Komatsu PC700LC -11E0 Hydraulic Excavator Shop Manual UENBM00513 PDF

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Komatsu PC700LC -11E0 Hydraulic Excavator Shop Manual UENBM00513 – PDF DOWNLOAD

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Komatsu PC700LC -11E0 Hydraulic Excavator Shop Manual UENBM00513 – PDF DOWNLOAD

Language : English
Pages : 2732
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC700LC -11E0 Hydraulic Excavator Shop Manual UENBM00513 – PDF DOWNLOAD

• SERIAL NUMBERS K75001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 21
FOREWORD, SAFETY, BASIC INFORMATION . 27
HOW TO READ THE SHOP MANUAL . 27
SAFETY NOTICE FOR OPERATION . 29
PRECAUTIONS TO PREVENT FIRE . 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 41
METHOD FOR CHECKING ENGINE TYPE . 42
PRECAUTIONS FOR DEF . 44
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 44
PRECAUTIONS FOR ADDING 44
PRECAUTIONS FOR STORING . 44
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 44
THE OTHER PRECAUTIONS . 44
STORE AdBlue/DEF 45
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 46
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 49
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 56
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 58
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 59
PRACTICAL USE OF KOMTRAX 60
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 63
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 65
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 69
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 75
HOW TO READ ELECTRICAL WIRE CODE 76
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 80
STANDARD TIGHTENING TORQUE TABLE 83
CONVERSION TABLE 90
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 156
AdBlue/DEF MIXING TUBE 156
SCR ASSEMBLY 156
AdBlue/DEF TANK . 159
AdBlue/DEF PUMP . 161
AdBlue/DEF INJECTOR . 162
AdBlue/DEF HOSE . 163
AdBlue/DEF TANK HEATING VALVE . 164
BOOT-UP SYSTEM 165
LAYOUT DRAWING OF BOOT-UP SYSTEM 165
SYSTEM OPERATING LAMP SYSTEM 166
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 166
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 166
BATTERY DISCONNECT SWITCH . 168
FUNCTION OF BATTERY DISCONNECT SWITCH . 168
ENGINE SYSTEM . 169
LAYOUT DRAWING OF ENGINE SYSTEM . 169
FUNCTION OF ENGINE SYSTEM . 170
ENGINE CONTROL SYSTEM . 171
ENGINE CONTROL SYSTEM DIAGRAM . 171
FUNCTION OF ENGINE CONTROL SYSTEM . 171
AUTO-DECELERATION SYSTEM 174
AUTO-DECELERATION SYSTEM DIAGRAM 174
FUNCTION OF AUTO-DECELERATION SYSTEM 174
OPERATION OF AUTO-DECELERATION SYSTEM . 175
AUTOMATIC LOW IDLE SYSTEM . 176
AUTOMATIC LOW IDLE SYSTEM DIAGRAM . 176
FUNCTION OF AUTOMATIC LOW IDLE SYSTEM . 176
OPERATION OF AUTOMATIC LOW IDLE SYSTEM 177
ENGINE AUTOMATIC WARM-UP SYSTEM . 178
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 178
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 179
OVERHEAT PREVENTION SYSTEM 181
OVERHEAT PREVENTION SYSTEM DIAGRAM 181
FUNCTION OF OVERHEAT PREVENTION SYSTEM 182
TURBOCHARGER PROTECTION SYSTEM 183
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 183
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 184
AUTOMATIC IDLE STOP SYSTEM 185
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 185
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 185
COMPONENT PARTS OF ENGINE SYSTEM 188
PTO . 188
VGT . 189
EGR SYSTEM 192
EGR VALVE . 194
EGR COOLER 196
KCCV SYSTEM . 197
KCCV VENTILATOR . 199
KDPF 201
COOLING SYSTEM 206
LAYOUT DRAWING OF COOLING SYSTEM 206
SPECIFICATIONS OF COOLING SYSTEM 207
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN . 208
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN . 208
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN . 209
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN . 210
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN . 210
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN . 210
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 212
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN 212
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 212
COMPONENT PARTS OF COOLING SYSTEM . 213
COOLING FAN PUMP 213
COOLING FAN MOTOR . 221
CONTROL SYSTEM 228
LAYOUT DRAWING OF CONTROL SYSTEM 228
MACHINE MONITOR SYSTEM 230
MACHINE MONITOR SYSTEM DIAGRAM 230
FUNCTION OF MACHINE MONITOR SYSTEM 230
KomVision SYSTEM 232
LAYOUT DRAWING OF KOMVISION SYSTEM 232
KomVision SYSTEM DIAGRAM 234
FUNCTION OF KomVision SYSTEM 234
KOMTRAX SYSTEM 236
KOMTRAX SYSTEM DIAGRAM 236
FUNCTION OF KOMTRAX SYSTEM 236
COMPONENT PARTS OF CONTROL SYSTEM . 237
MACHINE MONITOR . 237
KomVision CONTROLLER 250
KomVision CAMERA 254
KOMTRAX TERMINAL 254
PUMP CONTROLLER . 257
RESISTOR FOR TVC VALVE 261
CAN TERMINATING RESISTOR 261
ENGINE CONTROLLER . 263
FUEL CONTROL DIAL . 269
FUEL FEED PUMP 271
FUEL FEED PUMP SWITCH . 272
HYDRAULIC SYSTEM 273
LAYOUT DRAWING OF HYDRAULIC SYSTEM 273
OLSS 276
STRUCTURE OF OLSS . 276
FUNCTION OF OLSS 276
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 277
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 288
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 288
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 290
COMPONENT PARTS OF HYDRAULIC SYSTEM . 293
HYDRAULIC TANK 293
MAIN PUMP . 295
CONTROL VALVE . 322
VARIABLE BACK PRESSURE VALVE 342
WORK EQUIPMENT SYSTEM . 345
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 345
ONE-TOUCH POWER MAXIMIZING SYSTEM . 351
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 351
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 352
MACHINE PUSH-UP SYSTEM 353
MACHINE PUSH-UP SYSTEM DIAGRAM 353
FUNCTION OF MACHINE PUSH-UP SYSTEM 354
PPC LOCK SYSTEM . 355
PPC LOCK SYSTEM DIAGRAM . 355
FUNCTION OF PPC LOCK SYSTEM . 355
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 356
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 356
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 356
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 357
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 358
WORK EQUIPMENT AND SWING PPC VALVE 358
1ST-LINE ATTACHMENT PPC VALVE . 362
PPC SHUTTLE VALVE . 364
SOLENOID VALVE 365
ANTI-DROP VALVE FOR BOOM 367
ANTI-DROP VALVE FOR ARM . 371
PILOT CIRCUIT ACCUMULATOR . 376
SWING SYSTEM 377
LAYOUT DRAWING OF SWING SYSTEM 377
SWING CONTROL SYSTEM DIAGRAM 380
FUNCTION OF SWING CONTROL SYSTEM 381
COMPONENT PARTS OF SWING SYSTEM . 384
SWING MOTOR . 384
SWING MACHINERY . 395
SWING CIRCLE 396
TRAVEL SYSTEM . 398
LAYOUT DRAWING OF TRAVEL SYSTEM . 398
TRAVEL CONTROL SYSTEM DIAGRAM . 402
FUNCTION OF TRAVEL CONTROL SYSTEM . 403
COMPONENT PARTS OF TRAVEL SYSTEM 405
TRAVEL MOTOR 405
FINAL DRIVE . 415
TRAVEL PPC VALVE 416
CENTER SWIVEL JOINT . 421
UNDERCARRIAGE AND FRAME . 423
LAYOUT DRAWING OF UNDERCARRIAGE . 423
SPECIFICATIONS OF UNDERCARRIAGE . 423
WORK EQUIPMENT 424
STRUCTURE OF WORK EQUIPMENT . 424
FUNCTION OF WORK EQUIPMENT 425
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 426
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 426
BUCKET CLEARANCE ADJUSTMENT SHIM 427
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 427
CAB AND ITS ATTACHMENTS . 428
ROPS CAB 428
STRUCTURE OF ROPS CAB . 428
FUNCTION OF ROPS CAB 428
CAB MOUNT . 429
STRUCTURE OF CAB MOUNT 429
FUNCTION OF CAB MOUNT . 429
CAB TIPPING STOPPER . 430
STRUCTURE OF CAB TIPPING STOPPER 430
FUNCTION OF CAB TIPPING STOPPER . 430
20 STANDARD VALUE TABLE . 431
CONTENTS 432
ABBREVIATION LIST . 433
STANDARD VALUE TABLE FOR ENGINE . 439
STANDARD VALUE TABLE FOR ENGINE: PC700LC-11E0 . 439
STANDARD VALUE TABLE FOR MACHINE 444
STANDARD VALUE TABLE FOR MACHINE: PC700LC-11E0 444
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 461
30 TESTING AND ADJUSTING 465
CONTENTS 466
ABBREVIATION LIST . 469
RELATED INFORMATION ON TESTING AND ADJUSTING 475
TOOLS FOR TESTING AND ADJUSTING . 475
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 484
ENGINE AND COOLING SYSTEM . 486
TEST ENGINE SPEED . 486
METHOD FOR TESTING ENGINE SPEED . 486
TEST BOOST PRESSURE . 489
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 489
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL . 490
TEST EXHAUST GAS TEMPERATURE 491
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 491
TEST EXHAUST GAS COLOR 493
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 493
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 494
TEST AND ADJUST VALVE CLEARANCE . 496
METHOD FOR TESTING VALVE CLEARANCE 496
METHOD FOR ADJUSTING VALVE CLEARANCE 497
TEST COMPRESSION PRESSURE . 499
METHOD FOR TESTING COMPRESSION PRESSURE . 499
TEST BLOWBY PRESSURE 502
METHOD FOR TESTING BLOWBY PRESSURE 502
TEST ENGINE OIL PRESSURE 504
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR . 504
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 504
TEST EGR VALVE AND VGT OIL PRESSURE . 506
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 506
TEST FUEL PRESSURE 508
METHOD FOR TESTING FUEL PRESSURE 508
TEST FUEL RETURN RATE AND LEAKAGE . 510
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE . 510
BLEED AIR FROM FUEL SYSTEM 513
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 513
TEST FUEL CIRCUIT FOR LEAKAGE . 515
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 515
HANDLE CYLINDER CUT-OUT MODE OPERATION 517
HANDLE NO-INJECTION CRANKING OPERATION 518
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 519
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 519
CLEAN FUEL DOSER 520
METHOD FOR CLEANING FUEL DOSER 520
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 522
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 522
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 528
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 528
TEST SCR RELATED FUNCTIONS 529
TEST AdBlue/DEF PUMP RAISED PRESSURE 532
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 535
TEST AdBlue/DEF LINE HEATER RELAY 1 . 539
TEST AdBlue/DEF LINE HEATER RELAY 2 . 542
TEST AdBlue/DEF PUMP HEATER RELAY . 545
TEST AdBlue/DEF TANK HEATER VALVE . 548
TEST DENITRATION EFFICIENCY OF SCR 551
CLEAN AdBlue/DEF TANK . 555
METHOD FOR CLEANING AdBlue/DEF TANK . 555
POWER TRAIN . 559
TEST SWING CIRCLE BEARING CLEARANCE . 559
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 559
UNDERCARRIAGE AND FRAME . 560
TEST AND ADJUST TRACK TENSION . 560
METHOD FOR TESTING TRACK TENSION 560
METHOD FOR ADJUSTING TRACK TENSION 560
HYDRAULIC SYSTEM 562
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 562
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 562
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 563
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 567
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT . 567
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 569
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 572
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 580
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT . 584
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 584
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 585
TEST AND ADJUST PISTON PUMP CONTROL OIL PRESSURE 586
METHOD FOR TESTING TVC VALVE OUTLET PRESSURE 586
METHOD FOR TESTING CO AND NC VALVE OUTLET PRESSURE 587
METHOD FOR TESTING JET SENSOR OUTLET PRESSURE . 588
METHOD FOR ADJUSTING TVC VALVE 590
METHOD FOR ADJUSTING CO AND NC VALVE 591
METHOD FOR ADJUSTING JET SENSOR . 592
TEST SERVO PISTON STROKE 593
METHOD FOR TESTING SERVO PISTON STROKE 593
TEST OUTLET PRESSURE OF SOLENOID VALVE 595
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 595
OPERATING CONDITION OF SOLENOID VALVE . 596
TEST PPC VALVE OUTLET PRESSURE 599
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 599
TEST PPC SHUTTLE VALVE OUTLET PRESSURE 601
METHOD FOR TESTING PPC SHUTTLE VALVE OUTLET PRESSURE 601
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 605
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 605
TEST AND ADJUST TRAVEL DEVIATION 606
METHOD FOR TESTING TRAVEL DEVIATION . 606
METHOD FOR ADJUSTING TRAVEL DEVIATION . 606
TEST COOLING FAN SPEED 608
METHOD FOR TESTING COOLING FAN SPEED 608
TEST OIL PRESSURE IN FAN PUMP CIRCUIT . 609
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT . 609
TEST FAN PUMP EPC ELECTRIC CURRENT 610
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 610
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 611
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 611
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 612
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 612
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 612
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 613
TEST OIL LEAKAGE 614
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 614
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 615
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 615
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 616
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 616
METHOD FOR TESTING OIL LEAKAGE OF SWIVEL JOINT 617
BLEED AIR FROM HYDRAULIC CIRCUIT 619
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 620
CAB AND ITS ATTACHMENTS . 623
TEST CAB TIPPING STOPPER 623
METHOD FOR TESTING CAB TIPPING STOPPER 623
METHOD FOR ADJUSTING MIRRORS 624
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 624
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 625
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 626
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 627
ELECTRICAL SYSTEM . 629
SET AND OPERATE MACHINE MONITOR . 629
OPERATOR MODE . 632
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 632
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 632
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 633
CHECKING FUNCTION OF SERVICE METER 634
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 634
SERVICE MODE 636
METHOD FOR OPERATING SERVICE MODE . 636
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 639
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 645
ABNORMALITY RECORD MENU . 656
METHOD FOR CONFIRMING MAINTENANCE RECORD 661
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 662
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 666
DEFAULT MENU 667
DIAGNOSTIC TESTS MENU . 673
ADJUSTMENT MENU . 683
METHOD FOR PERFORMING NO-INJECTION CRANKING . 687
KOMTRAX SETTINGS MENU . 688
METHOD FOR DISPLAYING SERVICE MESSAGE . 690
METHOD FOR STARTING UP KOMTRAX TERMINAL . 692
ADJUST REARVIEW CAMERA ANGLE 697
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE . 697
ADJUST KomVision CAMERA ANGLE . 699
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 700
ADJUST KomVision RELATED ITEMS 702
SETTING OF KomVision (MAIN SETTING) . 702
SETTING OF KomVision (CAMERA SETTING) . 704
SETTING OF KomVision (CAMERA CALIBRATION) . 704
KomVision screen – Check 12 m visibility 718
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 721
HANDLE BATTERY DISCONNECT SWITCH 722
TEST DIODES . 723
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 723
METHOD FOR TESTING DIODE USING ANALOG TESTER 723
Pm CLINIC . 724
Pm CLINIC SERVICE . 724
Pm CLINIC CHECK SHEET: PC700LC-11E0 . 727
40 TROUBLESHOOTING 745
CONTENTS 746
ABBREVIATION LIST . 757
RELATED INFORMATION ON TROUBLESHOOTING 763
GENERAL TROUBLESHOOTING POINTS 763
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 764
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 776
CHECKS BEFORE TROUBLESHOOTING . 778
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 780
WALK-AROUND CHECK . 780
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 782
CHECK FUEL LEVEL AND TYPE . 782
CHECK IMPURE INGREDIENT IN FUEL . 783
CHECK FUEL PREFILTER 783
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 783
FUEL PREFILTER CARTRIDGE – REPLACE 784
CHECK MAIN FILTER . 785
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 786
CHECK COOLANT LEVEL (RESERVOIR TANK) 788
CHECK CLOGGING OF AIR CLEANER . 788
OUTER ELEMENT – CLEAN . 788
ELEMENTS – REPLACE 791
CHECK HYDRAULIC OIL LEVEL . 791
CHECK HYDRAULIC OIL STRAINER 793
CHECK HYDRAULIC FILTER 793
CHECK OIL LEVEL IN SWING MACHINERY CASE . 794
CHECK OIL LEVEL IN PTO CASE . 795
CHECK PTO LUBRICATION FILTER STRAINER . 795
CHECK OIL LEVEL IN FINAL DRIVE CASE . 796
BLEED AIR FROM FUEL SYSTEM 797
BLEED AIR FROM HYDRAULIC SYSTEM . 797
ELECTRICAL EQUIPMENT – CHECK METHOD . 797
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 803
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 803
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 803
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 803
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL . 804
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER . 804
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 804
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 808
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 811
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 815
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 817
CONNECTOR LIST AND LAYOUT . 820
CONNECTOR CONTACT IDENTIFICATION 834
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 874
FUSE LOCATION TABLE . 880
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 883
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 887
FAILURE CODES TABLE . 889
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 906
FAILURE CODE [879AKA] . 906
FAILURE CODE [879AKB] . 907
FAILURE CODE [879BKA] . 908
FAILURE CODE [879BKB] . 910
FAILURE CODE [879CKA] . 912
FAILURE CODE [879CKB] . 913
FAILURE CODE [879DKZ] . 914
FAILURE CODE [879EMC] . 916
FAILURE CODE [879FMC] . 917
FAILURE CODE [879GKX] . 918
FAILURE CODE [989L00] . 920
FAILURE CODE [989M00] . 921
FAILURE CODE [989N00] . 922
FAILURE CODE [A1U0N3] . 923
FAILURE CODE [A1U0N4] . 925
FAILURE CODE [A900FR] . 927
FAILURE CODE [A900N6] . 928
FAILURE CODE [A900NY] . 929
FAILURE CODE [AA10NX] . 930
FAILURE CODE [AB00KE] . 932
FAILURE CODE [AQ10N3] . 934
FAILURE CODE [AS00N3] . 936
FAILURE CODE [AS00R2] . 938
FAILURE CODE [AS00R3] . 939
FAILURE CODE [AS00R4] . 940
FAILURE CODE [AS00R5] . 941
FAILURE CODE [AS00R6] . 942
FAILURE CODE [AS00ZK] . 943
FAILURE CODE [AS10KM] . 944
FAILURE CODE [AS10NR] . 945
FAILURE CODE [AS10NT] . 946
FAILURE CODE [B@BAZG] . 947
FAILURE CODE [B@BAZK] . 948
FAILURE CODE [B@BCNS] . 950
FAILURE CODE [B@BCZK] . 951
FAILURE CODE [B@HANS] . 953
FAILURE CODE [CA115] 954
FAILURE CODE [CA122] 955
FAILURE CODE [CA123] 957
FAILURE CODE [CA131] 959
FAILURE CODE [CA132] 961
FAILURE CODE [CA135] 963
FAILURE CODE [CA141] 965
FAILURE CODE [CA144] 967
FAILURE CODE [CA145] 969
FAILURE CODE [CA153] 971
FAILURE CODE [CA154] 974
FAILURE CODE [CA187] 977
FAILURE CODE [CA221] 979
FAILURE CODE [CA222] 981
FAILURE CODE [CA227] 983
FAILURE CODE [CA234] 984
FAILURE CODE [CA238] 985
FAILURE CODE [CA239] 987
FAILURE CODE [CA249] 989
FAILURE CODE [CA256] 991
FAILURE CODE [CA271] 993
FAILURE CODE [CA272] 995
FAILURE CODE [CA273] 996
FAILURE CODE [CA274] 998
FAILURE CODE [CA322] 999
FAILURE CODE [CA323] 1001
FAILURE CODE [CA324] 1003
FAILURE CODE [CA325] 1005
FAILURE CODE [CA331] 1007
FAILURE CODE [CA332] 1009
FAILURE CODE [CA343] 1011
FAILURE CODE [CA351] 1012
FAILURE CODE [CA352] 1013
FAILURE CODE [CA356] 1016
FAILURE CODE [CA357] 1018
FAILURE CODE [CA386] 1020
FAILURE CODE [CA441] 1021
FAILURE CODE [CA442] 1023
FAILURE CODE [CA449] 1024
FAILURE CODE [CA451] 1025
FAILURE CODE [CA452] 1027
FAILURE CODE [CA515] 1029
FAILURE CODE [CA516] 1031
FAILURE CODE [CA553] 1033
FAILURE CODE [CA555] 1034
FAILURE CODE [CA556] 1035
FAILURE CODE [CA559] 1036
FAILURE CODE [CA595] 1041
FAILURE CODE [CA687] 1042
FAILURE CODE [CA689] 1044
FAILURE CODE [CA691] 1046
FAILURE CODE [CA692] 1048
FAILURE CODE [CA697] 1050
FAILURE CODE [CA698] 1051
FAILURE CODE [CA731] 1052
FAILURE CODE [CA778] 1053
FAILURE CODE [CA1117] .1056
FAILURE CODE [CA1664] .1057
FAILURE CODE [CA1669] .1061
FAILURE CODE [CA1673] .1062
FAILURE CODE [CA1677] .1063
FAILURE CODE [CA1678] .1064
FAILURE CODE [CA1682] .1065
FAILURE CODE [CA1683] .1067
FAILURE CODE [CA1684] .1069
FAILURE CODE [CA1686] .1071
FAILURE CODE [CA1691] .1072
FAILURE CODE [CA1694] .1075
FAILURE CODE [CA1695] .1077
FAILURE CODE [CA1696] .1078
FAILURE CODE [CA1712] .1080
FAILURE CODE [CA1713] .1083
FAILURE CODE [CA1714] .1086
FAILURE CODE [CA1715] .1087
FAILURE CODE [CA1776] .1088
FAILURE CODE [CA1777] .1091
FAILURE CODE [CA1843] .1094
FAILURE CODE [CA1844] .1096
FAILURE CODE [CA1879] .1099
FAILURE CODE [CA1881] .1102
FAILURE CODE [CA1883] .1104
FAILURE CODE [CA1885] .1108
FAILURE CODE [CA1887] .1110
FAILURE CODE [CA1921] .1112
FAILURE CODE [CA1922] .1115
FAILURE CODE [CA1923] .1120
FAILURE CODE [CA1924] .1122
FAILURE CODE [CA1925] .1124
FAILURE CODE [CA1927] .1126
FAILURE CODE [CA1928] .1128
FAILURE CODE [CA1942] .1130
FAILURE CODE [CA1963] .1131
FAILURE CODE [CA1977] .1135
FAILURE CODE [CA1993] .1138
FAILURE CODE [CA2185] .1141
FAILURE CODE [CA2186] .1143
FAILURE CODE [CA2249] .1145
FAILURE CODE [CA2265] .1146
FAILURE CODE [CA2266] .1148
FAILURE CODE [CA2271] .1150
FAILURE CODE [CA2272] .1152
FAILURE CODE [CA2349] .1154
FAILURE CODE [CA2353] .1156
FAILURE CODE [CA2357] .1158
FAILURE CODE [CA2381] .1159
FAILURE CODE [CA2382] .1161
FAILURE CODE [CA2383] .1163
FAILURE CODE [CA2386] .1165
FAILURE CODE [CA2387] .1167
FAILURE CODE [CA2555] .1168
FAILURE CODE [CA2556] .1170
FAILURE CODE [CA2637] .1172
FAILURE CODE [CA2639] .1174
FAILURE CODE [CA2732] .1176
FAILURE CODE [CA2733] .1178
FAILURE CODE [CA2741] .1180
FAILURE CODE [CA2765] .1181
FAILURE CODE [CA2771] .1182
FAILURE CODE [CA2777] .1188
FAILURE CODE [CA2878] .1191
FAILURE CODE [CA2881] .1194
FAILURE CODE [CA2976] .1197
FAILURE CODE [CA3133] .1199
FAILURE CODE [CA3134] .1201
FAILURE CODE [CA3135] .1203
FAILURE CODE [CA3142] .1206
FAILURE CODE [CA3143] .1207
FAILURE CODE [CA3144] .1208
FAILURE CODE [CA3146] .1210
FAILURE CODE [CA3147] .1211
FAILURE CODE [CA3148] .1212
FAILURE CODE [CA3151] .1214
FAILURE CODE [CA3165] .1219
FAILURE CODE [CA3167] .1222
FAILURE CODE [CA3229] .1226
FAILURE CODE [CA3231] .1229
FAILURE CODE [CA3232] .1232
FAILURE CODE [CA3235] .1237
FAILURE CODE [CA3239] .1239
FAILURE CODE [CA3241] .1242
FAILURE CODE [CA3242] .1245
FAILURE CODE [CA3251] .1248
FAILURE CODE [CA3253] .1252
FAILURE CODE [CA3254] .1258
FAILURE CODE [CA3255] .1262
FAILURE CODE [CA3256] .1265
FAILURE CODE [CA3311] .1268
FAILURE CODE [CA3312] .1271
FAILURE CODE [CA3313] .1274
FAILURE CODE [CA3314] .1275
FAILURE CODE [CA3315] .1276
FAILURE CODE [CA3316] .1279
FAILURE CODE [CA3317] .1280
FAILURE CODE [CA3318] .1281
FAILURE CODE [CA3319] .1284
FAILURE CODE [CA3321] .1285
FAILURE CODE [CA3322] .1286
FAILURE CODE [CA3419] .1289
FAILURE CODE [CA3421] .1291
FAILURE CODE [CA3497] .1293
FAILURE CODE [CA3498] .1294
FAILURE CODE [CA3543] .1295
FAILURE CODE [CA3545] .1300
FAILURE CODE [CA3547] .1302
FAILURE CODE [CA3558] .1303
FAILURE CODE [CA3559] .1305
FAILURE CODE [CA3562] .1307
FAILURE CODE [CA3563] .1309
FAILURE CODE [CA3567] .1312
FAILURE CODE [CA3568] .1315
FAILURE CODE [CA3571] .1319
FAILURE CODE [CA3572] .1321
FAILURE CODE [CA3574] .1323
FAILURE CODE [CA3575] .1326
FAILURE CODE [CA3577] .1328
FAILURE CODE [CA3578] .1330
FAILURE CODE [CA3582] .1332
FAILURE CODE [CA3583] .1337
FAILURE CODE [CA3596] .1339
FAILURE CODE [CA3649] .1343
FAILURE CODE [CA3681] .1346
FAILURE CODE [CA3682] .1351
FAILURE CODE [CA3713] .1357
FAILURE CODE [CA3717] .1360
FAILURE CODE [CA3718] .1361
FAILURE CODE [CA3725] .1362
FAILURE CODE [CA3748] .1365
FAILURE CODE [CA3751] .1367
FAILURE CODE [CA3755] .1369
FAILURE CODE [CA3866] .1371
FAILURE CODE [CA3867] .1375
FAILURE CODE [CA3868] .1378
FAILURE CODE [CA3899] .1382
FAILURE CODE [CA3911] .1385
FAILURE CODE [CA3912] .1389
FAILURE CODE [CA3932] .1391
FAILURE CODE [CA3933] .1393
FAILURE CODE [CA3934] .1395
FAILURE CODE [CA3935] .1398
FAILURE CODE [CA3936] .1400
FAILURE CODE [CA4151] .1402
FAILURE CODE [CA4152] .1406
FAILURE CODE [CA4155] .1410
FAILURE CODE [CA4156] .1412
FAILURE CODE [CA4157] .1415
FAILURE CODE [CA4158] .1417
FAILURE CODE [CA4159] .1419
FAILURE CODE [CA4161] .1421
FAILURE CODE [CA4162] .1424
FAILURE CODE [CA4163] .1427
FAILURE CODE [CA4164] .1429
FAILURE CODE [CA4165] .1432
FAILURE CODE [CA4166] .1435
FAILURE CODE [CA4168] .1438
FAILURE CODE [CA4169] .1443
FAILURE CODE [CA4171] .1448
FAILURE CODE [CA4249] .1453
FAILURE CODE [CA4251] .1457
FAILURE CODE [CA4259] .1461
FAILURE CODE [CA4261] .1464
FAILURE CODE [CA4277] .1467
FAILURE CODE [CA4281] .1471
FAILURE CODE [CA4459] .1474
FAILURE CODE [CA4461] .1477
FAILURE CODE [CA4658] .1480
FAILURE CODE [CA4731] .1484
FAILURE CODE [CA4732] .1485
FAILURE CODE [CA4739] .1486
FAILURE CODE [CA4768] .1487
FAILURE CODE [CA4769] .1489
FAILURE CODE [CA4842] .1492
FAILURE CODE [CA4952] .1496
FAILURE CODE [CA5115] .1498
FAILURE CODE [CA5179] .1501
FAILURE CODE [CA5181] .1503
FAILURE CODE [CA5383] .1505
FAILURE CODE [D110KB] .1507
FAILURE CODE [D163KB] .1509
FAILURE CODE [D195KA] .1511
FAILURE CODE [D195KB] .1513
FAILURE CODE [D19JKZ] .1515
FAILURE CODE [D811MC] .1517
FAILURE CODE [D862KA] .1518
FAILURE CODE [D8ALKA] .1519
FAILURE CODE [D8ALKB] .1521
FAILURE CODE [D8AQKR] .1523
FAILURE CODE [DA20MC] .1527
FAILURE CODE [DA22KK] .1528
FAILURE CODE [DA25KP] .1530
FAILURE CODE [DA26KP] .1532
FAILURE CODE [DA29KQ] .1535
FAILURE CODE [DA2LKA] .1537
FAILURE CODE [DA2LKB] .1539
FAILURE CODE [DA2QKR] .1541
FAILURE CODE [DA2RKR] .1546
FAILURE CODE [DAF0KM] .1551
FAILURE CODE [DAF0MB] .1552
FAILURE CODE [DAF0MC] .1553
FAILURE CODE [DAF8KB] .1554
FAILURE CODE [DAF9KQ] .1556
FAILURE CODE [DAFGMC] .1557
FAILURE CODE [DAFLKA] .1558
FAILURE CODE [DAFLKB] .1560
FAILURE CODE [DAFQKR] .1562
FAILURE CODE [DAZ9KQ] .1566
FAILURE CODE [DAZQKR] .1567
FAILURE CODE [DB2QKR] .1571
FAILURE CODE [DB2RKR] .1576
FAILURE CODE [DBP0KM] .1581
FAILURE CODE [DBP0KT] .1582
FAILURE CODE [DBP5KB] .1583
FAILURE CODE [DBP5KY] .1586
FAILURE CODE [DBPQKR] .1589
FAILURE CODE [DDNRKA] .1594
FAILURE CODE [DDNRKY] .1596
FAILURE CODE [DDNS00] .1598
FAILURE CODE [DGE5KB] .1600
FAILURE CODE [DGH2KA] .1601
FAILURE CODE [DGH2KB] .1603
FAILURE CODE [DHA4KA] .1605
FAILURE CODE [DHAAMA] .1607
FAILURE CODE [DHACMA] .1609
FAILURE CODE [DHPAMA] .1611
FAILURE CODE [DHPBMA] .1613
FAILURE CODE [DHS3MA] .1615
FAILURE CODE [DHS4MA] .1618
FAILURE CODE [DHS8MA] .1621
FAILURE CODE [DHS9MA] .1624
FAILURE CODE [DHSAMA] .1627
FAILURE CODE [DHSBMA] .1630
FAILURE CODE [DHSCMA] .1633
FAILURE CODE [DHSDMA] .1636
FAILURE CODE [DHSFMA] .1639
FAILURE CODE [DHSGMA] .1642
FAILURE CODE [DHSHMA] .1645
FAILURE CODE [DHSJMA] .1648
FAILURE CODE [DHSVMA] .1651
FAILURE CODE [DKULKA] .1653
FAILURE CODE [DKULKB] .1655
FAILURE CODE [DKULKY] .1657
FAILURE CODE [DLM3KA] .1659
FAILURE CODE [DLM3KB] .1661
FAILURE CODE [DLM3MB] .1663
FAILURE CODE [DR10KA] .1664
FAILURE CODE [DR12KA] .1667
FAILURE CODE [DR20KA] .1669
FAILURE CODE [DR21KX] .1671
FAILURE CODE [DR30KA] .1673
FAILURE CODE [DR31KX] .1675
FAILURE CODE [DR40KA] .1677
FAILURE CODE [DUMBKA] .1679
FAILURE CODE [DUMBKB] .1681
FAILURE CODE [DV20KB] .1683
FAILURE CODE [DW43KA] .1684
FAILURE CODE [DW43KB] .1686
FAILURE CODE [DW43KY] .1688
FAILURE CODE [DW45KA] .1689
FAILURE CODE [DW45KB] .1692
FAILURE CODE [DW45KY] .1695
FAILURE CODE [DW48KA] .1697
FAILURE CODE [DW48KB] .1699
FAILURE CODE [DW48KY] .1701
FAILURE CODE [DW4CKY] .1702
FAILURE CODE [DW4XKA] .1704
FAILURE CODE [DW4XKB] .1706
FAILURE CODE [DW4XKY] .1708
FAILURE CODE [DW7BKA] .1709
FAILURE CODE [DW7BKB] .1711
FAILURE CODE [DW7BKY] .1713
FAILURE CODE [DWK0KA] .1714
FAILURE CODE [DWK0KB] .1716
FAILURE CODE [DWK0KY] .1718
FAILURE CODE [DWK2KA] .1719
FAILURE CODE [DWK2KB] .1721
FAILURE CODE [DWK2KY] .1723
FAILURE CODE [DWK8KA] .1724
FAILURE CODE [DWK8KB] .1726
FAILURE CODE [DWK8KY] .1728
FAILURE CODE [DX16KA] .1729
FAILURE CODE [DX16KB] .1731
FAILURE CODE [DXA2KA] .1732
FAILURE CODE [DXA2KB] .1735
FAILURE CODE [DXA3KA] .1737
FAILURE CODE [DXA3KB] .1740
FAILURE CODE [DY20KA] .1742
FAILURE CODE [DY20MA] .1744
FAILURE CODE [DY2CKB] .1746
FAILURE CODE [DY2DKB] .1748
FAILURE CODE [DY2EKB] .1750
FAILURE CODE [DY2FMA] .1752
FAILURE CODE [DY2GKM] .1754
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1756
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1756
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1762
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1765
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1767
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1769
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1772
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1773
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1774
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1775
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1776
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1777
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1778
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1779
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1780
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1781
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1782
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1784
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1785
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1786
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1787
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1789
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1790
E-23 FUNCTION SWITCH DOES NOT OPERATE .1791
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1792
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1793
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1794
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1795
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1796
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1797
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1798
E-31 ALARM BUZZER CANNOT BE CANCELED 1799
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1800
E-33 SERVICE MODE CANNOT BE SELECTED 1801
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1802
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1805
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1807
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1810
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1812
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1814
E-40 ALARM DOES NOT SOUND DURING TRAVEL .1815
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1817
E-42 HORN DOES NOT SOUND 1818
E-43 HORN DOES NOT STOP SOUNDING 1821
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1823
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1824
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1826
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1827
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1828
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1829
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1830
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1831
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1832
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1833
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1834
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1835
E-56 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1837
E-57 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 1838
E-58 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1840
E-59 STEP LIGHT DOES NOT LIGHT UP .1841
E-60 STEP LIGHT DOES NOT GO OUT .1843
E-61 BOOM SHOCKLESS FUNCTION CANNOT BE CANCELED .1845
E-62 BOOM SHOCKLESS FUNCTION DOES NOT WORK 1847
E-63 ELECTRIC GREASE GUN DOES NOT WORK 1848
E-64 ELECTRIC GREASE GUN DOES NOT STOP 1850
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1851
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1851
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1852
H-3 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1854
H-4 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1855
H-5 TRAVEL SPEED OR POWER IS LOW 1856
H-6 AUTO-DECELERATION FUNCTION CANNOT BE CANCELED .1857
H-7 SPEED OR POWER OF BOOM IS LOW .1858
H-8 ARM SPEED OR POWER IS LOW .1860
H-9 BUCKET SPEED OR POWER IS LOW 1861
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION .1862
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE .1863
H-12 HYDRAULIC DRIFT OF ARM IS LARGE 1864
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE .1865
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1866
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1867
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1868
H-17 MACHINE DOES NOT TRAVEL STRAIGHT .1869
H-18 SPEED OF BOOM AND BUCKET IS SLOW AT COMBINED OPERATION OF ARM, BOOM AND BUCKET .1870
H-19 SPEED OF BOOM, ARM, SWING AND TRAVEL IS SLOW AT COMBINED OPERATION OF BUCKET, BOOM AND ARM .1871
H-20 SWING SPEED IS SLOW AT COMBINED OPERATION OF ARM AND SWING .1872
H-21 TRAVEL DEVIATION IS LARGE AT START OF TRAVELING 1873
H-22 TRAVEL DEVIATION IS LARGE AT COMBINED OPERATION 1875
H-23 ONE OF TRACKS DOES NOT RUN .1876
H-24 TRAVEL SPEED DOES NOT CHANGE .1878
H-25 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1879
H-26 SWINGS ONLY IN ONE DIRECTION .1880
H-27 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1881
H-28 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1882
H-29 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1883
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1884
H-31 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1885
H-32 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1886
H-33 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1887
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1888
H-35 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1889
H-36 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1890
TROUBLESHOOTING OF ENGINE (S-MODE) 1891
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1891
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1892
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1893
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1894
S-4 ENGINE STARTABILITY IS POOR .1895
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1897
S-6 ENGINE STOPS DURING OPERATION .1899
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1901
S-8 ENGINE LACKS POWER 1902
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1904
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1906
S-11 OIL BECOMES CONTAMINATED QUICKLY .1907
S-12 FUEL CONSUMPTION IS EXCESSIVE 1908
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1909
S-14 OIL PRESSURE DROPS .1910
S-15 FUEL MIXES INTO ENGINE OIL .1912
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1913
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1914
S-18 UNUSUAL NOISE IS HEARD .1915
S-19 VIBRATION IS EXCESSIVE .1916
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1917
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1918
S-22 ACTIVE REGENERATION TAKES TIME .1920
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1922
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1923
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1925
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1926
50 DISASSEMBLY AND ASSEMBLY .1927
CONTENTS 1928
ABBREVIATION LIST .1933
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1939
HOW TO READ THIS MANUAL .1939
COATING MATERIALS LIST 1941
SPECIAL TOOLS LIST 1945
SKETCHES OF SPECIAL TOOLS .1962
ENGINE AND COOLING SYSTEM .1969
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .1969
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1969
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1972
REMOVE AND INSTALL INJECTOR ASSEMBLY 1977
METHOD FOR REMOVING INJECTOR ASSEMBLY .1977
METHOD FOR INSTALLING INJECTOR ASSEMBLY .1982
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 1991
METHOD FOR REMOVING FUEL DOSER ASSEMBLY .1991
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY .1992
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .1994
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1995
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2005
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2022
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2022
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2024
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2026
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2026
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2029
REMOVE AND INSTALL STARTER ASSEMBLY .2033
METHOD FOR REMOVING STARTER ASSEMBLY 2033
METHOD FOR INSTALLING STARTER ASSEMBLY 2033
REMOVE AND INSTALL ALTERNATOR BELT 2035
METHOD FOR REMOVING ALTERNATOR BELT .2035
METHOD FOR INSTALLING ALTERNATOR BELT .2036
REMOVE AND INSTALL RADIATOR ASSEMBLY 2038
METHOD FOR REMOVING RADIATOR ASSEMBLY .2038
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2041
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2045
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2045
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2048
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2052
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2052
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2054
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY .2057
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2057
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2066
REMOVE AND INSTALL ENGINE PTO AND HYDRAULIC ASSEMBLY 2075
METHOD FOR REMOVING ENGINE PTO AND HYDRAULIC ASSEMBLY .2075
METHOD FOR INSTALLING ENGINE PTO AND HYDRAULIC ASSEMBLY .2086
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2097
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2097
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2098
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2101
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2101
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2103
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2110
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2110
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2115
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2120
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2120
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2123
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2127
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2128
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2134
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2139
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2139
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2140
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2142
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2142
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2143
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2149
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2149
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2149
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2150
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2150
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2152
REMOVE AND INSTALL KDPF ASSEMBLY 2155
METHOD FOR REMOVING KDPF ASSEMBLY .2155
METHOD FOR INSTALLING KDPF ASSEMBLY .2159
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2168
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2169
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2173
REMOVE AND INSTALL SCR ASSEMBLY .2178
METHOD FOR REMOVING SCR ASSEMBLY 2178
METHOD FOR INSTALLING SCR ASSEMBLY 2180
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2184
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2185
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2191
REMOVE AND INSTALL KCCV ASSEMBLY 2203
METHOD FOR REMOVING KCCV ASSEMBLY .2203
METHOD FOR INSTALLING KCCV ASSEMBLY .2204
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2207
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2207
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2212
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2219
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2219
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2222
REMOVE AND INSTALL AdBlue/DEF PUMP 2226
METHOD FOR REMOVING AdBlue/DEF PUMP .2226
METHOD FOR INSTALLING AdBlue/DEF PUMP .2229
REMOVE AND INSTALL AdBlue/DEF HOSE 2232
METHOD FOR REMOVING AdBlue/DEF HOSE .2233
METHOD FOR INSTALLING AdBlue/DEF HOSE .2241
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2247
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2247
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2248
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2249
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2249
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2250
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2251
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2251
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2252
POWER TRAIN .2253
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY .2253
METHOD FOR DISASSEMBLING PTO ASSEMBLY .2253
METHOD FOR ASSEMBLING PTO ASSEMBLY 2254
REMOVE AND INSTALL PTO ASSEMBLY .2257
METHOD FOR REMOVING PTO ASSEMBLY 2257
METHOD FOR INSTALLING PTO ASSEMBLY 2258
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2261
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2261
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2262
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2263
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2264
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2269
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2278
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2278
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2279
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2281
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2281
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2285
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2290
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2290
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2291
HYDRAULIC SYSTEM 2292
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2292
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2292
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2293
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2294
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2295
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2296
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2297
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2297
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2299
REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY 2302
METHOD FOR REMOVING HYDRAULIC PUMP ASSEMBLY .2302
METHOD FOR INSTALLING HYDRAULIC PUMP ASSEMBLY .2304
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2310
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2310
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2313
REMOVE AND INSTALL SWING MOTOR ASSEMBLY .2317
METHOD FOR REMOVING SWING MOTOR ASSEMBLY 2317
METHOD FOR INSTALLING SWING MOTOR ASSEMBLY 2318
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2319
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2319
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2320
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2322
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2322
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2323
DISASSEMBLE AND ASSEMBLE GREASE GUN ASSEMBLY 2325
METHOD FOR DISASSEMBLING GREASE GUN ASSEMBLY 2325
METHOD FOR ASSEMBLING GREASE GUN ASSEMBLY .2325
WORK EQUIPMENT 2326
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY .2326
METHOD FOR REMOVING BUCKET CYLINDER ASSEMBLY 2326
METHOD FOR INSTALLING BUCKET CYLINDER ASSEMBLY 2327
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY 2329
METHOD FOR REMOVING ARM CYLINDER ASSEMBLY .2329
METHOD FOR INSTALLING ARM CYLINDER ASSEMBLY .2330
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY .2332
METHOD FOR REMOVING BOOM CYLINDER ASSEMBLY 2332
METHOD FOR INSTALLING BOOM CYLINDER ASSEMBLY 2333
REMOVE AND INSTALL BUCKET ASSEMBLY 2335
METHOD FOR REMOVING BUCKET ASSEMBLY .2335
METHOD FOR INSTALLING BUCKET ASSEMBLY .2336
REMOVE AND INSTALL ARM ASSEMBLY .2337
METHOD FOR REMOVING ARM ASSEMBLY 2337
METHOD FOR INSTALLING ARM ASSEMBLY 2339
REMOVE AND INSTALL BOOM ASSEMBLY 2341
METHOD FOR REMOVING BOOM ASSEMBLY .2341
METHOD FOR INSTALLING BOOM ASSEMBLY .2342
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2344
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2344
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2346
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 2348
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2348
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2350
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM .2351
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM 2351
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM 2353
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY .2354
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY .2354
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY 2354
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2355
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2356
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2358
CAB AND ITS ATTACHMENTS .2363
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2363
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2363
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2370
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2379
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2381
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2381
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2391
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2391
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2394
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2400
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2400
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2403
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2408
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2408
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2413
REMOVE AND INSTALL OPERATOR’S SEAT 2420
METHOD FOR REMOVING OPERATOR’S SEAT .2420
METHOD FOR INSTALLING OPERATOR’S SEAT .2422
REMOVE AND INSTALL SEAT BELT 2425
METHOD FOR REMOVING SEAT BELT .2425
METHOD FOR INSTALLING SEAT BELT .2425
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2427
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2427
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2432
UNDERCARRIAGE AND FRAME .2441
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 2441
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2443
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2445
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD .2446
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2452
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2454
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2456
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2460
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2462
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2466
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2469
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2471
ELECTRICAL SYSTEM .2474
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2474
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2474
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2475
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2478
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2478
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2480
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2483
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2483
METHOD FOR INSTALLING KomVision CONTROLLER 2484
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2485
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2485
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2487
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2491
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2491
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2492
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2493
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2493
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2494
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2496
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2496
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2498
REMOVE AND INSTALL KomVision CAMERA .2500
METHOD FOR REMOVING KomVision CAMERA 2500
METHOD FOR INSTALLING KomVision CAMERA 2501
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2503
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2503
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2505
60 MAINTENANCE STANDARD .2507
CONTENTS 2508
ABBREVIATION LIST .2509
ENGINE AND COOLING SYSTEM .2515
MAINTENANCE STANDARD OF ENGINE MOUNT 2515
MAINTENANCE STANDARD FOR PTO 2517
MAINTENANCE STANDARD OF COOLING SYSTEM 2518
MAINTENANCE STANDARD OF COOLING FAN PUMP 2519
MAINTENANCE STANDARD OF SERVO VALVE .2520
MAINTENANCE STANDARD OF COOLING FAN MOTOR .2521
POWER TRAIN .2522
MAINTENANCE STANDARD OF SWING CIRCLE 2522
MAINTENANCE STANDARD OF SWING MACHINERY .2523
MAINTENANCE STANDARD OF FINAL DRIVE .2525
MAINTENANCE STANDARD OF SPROCKET 2527
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2528
UNDERCARRIAGE AND FRAME .2530
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2530
MAINTENANCE STANDARD OF IDLER .2532
MAINTENANCE STANDARD OF TRACK ROLLER 2534
MAINTENANCE STANDARD OF CARRIER ROLLER 2536
MAINTENANCE STANDARD OF TRACK SHOE 2537
MAINTENANCE STANDARD OF DOUBLE SHOE .2540
MAINTENANCE STANDARD OF TRIPLE SHOE .2541
HYDRAULIC SYSTEM 2542
MAINTENANCE STANDARD OF MAIN PUMP .2542
MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE .2544
MAINTENANCE STANDARD OF MAIN PUMP TVC VALVE .2546
MAINTENANCE STANDARD OF MAIN PUMP CO AND NC VALVE .2547
MAINTENANCE STANDARD OF SWING MOTOR .2548
MAINTENANCE STANDARD OF CONTROL VALVE .2549
MAINTENANCE STANDARD OF TRAVEL SHUTTLE VALVE OF CONTROL VALVE .2555
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE VALVE 2556
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2557
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .2559
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2561
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2564
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE .2567
MAINTENANCE STANDARD OF SOLENOID VALVE 2569
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2570
WORK EQUIPMENT 2571
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2571
DIMENSION OF ARM 2576
DIMENSIONS OF BUCKET 2578
MAINTENANCE STANDARD OF BOOM CYLINDER .2580
MAINTENANCE STANDARD OF ARM CYLINDER 2581
MAINTENANCE STANDARD OF BUCKET CYLINDER .2582
80 APPENDIX .2583
CONTENTS 2584
ABBREVIATION LIST .2586
AIR CONDITIONER SYSTEM 2592
PRECAUTIONS FOR REFRIGERANT .2592
AIR CONDITIONER COMPONENT .2593
SPECIFICATIONS OF AIR CONDITIONER .2595
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2596
OUTLINE OF REFRIGERATION CYCLE 2597
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2599
AIR CONDITIONER UNIT 2599
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2599
FUNCTION OF AIR CONDITIONER UNIT 2601
COMPONENT PARTS OF AIR CONDITIONER UNIT .2603
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2604
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2604
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2604
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2604
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2605
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2605
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2605
FUNCTION OF DUAL PRESSURE SWITCH 2606
AIR CONDITIONER CONTROLLER 2607
STRUCTURE OF AIR CONDITIONER CONTROLLER .2607
COMPRESSOR 2608
STRUCTURE OF COMPRESSOR .2608
SPECIFICATIONS OF COMPRESSOR 2608
FUNCTION OF COMPRESSOR 2608
CONDENSER .2609
STRUCTURE OF CONDENSER 2609
SPECIFICATIONS OF CONDENSER .2609
FUNCTION OF CONDENSER .2609
RECEIVER DRIER 2610
STRUCTURE OF RECEIVER DRIER .2610
SPECIFICATIONS OF RECEIVER DRIER 2610
FUNCTION OF RECEIVER DRIER 2610
SENSORS FOR AIR CONDITIONER SYSTEM 2611
STRUCTURE OF SUNLIGHT SENSOR 2611
FUNCTION OF SUNLIGHT SENSOR .2611
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2611
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2611
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2613
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2615
AIR CONDITIONER SYSTEM DIAGRAM 2617
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2618
FUNCTION OF AIR CONDITIONER CONTROLLER 2619
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2620
TESTING AIR LEAKAGE (DUCT) 2624
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2624
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2626
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2627
TEST VENT (MODE) CHANGEOVER .2628
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2628
TESTING FRESH/RECIRC AIR CHANGEOVER .2630
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2630
TEST SUNLIGHT SENSOR 2631
METHOD FOR TESTING SUNLIGHT SENSOR 2631
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2632
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2632
TEST RELAYS .2633
METHOD FOR TESTING RELAYS .2633
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2634
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2635
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2638
FAILURE CODE [879AKA] .2640
FAILURE CODE [879AKB] .2641
FAILURE CODE [879BKA] .2642
FAILURE CODE [879BKB] .2644
FAILURE CODE [879CKA] .2646
FAILURE CODE [879CKB] .2647
FAILURE CODE [879DKZ] .2648
FAILURE CODE [879EMC] .2650
FAILURE CODE [879FMC] .2651
FAILURE CODE [879GKX] .2652
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2654
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2656
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2659
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2661
TROUBLESHOOTING USING GAUGE PRESSURE 2663
CONNECTION OF SERVICE TOOL 2666
METHOD FOR CONNECTING SERVICE TOOL 2666
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2668
HANDLE COMPRESSOR OIL .2670
90 CIRCUIT DIAGRAMS .2673
CONTENTS 2674
ABBREVIATION LIST .2675
HYDRAULIC CIRCUIT DIAGRAM .2681
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2681
HYDRAULIC CIRCUIT DIAGRAM .2685
ELECTRICAL CIRCUIT DIAGRAM 2687
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2687
ELECTRICAL CIRCUIT DIAGRAM (1/12) .2691
ELECTRICAL CIRCUIT DIAGRAM (2/12) .2693
ELECTRICAL CIRCUIT DIAGRAM (3/12) .2695
ELECTRICAL CIRCUIT DIAGRAM (4/12) .2697
ELECTRICAL CIRCUIT DIAGRAM (5/12) .2699
ELECTRICAL CIRCUIT DIAGRAM (6/12) .2701
ELECTRICAL CIRCUIT DIAGRAM (7/12) .2703
ELECTRICAL CIRCUIT DIAGRAM (8/12) .2705
ELECTRICAL CIRCUIT DIAGRAM (9/12) .2707
ELECTRICAL CIRCUIT DIAGRAM (10/12) 2709
ELECTRICAL CIRCUIT DIAGRAM (11/12) 2711
ELECTRICAL CIRCUIT DIAGRAM (12/12) 2713
INDEX 2715

DESCRIPTION:

Komatsu PC700LC -11E0 Hydraulic Excavator Shop Manual UENBM00513 – 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