
FAILURE CODE [CA1691] .1064
FAILURE CODE [CA1694] .1067
FAILURE CODE [CA1695] .1069
FAILURE CODE [CA1696] .1070
FAILURE CODE [CA1712] .1072
FAILURE CODE [CA1713] .1075
FAILURE CODE [CA1714] .1078
FAILURE CODE [CA1715] .1079
FAILURE CODE [CA1776] .1080
FAILURE CODE [CA1777] .1083
FAILURE CODE [CA1843] .1086
FAILURE CODE [CA1844] .1088
FAILURE CODE [CA1879] .1091
FAILURE CODE [CA1881] .1094
FAILURE CODE [CA1883] .1096
FAILURE CODE [CA1885] .1100
FAILURE CODE [CA1887] .1102
FAILURE CODE [CA1921] .1104
FAILURE CODE [CA1922] .1107
FAILURE CODE [CA1923] .1112
FAILURE CODE [CA1924] .1114
FAILURE CODE [CA1925] .1116
FAILURE CODE [CA1927] .1118
FAILURE CODE [CA1928] .1120
FAILURE CODE [CA1942] .1122
FAILURE CODE [CA1963] .1123
FAILURE CODE [CA1977] .1127
FAILURE CODE [CA1993] .1130
FAILURE CODE [CA2185] .1133
FAILURE CODE [CA2186] .1135
FAILURE CODE [CA2249] .1137
FAILURE CODE [CA2265] .1138
FAILURE CODE [CA2266] .1140
FAILURE CODE [CA2271] .1142
FAILURE CODE [CA2272] .1144
FAILURE CODE [CA2349] .1146
FAILURE CODE [CA2353] .1148
FAILURE CODE [CA2357] .1150
FAILURE CODE [CA2381] .1151
FAILURE CODE [CA2382] .1153
FAILURE CODE [CA2383] .1155
FAILURE CODE [CA2386] .1157
FAILURE CODE [CA2387] .1159
FAILURE CODE [CA2555] .1160
FAILURE CODE [CA2556] .1162
FAILURE CODE [CA2637] .1164
FAILURE CODE [CA2639] .1166
FAILURE CODE [CA2732] .1168
FAILURE CODE [CA2733] .1170
FAILURE CODE [CA2741] .1172
FAILURE CODE [CA2765] .1173
FAILURE CODE [CA2771] .1174
FAILURE CODE [CA2777] .1180
FAILURE CODE [CA2878] .1183
FAILURE CODE [CA2881] .1186
FAILURE CODE [CA2976] .1189
FAILURE CODE [CA3133] .1191
FAILURE CODE [CA3134] .1193
FAILURE CODE [CA3135] .1195
FAILURE CODE [CA3142] .1198
FAILURE CODE [CA3143] .1199
FAILURE CODE [CA3144] .1200
FAILURE CODE [CA3146] .1202
FAILURE CODE [CA3147] .1203
FAILURE CODE [CA3148] .1204
FAILURE CODE [CA3151] .1206
FAILURE CODE [CA3165] .1211
FAILURE CODE [CA3167] .1214
FAILURE CODE [CA3229] .1218
FAILURE CODE [CA3231] .1221
FAILURE CODE [CA3232] .1224
FAILURE CODE [CA3235] .1229
FAILURE CODE [CA3239] .1231
FAILURE CODE [CA3241] .1234
FAILURE CODE [CA3242] .1237
FAILURE CODE [CA3251] .1240
FAILURE CODE [CA3253] .1244
FAILURE CODE [CA3254] .1250
FAILURE CODE [CA3255] .1254
FAILURE CODE [CA3256] .1257
FAILURE CODE [CA3311] .1260
FAILURE CODE [CA3312] .1263
FAILURE CODE [CA3313] .1266
FAILURE CODE [CA3314] .1267
FAILURE CODE [CA3315] .1268
FAILURE CODE [CA3316] .1271
FAILURE CODE [CA3317] .1272
FAILURE CODE [CA3318] .1273
FAILURE CODE [CA3319] .1276
FAILURE CODE [CA3321] .1277
FAILURE CODE [CA3322] .1278
FAILURE CODE [CA3419] .1281
FAILURE CODE [CA3421] .1283
FAILURE CODE [CA3497] .1285
FAILURE CODE [CA3498] .1286
FAILURE CODE [CA3543] .1287
FAILURE CODE [CA3545] .1292
FAILURE CODE [CA3547] .1294
FAILURE CODE [CA3558] .1295
FAILURE CODE [CA3559] .1297
FAILURE CODE [CA3562] .1299
FAILURE CODE [CA3563] .1301
FAILURE CODE [CA3567] .1304
FAILURE CODE [CA3568] .1307
FAILURE CODE [CA3571] .1311
FAILURE CODE [CA3572] .1313
FAILURE CODE [CA3574] .1315
FAILURE CODE [CA3575] .1318
FAILURE CODE [CA3577] .1320
FAILURE CODE [CA3578] .1322
FAILURE CODE [CA3582] .1324
FAILURE CODE [CA3583] .1329
FAILURE CODE [CA3596] .1331
FAILURE CODE [CA3649] .1335
FAILURE CODE [CA3681] .1338
FAILURE CODE [CA3682] .1343
FAILURE CODE [CA3713] .1349
FAILURE CODE [CA3717] .1352
FAILURE CODE [CA3718] .1353
FAILURE CODE [CA3725] .1354
FAILURE CODE [CA3748] .1357
FAILURE CODE [CA3751] .1359
FAILURE CODE [CA3755] .1361
FAILURE CODE [CA3866] .1363
FAILURE CODE [CA3867] .1367
FAILURE CODE [CA3868] .1370
FAILURE CODE [CA3899] .1374
FAILURE CODE [CA3911] .1377
FAILURE CODE [CA3912] .1381
FAILURE CODE [CA3932] .1383
FAILURE CODE [CA3933] .1385
FAILURE CODE [CA3934] .1387
FAILURE CODE [CA3935] .1390
FAILURE CODE [CA3936] .1392
FAILURE CODE [CA4151] .1394
FAILURE CODE [CA4152] .1398
FAILURE CODE [CA4155] .1402
FAILURE CODE [CA4156] .1404
FAILURE CODE [CA4157] .1407
FAILURE CODE [CA4158] .1409
FAILURE CODE [CA4159] .1411
FAILURE CODE [CA4161] .1413
FAILURE CODE [CA4162] .1416
FAILURE CODE [CA4163] .1419
FAILURE CODE [CA4164] .1421
FAILURE CODE [CA4165] .1424
FAILURE CODE [CA4166] .1427
FAILURE CODE [CA4168] .1430
FAILURE CODE [CA4169] .1435
FAILURE CODE [CA4171] .1440
FAILURE CODE [CA4249] .1445
FAILURE CODE [CA4251] .1449
FAILURE CODE [CA4259] .1453
FAILURE CODE [CA4261] .1456
FAILURE CODE [CA4277] .1459
FAILURE CODE [CA4281] .1463
FAILURE CODE [CA4459] .1466
FAILURE CODE [CA4461] .1469
FAILURE CODE [CA4658] .1472
FAILURE CODE [CA4731] .1476
FAILURE CODE [CA4732] .1477
FAILURE CODE [CA4739] .1478
FAILURE CODE [CA4768] .1479
FAILURE CODE [CA4769] .1481
FAILURE CODE [CA4842] .1484
FAILURE CODE [CA4952] .1488
FAILURE CODE [CA5115] .1490
FAILURE CODE [CA5179] .1493
FAILURE CODE [CA5181] .1495
FAILURE CODE [CA5383] .1497
FAILURE CODE [D110KB] .1499
FAILURE CODE [D163KB] .1501
FAILURE CODE [D195KA] .1503
FAILURE CODE [D195KB] .1505
FAILURE CODE [D19JKZ] .1507
FAILURE CODE [D811MC] .1509
FAILURE CODE [D862KA] .1510
FAILURE CODE [D8ALKA] .1511
FAILURE CODE [D8ALKB] .1513
FAILURE CODE [D8AQKR] .1515
FAILURE CODE [DA20MC] .1519
FAILURE CODE [DA22KK] .1520
FAILURE CODE [DA25KP] .1522
FAILURE CODE [DA26KP] .1524
FAILURE CODE [DA29KQ] .1527
FAILURE CODE [DA2LKA] .1529
FAILURE CODE [DA2LKB] .1531
FAILURE CODE [DA2QKR] .1533
FAILURE CODE [DA2RKR] .1538
FAILURE CODE [DAF0KM] .1543
FAILURE CODE [DAF0MB] .1544
FAILURE CODE [DAF0MC] .1545
FAILURE CODE [DAF8KB] .1546
FAILURE CODE [DAF9KQ] .1548
FAILURE CODE [DAFGMC] .1549
FAILURE CODE [DAFLKA] .1550
FAILURE CODE [DAFLKB] .1552
FAILURE CODE [DAFQKR] .1554
FAILURE CODE [DAZ9KQ] .1558
FAILURE CODE [DAZQKR] .1559
FAILURE CODE [DB2QKR] .1563
FAILURE CODE [DB2RKR] .1568
FAILURE CODE [DBP0KM] .1573
FAILURE CODE [DBP0KT] .1574
FAILURE CODE [DBP5KB] .1575
FAILURE CODE [DBP5KY] .1578
FAILURE CODE [DBPQKR] .1581
FAILURE CODE [DDNRKA] .1586
FAILURE CODE [DDNRKY] .1588
FAILURE CODE [DDNS00] .1590
FAILURE CODE [DGE5KB] .1592
FAILURE CODE [DGH2KA] .1593
FAILURE CODE [DGH2KB] .1595
FAILURE CODE [DHA4KA] .1597
FAILURE CODE [DHAAMA] .1599
FAILURE CODE [DHACMA] .1601
FAILURE CODE [DHPAMA] .1603
FAILURE CODE [DHPBMA] .1605
FAILURE CODE [DHS3MA] .1607
FAILURE CODE [DHS4MA] .1610
FAILURE CODE [DHS8MA] .1613
FAILURE CODE [DHS9MA] .1616
FAILURE CODE [DHSAMA] .1619
FAILURE CODE [DHSBMA] .1622
FAILURE CODE [DHSCMA] .1625
FAILURE CODE [DHSDMA] .1628
FAILURE CODE [DHSFMA] .1631
FAILURE CODE [DHSGMA] .1634
FAILURE CODE [DHSHMA] .1637
FAILURE CODE [DHSJMA] .1640
FAILURE CODE [DHSVMA] .1643
FAILURE CODE [DKULKA] .1645
FAILURE CODE [DKULKB] .1647
FAILURE CODE [DKULKY] .1649
FAILURE CODE [DLM3KA] .1651
FAILURE CODE [DLM3KB] .1653
FAILURE CODE [DLM3MB] .1655
FAILURE CODE [DR10KA] .1656
FAILURE CODE [DR12KA] .1659
FAILURE CODE [DR20KA] .1661
FAILURE CODE [DR21KX] .1663
FAILURE CODE [DR30KA] .1665
FAILURE CODE [DR31KX] .1667
FAILURE CODE [DR40KA] .1669
FAILURE CODE [DUMBKA] .1671
FAILURE CODE [DUMBKB] .1673
FAILURE CODE [DV20KB] .1675
FAILURE CODE [DW43KA] .1676
FAILURE CODE [DW43KB] .1678
FAILURE CODE [DW43KY] .1680
FAILURE CODE [DW45KA] .1681
FAILURE CODE [DW45KB] .1684
FAILURE CODE [DW45KY] .1687
FAILURE CODE [DW48KA] .1689
FAILURE CODE [DW48KB] .1691
FAILURE CODE [DW48KY] .1693
FAILURE CODE [DW4CKY] .1694
FAILURE CODE [DW4XKA] .1696
FAILURE CODE [DW4XKB] .1698
FAILURE CODE [DW4XKY] .1700
FAILURE CODE [DW7BKA] .1701
FAILURE CODE [DW7BKB] .1703
FAILURE CODE [DW7BKY] .1705
FAILURE CODE [DWK0KA] .1706
FAILURE CODE [DWK0KB] .1708
FAILURE CODE [DWK0KY] .1710
FAILURE CODE [DWK2KA] .1711
FAILURE CODE [DWK2KB] .1713
FAILURE CODE [DWK2KY] .1715
FAILURE CODE [DWK8KA] .1716
FAILURE CODE [DWK8KB] .1718
FAILURE CODE [DWK8KY] .1720
FAILURE CODE [DX16KA] .1721
FAILURE CODE [DX16KB] .1723
FAILURE CODE [DXA2KA] .1724
FAILURE CODE [DXA2KB] .1727
FAILURE CODE [DXA3KA] .1729
FAILURE CODE [DXA3KB] .1732
FAILURE CODE [DY20KA] .1734
FAILURE CODE [DY20MA] .1736
FAILURE CODE [DY2CKB] .1738
FAILURE CODE [DY2DKB] .1740
FAILURE CODE [DY2EKB] .1742
FAILURE CODE [DY2FMA] .1744
FAILURE CODE [DY2GKM] .1746
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1748
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1748
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1754
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1757
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1759
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1761
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1764
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1765
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1766
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1767
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1768
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1769
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1770
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1771
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1772
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1773
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1774
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1776
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1777
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1778
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1779
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1781
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1782
E-23 FUNCTION SWITCH DOES NOT OPERATE .1783
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1784
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1785
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1786
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1787
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1788
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1789
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1790
E-31 ALARM BUZZER CANNOT BE CANCELED 1791
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1792
E-33 SERVICE MODE CANNOT BE SELECTED 1793
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1794
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1797
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1799
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1802
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1804
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1806
E-40 ALARM DOES NOT SOUND DURING TRAVEL .1807
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1809
E-42 HORN DOES NOT SOUND 1810
E-43 HORN DOES NOT STOP SOUNDING 1813
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1815
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1816
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1818
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1819
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1820
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1821
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1822
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1823
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1824
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1825
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1826
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1827
E-56 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1829
E-57 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 1830
E-58 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1832
E-59 STEP LIGHT DOES NOT LIGHT UP .1833
E-60 STEP LIGHT DOES NOT GO OUT .1835
E-61 BOOM SHOCKLESS FUNCTION CANNOT BE CANCELED .1837
E-62 BOOM SHOCKLESS FUNCTION DOES NOT WORK 1839
E-63 ELECTRIC GREASE GUN DOES NOT WORK 1840
E-64 ELECTRIC GREASE GUN DOES NOT STOP 1842
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1843
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1843
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1844
H-3 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1846
H-4 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1847
H-5 TRAVEL SPEED OR POWER IS LOW 1848
H-6 AUTO-DECELERATION FUNCTION CANNOT BE CANCELED .1849
H-7 SPEED OR POWER OF BOOM IS LOW .1850
H-8 ARM SPEED OR POWER IS LOW .1852
H-9 BUCKET SPEED OR POWER IS LOW 1853
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION .1854
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE .1855
H-12 HYDRAULIC DRIFT OF ARM IS LARGE 1856
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE .1857
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1858
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1859
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1860
H-17 MACHINE DOES NOT TRAVEL STRAIGHT .1861
H-18 SPEED OF BOOM AND BUCKET IS SLOW AT COMBINED OPERATION OF ARM, BOOM AND BUCKET .1862
H-19 SPEED OF BOOM, ARM, SWING AND TRAVEL IS SLOW AT COMBINED OPERATION OF BUCKET, BOOM AND ARM .1863
H-20 SWING SPEED IS SLOW AT COMBINED OPERATION OF ARM AND SWING .1864
H-21 TRAVEL DEVIATION IS LARGE AT START OF TRAVELING 1865
H-22 TRAVEL DEVIATION IS LARGE AT COMBINED OPERATION 1867
H-23 ONE OF TRACKS DOES NOT RUN .1868
H-24 TRAVEL SPEED DOES NOT CHANGE .1870
H-25 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1871
H-26 SWINGS ONLY IN ONE DIRECTION .1872
H-27 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1873
H-28 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1874
H-29 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1875
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1876
H-31 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1877
H-32 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1878
H-33 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1879
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1880
H-35 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1881
H-36 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1882
TROUBLESHOOTING OF ENGINE (S-MODE) 1883
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1883
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1884
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1885
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1886
S-4 ENGINE STARTABILITY IS POOR .1887
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1889
S-6 ENGINE STOPS DURING OPERATION .1891
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1893
S-8 ENGINE LACKS POWER 1894
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1896
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1898
S-11 OIL BECOMES CONTAMINATED QUICKLY .1899
S-12 FUEL CONSUMPTION IS EXCESSIVE 1900
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1901
S-14 OIL PRESSURE DROPS .1902
S-15 FUEL MIXES INTO ENGINE OIL .1904
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1905
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1906
S-18 UNUSUAL NOISE IS HEARD .1907
S-19 VIBRATION IS EXCESSIVE .1908
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1909
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1910
S-22 ACTIVE REGENERATION TAKES TIME .1912
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1914
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1915
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1917
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1918
50 DISASSEMBLY AND ASSEMBLY .1919
CONTENTS 1920
ABBREVIATION LIST .1925
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1931
HOW TO READ THIS MANUAL .1931
COATING MATERIALS LIST 1933
SPECIAL TOOLS LIST 1937
SKETCHES OF SPECIAL TOOLS .1954
ENGINE AND COOLING SYSTEM .1961
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .1961
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1961
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1964
REMOVE AND INSTALL INJECTOR ASSEMBLY 1969
METHOD FOR REMOVING INJECTOR ASSEMBLY .1969
METHOD FOR INSTALLING INJECTOR ASSEMBLY .1974
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 1983
METHOD FOR REMOVING FUEL DOSER ASSEMBLY .1983
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY .1984
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .1986
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1987
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1997
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2014
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2014
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2016
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2018
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2018
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2021
REMOVE AND INSTALL STARTER ASSEMBLY .2025
METHOD FOR REMOVING STARTER ASSEMBLY 2025
METHOD FOR INSTALLING STARTER ASSEMBLY 2025
REMOVE AND INSTALL ALTERNATOR BELT 2027
METHOD FOR REMOVING ALTERNATOR BELT .2027
METHOD FOR INSTALLING ALTERNATOR BELT .2028
REMOVE AND INSTALL RADIATOR ASSEMBLY 2030
METHOD FOR REMOVING RADIATOR ASSEMBLY .2030
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2033
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2037
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2037
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2040
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2044
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2044
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2046
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY .2049
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2049
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2058
REMOVE AND INSTALL ENGINE PTO AND HYDRAULIC ASSEMBLY 2067
METHOD FOR REMOVING ENGINE PTO AND HYDRAULIC ASSEMBLY .2067
METHOD FOR INSTALLING ENGINE PTO AND HYDRAULIC ASSEMBLY .2078
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2089
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2089
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2090
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2093
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2093
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2095
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2102
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2102
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2107
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2112
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2112
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2115
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2119
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2120
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2126
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2131
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2131
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2132
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2134
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2134
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2134
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2136
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2136
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2136
REMOVE AND INSTALL KDPF ASSEMBLY 2137
METHOD FOR REMOVING KDPF ASSEMBLY .2137
METHOD FOR INSTALLING KDPF ASSEMBLY .2141
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2150
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2151
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2155
REMOVE AND INSTALL SCR ASSEMBLY .2160
METHOD FOR REMOVING SCR ASSEMBLY 2160
METHOD FOR INSTALLING SCR ASSEMBLY 2162
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2166
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2167
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2173
REMOVE AND INSTALL KCCV ASSEMBLY 2185
METHOD FOR REMOVING KCCV ASSEMBLY .2185
METHOD FOR INSTALLING KCCV ASSEMBLY .2186
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2189
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2189
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2194
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2201
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2201
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2204
REMOVE AND INSTALL AdBlue/DEF PUMP 2208
METHOD FOR REMOVING AdBlue/DEF PUMP .2208
METHOD FOR INSTALLING AdBlue/DEF PUMP .2211
REMOVE AND INSTALL AdBlue/DEF HOSE 2214
METHOD FOR REMOVING AdBlue/DEF HOSE .2215
METHOD FOR INSTALLING AdBlue/DEF HOSE .2223
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2229
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2229
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2230
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2231
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2231
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2232
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2233
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2233
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2234
POWER TRAIN .2235
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY .2235
METHOD FOR DISASSEMBLING PTO ASSEMBLY .2235
METHOD FOR ASSEMBLING PTO ASSEMBLY 2236
REMOVE AND INSTALL PTO ASSEMBLY .2239
METHOD FOR REMOVING PTO ASSEMBLY 2239
METHOD FOR INSTALLING PTO ASSEMBLY 2240
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2243
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2243
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2244
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2245
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2246
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2251
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2260
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2260
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2261
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2263
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2263
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2267
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2272
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2272
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2273
UNDERCARRIAGE AND FRAME .2274
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 2274
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING .2274
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 2275
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2277
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY .2277
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY .2278
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2279
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY .2279
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY .2279
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD .2281
METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD .2283
METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD 2284
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2287
METHOD FOR SEPARATING TRACK ASSEMBLY 2287
METHOD FOR INSTALLING TRACK ASSEMBLY 2288
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2290
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2290
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2291
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2292
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2292
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2293
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2296
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2296
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2297
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2299
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2299
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2300
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2303
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2303
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2304
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2306
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2306
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2307
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2309
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2309
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2309
HYDRAULIC SYSTEM 2312
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2312
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2312
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2313
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2314
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2315
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2316
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2317
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2317
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2319
REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY 2322
METHOD FOR REMOVING HYDRAULIC PUMP ASSEMBLY .2322
METHOD FOR INSTALLING HYDRAULIC PUMP ASSEMBLY .2324
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2330
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2330
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2333
REMOVE AND INSTALL SWING MOTOR ASSEMBLY .2337
METHOD FOR REMOVING SWING MOTOR ASSEMBLY 2337
METHOD FOR INSTALLING SWING MOTOR ASSEMBLY 2338
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2339
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2339
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2340
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2342
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2342
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2343
DISASSEMBLE AND ASSEMBLE GREASE GUN ASSEMBLY 2345
METHOD FOR DISASSEMBLING GREASE GUN ASSEMBLY 2345
METHOD FOR ASSEMBLING GREASE GUN ASSEMBLY .2345
WORK EQUIPMENT 2346
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY .2346
METHOD FOR REMOVING BUCKET CYLINDER ASSEMBLY 2346
METHOD FOR INSTALLING BUCKET CYLINDER ASSEMBLY 2347
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY 2349
METHOD FOR REMOVING ARM CYLINDER ASSEMBLY .2349
METHOD FOR INSTALLING ARM CYLINDER ASSEMBLY .2350
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY .2352
METHOD FOR REMOVING BOOM CYLINDER ASSEMBLY 2352
METHOD FOR INSTALLING BOOM CYLINDER ASSEMBLY 2353
REMOVE AND INSTALL BUCKET ASSEMBLY 2355
METHOD FOR REMOVING BUCKET ASSEMBLY .2355
METHOD FOR INSTALLING BUCKET ASSEMBLY .2356
REMOVE AND INSTALL ARM ASSEMBLY .2357
METHOD FOR REMOVING ARM ASSEMBLY 2357
METHOD FOR INSTALLING ARM ASSEMBLY 2359
REMOVE AND INSTALL BOOM ASSEMBLY 2361
METHOD FOR REMOVING BOOM ASSEMBLY .2361
METHOD FOR INSTALLING BOOM ASSEMBLY .2362
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2364
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2364
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2366
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 2368
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2368
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2370
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM .2371
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM 2371
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM 2373
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY .2374
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY .2374
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY 2374
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2375
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2376
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2378
CAB AND ITS ATTACHMENTS .2383
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2383
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2383
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2390
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2399
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2401
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2401
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2411
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2411
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2414
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2420
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2420
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2423
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2428
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2428
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2433
REMOVE AND INSTALL OPERATOR’S SEAT 2440
METHOD FOR REMOVING OPERATOR’S SEAT .2440
METHOD FOR INSTALLING OPERATOR’S SEAT .2442
REMOVE AND INSTALL SEAT BELT 2445
METHOD FOR REMOVING SEAT BELT .2445
METHOD FOR INSTALLING SEAT BELT .2445
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2447
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2447
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2452
ELECTRICAL SYSTEM .2461
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2461
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2461
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2462
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2465
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2465
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2467
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2470
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2470
METHOD FOR INSTALLING KomVision CONTROLLER 2471
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2472
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2472
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2474
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2478
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2478
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2479
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2480
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2480
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2481
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2483
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2483
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2485
REMOVE AND INSTALL KomVision CAMERA .2487
METHOD FOR REMOVING KomVision CAMERA 2487
METHOD FOR INSTALLING KomVision CAMERA 2488
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2490
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2490
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2492
60 MAINTENANCE STANDARD .2495
CONTENTS 2496
ABBREVIATION LIST .2497
ENGINE AND COOLING SYSTEM .2503
MAINTENANCE STANDARD OF ENGINE MOUNT 2503
MAINTENANCE STANDARD FOR PTO 2505
MAINTENANCE STANDARD OF COOLING SYSTEM 2506
MAINTENANCE STANDARD OF COOLING FAN PUMP 2507
MAINTENANCE STANDARD OF SERVO VALVE .2508
MAINTENANCE STANDARD OF COOLING FAN MOTOR .2509
POWER TRAIN .2510
MAINTENANCE STANDARD OF SWING CIRCLE 2510
MAINTENANCE STANDARD OF SWING MACHINERY .2511
MAINTENANCE STANDARD OF FINAL DRIVE .2513
MAINTENANCE STANDARD OF SPROCKET 2515
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2516
UNDERCARRIAGE AND FRAME .2518
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2518
MAINTENANCE STANDARD OF IDLER .2520
MAINTENANCE STANDARD OF TRACK ROLLER 2522
MAINTENANCE STANDARD OF CARRIER ROLLER 2524
MAINTENANCE STANDARD OF TRACK SHOE 2525
MAINTENANCE STANDARD OF DOUBLE SHOE .2528
MAINTENANCE STANDARD OF TRIPLE SHOE .2529
HYDRAULIC SYSTEM 2530
MAINTENANCE STANDARD OF MAIN PUMP .2530
MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE .2532
MAINTENANCE STANDARD OF MAIN PUMP TVC VALVE .2534
MAINTENANCE STANDARD OF MAIN PUMP CO AND NC VALVE .2535
MAINTENANCE STANDARD OF SWING MOTOR .2536
MAINTENANCE STANDARD OF CONTROL VALVE .2537
MAINTENANCE STANDARD OF TRAVEL SHUTTLE VALVE OF CONTROL VALVE .2543
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE VALVE 2544
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2545
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .2547
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2549
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2552
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE .2555
MAINTENANCE STANDARD OF SOLENOID VALVE 2557
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2558
WORK EQUIPMENT 2559
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2559
DIMENSION OF ARM 2564
DIMENSIONS OF BUCKET 2566
MAINTENANCE STANDARD OF BOOM CYLINDER .2568
MAINTENANCE STANDARD OF ARM CYLINDER 2569
MAINTENANCE STANDARD OF BUCKET CYLINDER .2570
80 APPENDIX .2571
CONTENTS 2572
ABBREVIATION LIST .2574
AIR CONDITIONER SYSTEM 2580
PRECAUTIONS FOR REFRIGERANT .2580
AIR CONDITIONER COMPONENT .2581
SPECIFICATIONS OF AIR CONDITIONER .2583
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2584
OUTLINE OF REFRIGERATION CYCLE 2585
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2587
AIR CONDITIONER UNIT 2587
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2587
FUNCTION OF AIR CONDITIONER UNIT 2589
COMPONENT PARTS OF AIR CONDITIONER UNIT .2591
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2592
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2592
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2592
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2592
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2593
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2593
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2593
FUNCTION OF DUAL PRESSURE SWITCH 2594
AIR CONDITIONER CONTROLLER 2595
STRUCTURE OF AIR CONDITIONER CONTROLLER .2595
COMPRESSOR 2596
STRUCTURE OF COMPRESSOR .2596
SPECIFICATIONS OF COMPRESSOR 2596
FUNCTION OF COMPRESSOR 2596
CONDENSER .2597
STRUCTURE OF CONDENSER 2597
SPECIFICATIONS OF CONDENSER .2597
FUNCTION OF CONDENSER .2597
RECEIVER DRIER 2598
STRUCTURE OF RECEIVER DRIER .2598
SPECIFICATIONS OF RECEIVER DRIER 2598
FUNCTION OF RECEIVER DRIER 2598
SENSORS FOR AIR CONDITIONER SYSTEM 2599
STRUCTURE OF SUNLIGHT SENSOR 2599
FUNCTION OF SUNLIGHT SENSOR .2599
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2599
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2599
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2601
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2603
AIR CONDITIONER SYSTEM DIAGRAM 2605
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2606
FUNCTION OF AIR CONDITIONER CONTROLLER 2607
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2608
TESTING AIR LEAKAGE (DUCT) 2612
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2612
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2614
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2615
TEST VENT (MODE) CHANGEOVER .2616
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2616
TESTING FRESH/RECIRC AIR CHANGEOVER .2618
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2618
TEST SUNLIGHT SENSOR 2619
METHOD FOR TESTING SUNLIGHT SENSOR 2619
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2620
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2620
TEST RELAYS .2621
METHOD FOR TESTING RELAYS .2621
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2622
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2623
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2626
FAILURE CODE [879AKA] .2628
FAILURE CODE [879AKB] .2629
FAILURE CODE [879BKA] .2630
FAILURE CODE [879BKB] .2632
FAILURE CODE [879CKA] .2634
FAILURE CODE [879CKB] .2635
FAILURE CODE [879DKZ] .2636
FAILURE CODE [879EMC] .2638
FAILURE CODE [879FMC] .2639
FAILURE CODE [879GKX] .2640
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2642
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2644
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2647
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2649
TROUBLESHOOTING USING GAUGE PRESSURE 2651
CONNECTION OF SERVICE TOOL 2654
METHOD FOR CONNECTING SERVICE TOOL 2654
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2656
HANDLE COMPRESSOR OIL .2658
90 CIRCUIT DIAGRAMS .2661
CONTENTS 2662
ABBREVIATION LIST .2663
HYDRAULIC CIRCUIT DIAGRAM .2669
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2669
HYDRAULIC CIRCUIT DIAGRAM .2673
ELECTRICAL CIRCUIT DIAGRAM 2675
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2675
ELECTRICAL CIRCUIT DIAGRAM (1/12) .2679
ELECTRICAL CIRCUIT DIAGRAM (2/12) .2681
ELECTRICAL CIRCUIT DIAGRAM (3/12) .2683
ELECTRICAL CIRCUIT DIAGRAM (4/12) .2685
ELECTRICAL CIRCUIT DIAGRAM (5/12) .2687
ELECTRICAL CIRCUIT DIAGRAM (6/12) .2689
ELECTRICAL CIRCUIT DIAGRAM (7/12) .2691
ELECTRICAL CIRCUIT DIAGRAM (8/12) .2693
ELECTRICAL CIRCUIT DIAGRAM (9/12) .2695
ELECTRICAL CIRCUIT DIAGRAM (10/12) 2697
ELECTRICAL CIRCUIT DIAGRAM (11/12) 2699
ELECTRICAL CIRCUIT DIAGRAM (12/12) 2701
INDEX 2703

DESCRIPTION:

Komatsu PC700LC-11E0 Hydraulic Excavator Shop Manual UENBM00511 – PDF DOWNLOAD

• SERIAL NUMBERS K75001 and up

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