Komatsu PC1250 -11 PC1250LC -11 PC1250SP-11 Hydraulic Excavator Shop Manual SEN06624-07 – DOWNLOAD

Komatsu PC1250 -11 PC1250LC -11 PC1250SP-11 Hydraulic Excavator Shop Manual SEN06624-07 – DOWNLOAD

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Komatsu PC1250 -11 PC1250LC -11 PC1250SP-11 Hydraulic Excavator Shop Manual SEN06624-07 – DOWNLOAD

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Komatsu PC1250 -11 PC1250LC -11 PC1250SP-11 Hydraulic Excavator Shop Manual SEN06624-07 – DOWNLOAD

SERIAL NUMBERS
PC1250- 50001 and up
PC1250LC- 50001 and up
PC1250SP- 50001 and up

• The Komatsu PC1250-11 PC1250LC-11 PC1250SP-11 Hydraulic Excavator Shop Manual (SEN06624-07) is a comprehensive guide for individuals who are involved in maintaining and repairing Komatsu PC1250-11 series hydraulic excavators. This manual provides detailed instructions for performing various maintenance and repair procedures on the hydraulic excavator, including engine repairs, hydraulic system repairs, electrical system repairs, and more.
• One of the key features of the Komatsu PC1250-11 PC1250LC-11 PC1250SP-11 Hydraulic Excavator Shop Manual is its clear and concise instructions. The manual provides step-by-step instructions for each maintenance and repair procedure, along with detailed illustrations and schematics to help users understand the process. The instructions are easy to follow, and are designed to help users avoid common mistakes that can lead to incorrect repairs or damage to the hydraulic excavator.
• The manual also includes comprehensive coverage of the hydraulic excavator components, including the engine, hydraulic system, electrical system, and more. This information is presented in an easy-to-understand format, and includes clear explanations of each step of the maintenance and repair process. The manual also includes information on the latest tools and technologies used in the maintenance and repair of hydraulic excavators, which can help users take advantage of the latest advancements in the field to maintain and repair their hydraulic excavator more efficiently and effectively.
• Another valuable aspect of the Komatsu PC1250-11 PC1250LC-11 PC1250SP-11 Hydraulic Excavator Shop Manual is its focus on safety. The manual includes important safety information and precautions to take during the maintenance and repair process, which can help users avoid injury and ensure that their hydraulic excavator is maintained and repaired safely.
• In conclusion, the Komatsu PC1250-11 PC1250LC-11 PC1250SP-11 Hydraulic Excavator Shop Manual (SEN06624-07) is an essential resource for anyone involved in maintaining and repairing Komatsu PC1250-11 series hydraulic excavators. It provides a wealth of information that can help users maintain and repair their hydraulic excavator correctly and efficiently, and can save them time and money by enabling them to avoid common mistakes and avoid the need for costly repairs. The manual is a valuable resource for anyone who wants to ensure that their hydraulic excavator is maintained and repaired properly and is ready to perform at its best.

TABLE OF CONTENTS:

Komatsu PC1250 -11 PC1250LC -11 PC1250SP-11 Hydraulic Excavator Shop Manual SEN06624-07 – DOWNLOAD

COVER………………………………………………………………………………………………………………………………….. 1
00 INDEX AND FOREWORD…………………………………………………………………………………………………………………… 3
INDEX……………………………………………………………………………………………………………………………… 4
ABBREVIATION LIST…………………………………………………………………………………………………………………… 23
FOREWORD, SAFETY, BASIC INFORMATION…………………………………………………………………………………………………… 29
HOW TO READ THE SHOP MANUAL………………………………………………………………………………………………………. 29
SAFETY NOTICE FOR OPERATION………………………………………………………………………………………………………. 31
PRECAUTIONS TO PREVENT FIRE………………………………………………………………………………………………………. 39
ACTIONS IF FIRE OCCURS…………………………………………………………………………………………………………… 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS……………………………………………………………………………………….. 40
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT……………………………………………………………………………………….. 41
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS……………………………………………………………………………… 44
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT………………………………………………………………………………………. 50
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT……………………………………………………………………………………… 52
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT……………………………………………………………………………………. 53
PRACTICAL USE OF KOMTRAX…………………………………………………………………………………………………………. 54
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER………………………………………………………………………………………. 55
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER……………………………………………………………… 55
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER……………………………………………………………… 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER……………………………………………………………… 57
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS…………………………………………………………………………… 59
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR……………………………………………………………………………. 63
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR…………………………………………………………………….. 64
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL…………………………………………………………………… 66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH…………………………………………………………………… 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE………………………………………………………………. 69
HOW TO READ ELECTRICAL WIRE CODE………………………………………………………………………………………………….. 70
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD………………………………………………………………………………………. 74
STANDARD TIGHTENING TORQUE TABLE………………………………………………………………………………………………….. 77
CONVERSION TABLE………………………………………………………………………………………………………………… 84
01 SPECIFICATIONS………………………………………………………………………………………………………………………. 89
CONTENTS…………………………………………………………………………………………………………………………… 90
ABBREVIATION LIST…………………………………………………………………………………………………………………… 91
SPECIFICATIONS……………………………………………………………………………………………………………………… 97
SPECIFICATION DRAWING……………………………………………………………………………………………………………. 97
SPECIFICATION DRAWING: PC1250-11………………………………………………………………………………………………. 97
SPECIFICATION DRAWING: PC1250SP-11…………………………………………………………………………………………….. 98
SPECIFICATION DRAWING: PC1250LC-11…………………………………………………………………………………………….. 99
SPECIFICATION DRAWING: PC1250-11 (LOADING SHOVEL SPECIFICATION)…………………………………………………………………… 100
WORKING RANGE DRAWINGS…………………………………………………………………………………………………………… 101
WORKING RANGE: PC1250-11……………………………………………………………………………………………………… 101
WORKING RANGE: PC1250SP-11……………………………………………………………………………………………………. 102
WORKING RANGE: PC1250LC-11……………………………………………………………………………………………………. 103
WORKING RANGE: PC1250-11 (LOADING SHOVEL SPECIFICATION)………………………………………………………………………….. 104
SPECIFICATIONS………………………………………………………………………………………………………………….. 105
SPECIFICATIONS: PC1250-11…………………………………………………………………………………………………….. 105
SPECIFICATIONS: PC1250SP-11…………………………………………………………………………………………………… 108
SPECIFICATIONS: PC1250LC-11…………………………………………………………………………………………………… 111
SPECIFICATIONS: PC1250-11 (LOADING SHOVEL SPECIFICATION)…………………………………………………………………………. 114
WEIGHT TABLE……………………………………………………………………………………………………………………. 118
WEIGHT TABLE: PC1250-11………………………………………………………………………………………………………. 118
WEIGHT TABLE: PC1250SP-11…………………………………………………………………………………………………….. 120
WEIGHT TABLE: PC1250LC-11…………………………………………………………………………………………………….. 122
WEIGHT TABLE: PC1250-11 (LOADING SHOVEL SPECIFICATION)…………………………………………………………………………… 124
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA)………………………………………………………………………………………. 126
USE OF FUEL, COOLANT AND LUBRICANTS TO ACCORDING TO AMBIENT TEMPERATURE……………………………………………………………. 126
10 STRUCTURE AND FUNCTION……………………………………………………………………………………………………………….. 129
CONTENTS…………………………………………………………………………………………………………………………… 130
ABBREVIATION LIST…………………………………………………………………………………………………………………… 134
BOOT-UP SYSTEM……………………………………………………………………………………………………………………… 140
LAYOUT DRAWING OF BOOT-UP SYSTEM………………………………………………………………………………………………….. 140
SYSTEM OPERATING LAMP SYSTEM……………………………………………………………………………………………………… 141
SYSTEM OPERATING LAMP SYSTEM DIAGRAM…………………………………………………………………………………………… 141
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM……………………………………………………………………………………….. 141
BATTERY DISCONNECT SWITCH………………………………………………………………………………………………………… 143
FUNCTION OF BATTERY DISCONNECT SWITCH………………………………………………………………………………………….. 143
ENGINE SYSTEM………………………………………………………………………………………………………………………. 144
LAYOUT DRAWING OF ENGINE SYSTEM…………………………………………………………………………………………………… 144
FUNCTION OF ENGINE SYSTEM…………………………………………………………………………………………………….. 145
ENGINE CONTROL SYSTEM……………………………………………………………………………………………………………. 146
ENGINE CONTROL SYSTEM DIAGRAM…………………………………………………………………………………………………. 146
FUNCTION OF ENGINE CONTROL SYSTEM……………………………………………………………………………………………… 146
AUTO-DECELERATION SYSTEM…………………………………………………………………………………………………………. 149
AUTO-DECELERATION SYSTEM DIAGRAM………………………………………………………………………………………………. 149
FUNCTION OF AUTO-DECELERATION SYSTEM…………………………………………………………………………………………… 149
OPERATION OF AUTO-DECELERATION SYSTEM………………………………………………………………………………………….. 150
AUTOMATIC LOW IDLE SYSTEM………………………………………………………………………………………………………… 151
AUTOMATIC LOW IDLE SYSTEM DIAGRAM……………………………………………………………………………………………… 151
FUNCTION OF AUTOMATIC LOW IDLE SYSTEM………………………………………………………………………………………….. 151
OPERATION OF AUTOMATIC LOW IDLE SYSTEM…………………………………………………………………………………………. 152
ENGINE AUTOMATIC WARM-UP SYSTEM…………………………………………………………………………………………………… 153
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM………………………………………………………………………………………… 153
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM…………………………………………………………………………………….. 154
OVERHEAT PREVENTION SYSTEM……………………………………………………………………………………………………….. 155
OVERHEAT PREVENTION SYSTEM DIAGRAM…………………………………………………………………………………………….. 155
FUNCTION OF OVERHEAT PREVENTION SYSTEM…………………………………………………………………………………………. 155
TURBOCHARGER PROTECTION SYSTEM……………………………………………………………………………………………………. 156
TURBOCHARGER PROTECTION SYSTEM DIAGRAM…………………………………………………………………………………………. 156
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM……………………………………………………………………………………… 157
AUTOMATIC IDLE STOP SYSTEM……………………………………………………………………………………………………….. 158
AUTOMATIC IDLE STOP SYSTEM DIAGRAM…………………………………………………………………………………………….. 158
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM…………………………………………………………………………………………. 158
COMPONENT PARTS OF ENGINE SYSTEM………………………………………………………………………………………………….. 161
PTO………………………………………………………………………………………………………………………… 161
PTO LUBRICATION SYSTEM……………………………………………………………………………………………………….. 162
VGT………………………………………………………………………………………………………………………… 164
EGR SYSTEM………………………………………………………………………………………………………………….. 168
EGR VALVE…………………………………………………………………………………………………………………… 171
EGR COOLER………………………………………………………………………………………………………………….. 173
KCCV SYSTEM…………………………………………………………………………………………………………………. 174
KCCV VENTILATOR……………………………………………………………………………………………………………… 176
KDPF……………………………………………………………………………………………………………………….. 178
COOLING SYSTEM……………………………………………………………………………………………………………………… 182
LAYOUT DRAWING OF COOLING SYSTEM………………………………………………………………………………………………….. 182
SPECIFICATIONS OF COOLING SYSTEM………………………………………………………………………………………………. 183
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN………………………………………………………………………………………….. 184
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN……………………………………………………………………………….. 184
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN……………………………………………………………………………. 185
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN………………………………………………………………………………………. 186
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN……………………………………………………………………………. 186
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN………………………………………………………………………… 186
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN……………………………………………………………………………………….. 188
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN…………………………………………………………………………….. 188
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN…………………………………………………………………………. 188
COMPONENT PARTS OF COOLING SYSTEM…………………………………………………………………………………………………. 189
COOLING FAN PUMP…………………………………………………………………………………………………………….. 189
COOLING FAN MOTOR……………………………………………………………………………………………………………. 204
CONTROL SYSTEM……………………………………………………………………………………………………………………… 211
LAYOUT DRAWING OF CONTROL SYSTEM………………………………………………………………………………………………….. 211
MACHINE MONITOR SYSTEM…………………………………………………………………………………………………………… 213
MACHINE MONITOR SYSTEM DIAGRAM………………………………………………………………………………………………… 213
KomVision SYSTEM………………………………………………………………………………………………………………… 214
LAYOUT DRAWING OF KOMVISION SYSTEM…………………………………………………………………………………………….. 214
KomVision SYSTEM DIAGRAM……………………………………………………………………………………………………… 216
FUNCTION OF KomVision SYSTEM………………………………………………………………………………………………….. 217
KOMTRAX Plus SYSTEM……………………………………………………………………………………………………………… 219
KOMTRAX Plus SYSTEM DIAGRAM…………………………………………………………………………………………………… 219
FUNCTION OF KOMTRAX Plus SYSTEM……………………………………………………………………………………………….. 220
COMPONENT PARTS OF CONTROL SYSTEM…………………………………………………………………………………………………. 224
MACHINE MONITOR……………………………………………………………………………………………………………… 224
KomVision CONTROLLER…………………………………………………………………………………………………………. 239
KomVision CAMERA…………………………………………………………………………………………………………….. 243
KOMTRAX TERMINAL…………………………………………………………………………………………………………….. 244
KOMTRAX Plus CONTROLLER………………………………………………………………………………………………………. 246
WIRELESS LAN UNIT……………………………………………………………………………………………………………. 251
PUMP CONTROLLER……………………………………………………………………………………………………………… 252
RESISTOR FOR TVC VALVE……………………………………………………………………………………………………….. 257
CAN TERMINATING RESISTOR……………………………………………………………………………………………………… 258
ENGINE CONTROLLER……………………………………………………………………………………………………………. 259
FUEL CONTROL DIAL……………………………………………………………………………………………………………. 273
FUEL FEED PUMP………………………………………………………………………………………………………………. 274
FUEL FEED PUMP SWITCH………………………………………………………………………………………………………… 275
HYDRAULIC SYSTEM……………………………………………………………………………………………………………………. 276
LAYOUT DRAWING OF HYDRAULIC SYSTEM………………………………………………………………………………………………… 276
OLSS…………………………………………………………………………………………………………………………… 279
STRUCTURE OF OLSS……………………………………………………………………………………………………………. 279
FUNCTION OF OLSS…………………………………………………………………………………………………………….. 280
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL………………………………………………………………………………………. 281
ENGINE AND PUMP COMBINED CONTROL SYSTEM……………………………………………………………………………………………. 292
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM…………………………………………………………………………………. 292
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM……………………………………………………………………………… 294
COMPONENT PARTS OF HYDRAULIC SYSTEM……………………………………………………………………………………………….. 296
HYDRAULIC TANK………………………………………………………………………………………………………………. 296
MAIN PUMP…………………………………………………………………………………………………………………… 298
CONTROL VALVE……………………………………………………………………………………………………………….. 348
VARIABLE BACK PRESSURE VALVE………………………………………………………………………………………………….. 374
WORK EQUIPMENT SYSTEM……………………………………………………………………………………………………………….. 377
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM……………………………………………………………………………………………. 377
MACHINE PUSH-UP SYSTEM…………………………………………………………………………………………………………… 383
MACHINE PUSH-UP SYSTEM DIAGRAM………………………………………………………………………………………………… 383
FUNCTION OF MACHINE PUSH-UP SYSTEM…………………………………………………………………………………………….. 384
HEAVY LIFT SYSTEM……………………………………………………………………………………………………………….. 385
HEAVY LIFT SYSTEM DIAGRAM…………………………………………………………………………………………………….. 385
FUNCTION OF HEAVY LIFT SYSTEM…………………………………………………………………………………………………. 387
OPERATION OF HEAVY LIFT SYSTEM………………………………………………………………………………………………… 387
BOOM SHOCKLESS CONTROL SYSTEM…………………………………………………………………………………………………….. 388
BOOM SHOCKLESS CONTROL FUNCTION SYSTEM DIAGRAM………………………………………………………………………………….. 388
FUNCTION OF BOOM SHOCKLESS CONTROL SYSTEM………………………………………………………………………………………. 388
OPERATION OF BOOM SHOCKLESS CONTROL SYSTEM……………………………………………………………………………………… 388
PPC LOCK SYSTEM…………………………………………………………………………………………………………………. 390
PPC LOCK SYSTEM DIAGRAM………………………………………………………………………………………………………. 390
FUNCTION OF PPC LOCK SYSTEM…………………………………………………………………………………………………… 390
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM…………………………………………………………………………………….. 391
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM………………………………………………………………………….. 391
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM………………………………………………………………………. 391
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM……………………………………………………………………… 392
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM…………………………………………………………………………………………… 393
WORK EQUIPMENT AND SWING PPC VALVE…………………………………………………………………………………………….. 393
SOLENOID VALVE………………………………………………………………………………………………………………. 398
PILOT CIRCUIT ACCUMULATOR…………………………………………………………………………………………………….. 404
SWING SYSTEM……………………………………………………………………………………………………………………….. 405
LAYOUT DRAWING OF SWING SYSTEM……………………………………………………………………………………………………. 405
SWING CONTROL SYSTEM DIAGRAM……………………………………………………………………………………………………… 408
FUNCTION OF SWING CONTROL SYSTEM………………………………………………………………………………………………. 409
SWING PRIORITY SYSTEM DIAGRAM…………………………………………………………………………………………………….. 412
FUNCTION OF SWING PRIORITY SYSTEM……………………………………………………………………………………………… 414
SWING COMPENSATION SYSTEM DIAGRAM…………………………………………………………………………………………………. 415
FUNCTION OF SWING COMPENSATION SYSTEM………………………………………………………………………………………….. 415
OPERATION OF SWING COMPENSATION SYSTEM…………………………………………………………………………………………. 415
COMPONENT PARTS OF SWING SYSTEM…………………………………………………………………………………………………… 416
SWING MOTOR…………………………………………………………………………………………………………………. 416
SWING MACHINERY……………………………………………………………………………………………………………… 428
SWING CIRCLE………………………………………………………………………………………………………………… 430
TRAVEL SYSTEM………………………………………………………………………………………………………………………. 431
LAYOUT DRAWING OF TRAVEL SYSTEM…………………………………………………………………………………………………… 431
TRAVEL CONTROL SYSTEM DIAGRAM…………………………………………………………………………………………………….. 435
FUNCTION OF TRAVEL CONTROL SYSTEM……………………………………………………………………………………………… 437
COMPONENT PARTS OF TRAVEL SYSTEM………………………………………………………………………………………………….. 438
TRAVEL MOTOR………………………………………………………………………………………………………………… 438
FINAL DRIVE…………………………………………………………………………………………………………………. 449
TRAVEL PPC VALVE…………………………………………………………………………………………………………….. 451
CENTER SWIVEL JOINT………………………………………………………………………………………………………….. 455
PNEUMATIC SYSTEM……………………………………………………………………………………………………………………. 457
LAYOUT DRAWING OF PNEUMATIC SYSTEM………………………………………………………………………………………………… 457
PNEUMATIC SYSTEM DIAGRAM…………………………………………………………………………………………………………. 458
FUNCTION OF PNEUMATIC SYSTEM………………………………………………………………………………………………….. 458
COMPONENT PARTS OF PNEUMATIC SYSTEM……………………………………………………………………………………………….. 459
AIR GOVERNOR………………………………………………………………………………………………………………… 459
AIR TANK……………………………………………………………………………………………………………………. 460
HORN VALVE………………………………………………………………………………………………………………….. 462
GREASE PUMP…………………………………………………………………………………………………………………. 463
LIFTING SYSTEM……………………………………………………………………………………………………………………… 464
HYDRAULICALLY OPERATED STAIRWAY SYSTEM…………………………………………………………………………………………….. 464
LAYOUT DRAWING OF HYDRAULICALLY OPERATED STAIRWAY SYSTEM…………………………………………………………………………. 464
HYDRAULICALLY OPERATED STAIRWAY SYSTEM DIAGRAM………………………………………………………………………………….. 465
FUNCTION OF HYDRAULICALLY OPERATED STAIRWAY SYSTEM………………………………………………………………………………. 466
COMPONENT PARTS OF LIFTING SYSTEM…………………………………………………………………………………………………. 467
SWITCH BOX………………………………………………………………………………………………………………….. 467
PROXIMITY SWITCH PART………………………………………………………………………………………………………… 468
CONTROL VALVE ASSEMBLY……………………………………………………………………………………………………….. 469
UNDERCARRIAGE AND FRAME……………………………………………………………………………………………………………… 470
LAYOUT DRAWING OF UNDERCARRIAGE…………………………………………………………………………………………………… 470
SPECIFICATIONS OF UNDERCARRIAGE……………………………………………………………………………………………….. 471
WORK EQUIPMENT……………………………………………………………………………………………………………………… 472
STRUCTURE OF WORK EQUIPMENT………………………………………………………………………………………………………. 472
FUNCTION OF WORK EQUIPMENT……………………………………………………………………………………………………….. 472
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM…………………………………………………………………………………………… 473
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM…………………………………………………………………………….. 473
BUCKET CLEARANCE ADJUSTMENT SHIM………………………………………………………………………………………………….. 473
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM……………………………………………………………………………………. 473
CAB AND ITS ATTACHMENTS……………………………………………………………………………………………………………… 474
CAB……………………………………………………………………………………………………………………………. 474
STRUCTURE OF CAB…………………………………………………………………………………………………………….. 474
CAB MOUNT………………………………………………………………………………………………………………………. 475
STRUCTURE OF CAB MOUNT……………………………………………………………………………………………………….. 475
FUNCTION OF CAB MOUNT………………………………………………………………………………………………………… 475
CAB TIPPING STOPPER……………………………………………………………………………………………………………… 476
STRUCTURE OF CAB TIPPING STOPPER………………………………………………………………………………………………. 476
FUNCTION OF CAB TIPPING STOPPER……………………………………………………………………………………………….. 476
20 STANDARD VALUE TABLE…………………………………………………………………………………………………………………. 477
CONTENTS…………………………………………………………………………………………………………………………… 478
ABBREVIATION LIST…………………………………………………………………………………………………………………… 479
STANDARD VALUE TABLE FOR ENGINE………………………………………………………………………………………………………. 485
STANDARD VALUE TABLE FOR ENGINE: PC1250-11…………………………………………………………………………………………. 485
STANDARD VALUE TABLE FOR ENGINE: PC1250SP-11……………………………………………………………………………………….. 490
STANDARD VALUE TABLE FOR ENGINE: PC1250LC-11……………………………………………………………………………………….. 495
STANDARD VALUE TABLE FOR MACHINE……………………………………………………………………………………………………… 500
STANDARD VALUE TABLE FOR MACHINE: PC1250-11………………………………………………………………………………………… 500
STANDARD VALUE TABLE FOR MACHINE: PC1250SP-11………………………………………………………………………………………. 514
STANDARD VALUE TABLE FOR MACHINE: PC1250LC-11………………………………………………………………………………………. 528
STANDARD VALUE TABLE FOR MACHINE: PC1250-11 (LOADING SHOVEL SPECIFICATION)…………………………………………………………….. 542
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE……………………………………………………………………………… 557
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE (LOADING SHOVEL SPECIFICATION)……………………………………………………. 561
30 TESTING AND ADJUSTING………………………………………………………………………………………………………………… 565
CONTENTS…………………………………………………………………………………………………………………………… 566
ABBREVIATION LIST…………………………………………………………………………………………………………………… 570
RELATED INFORMATION ON TESTING AND ADJUSTING…………………………………………………………………………………………… 576
TOOLS FOR TESTING AND ADJUSTING…………………………………………………………………………………………………… 576
SKETCH OF TOOLS FOR TESTING AND ADJUSTING………………………………………………………………………………………….. 583
ENGINE AND COOLING SYSTEM……………………………………………………………………………………………………………. 584
TEST ENGINE SPEED……………………………………………………………………………………………………………….. 584
METHOD FOR TESTING ENGINE SPEED……………………………………………………………………………………………….. 584
TEST BOOST PRESSURE……………………………………………………………………………………………………………… 587
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR…………………………………………………………………………….. 587
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL……………………………………………………………………………….. 588
TEST EXHAUST GAS TEMPERATURE……………………………………………………………………………………………………… 589
METHOD FOR TESTING EXHAUST GAS TEMPERATURE……………………………………………………………………………………… 589
TEST EXHAUST GAS COLOR…………………………………………………………………………………………………………… 591
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER………………………………………………………………………. 591
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER……………………………………………………………………………… 592
TEST MASS AIR FLOW AND TEMPERATURE SENSOR………………………………………………………………………………………….. 595
TEST MASS AIR FLOW AND TEMPERATURE SENSOR………………………………………………………………………………………. 595
TEST AND ADJUST VALVE CLEARANCE…………………………………………………………………………………………………… 597
METHOD FOR TESTING VALVE CLEARANCE…………………………………………………………………………………………….. 597
METHOD FOR ADJUSTING VALVE CLEARANCE…………………………………………………………………………………………… 598
TEST COMPRESSION PRESSURE………………………………………………………………………………………………………… 600
METHOD FOR TESTING COMPRESSION PRESSURE………………………………………………………………………………………… 600
TEST BLOWBY PRESSURE…………………………………………………………………………………………………………….. 604
METHOD FOR TESTING BLOWBY PRESSURE…………………………………………………………………………………………….. 604
TEST ENGINE OIL PRESSURE…………………………………………………………………………………………………………. 606
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR………………………………………………………………………… 606
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL…………………………………………………………………………… 606
TEST EGR VALVE AND VGT OIL PRESSURE……………………………………………………………………………………………….. 608
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE……………………………………………………………………………….. 608
TEST FUEL PRESSURE………………………………………………………………………………………………………………. 609
METHOD FOR TESTING FUEL PRESSURE………………………………………………………………………………………………. 609
TEST FUEL RETURN RATE AND LEAKAGE…………………………………………………………………………………………………. 611
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE…………………………………………………………………………………. 612
BLEED AIR FROM FUEL SYSTEM……………………………………………………………………………………………………….. 616
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM……………………………………………………………………………………….. 616
TEST FUEL CIRCUIT FOR LEAKAGE…………………………………………………………………………………………………….. 618
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE…………………………………………………………………………………….. 618
TEST SUPPLY PUMP………………………………………………………………………………………………………………… 620
METHOD FOR TESTING SUPPLY PUMP………………………………………………………………………………………………… 620
HANDLE CYLINDER CUT-OUT MODE OPERATION…………………………………………………………………………………………….. 623
TEST ALTERNATOR…………………………………………………………………………………………………………………. 624
METHOD FOR TESTING ALTERNATOR…………………………………………………………………………………………………. 624
HANDLE NO-INJECTION CRANKING OPERATION…………………………………………………………………………………………….. 625
CLEAN FUEL DOSER………………………………………………………………………………………………………………… 626
METHOD FOR CLEANING FUEL DOSER………………………………………………………………………………………………… 626
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER………………………………………………………………………………. 629
METHOD FOR WRITING INJECTOR COMPENSATION VALUE………………………………………………………………………………….. 629
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER……………………………………………………………………….. 635
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER………………………………………………………… 635
POWER TRAIN………………………………………………………………………………………………………………………… 636
TEST SWING CIRCLE BEARING CLEARANCE……………………………………………………………………………………………….. 636
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE……………………………………………………………………………….. 636
UNDERCARRIAGE AND FRAME……………………………………………………………………………………………………………… 638
TEST SPROCKET WEAR………………………………………………………………………………………………………………. 638
METHOD FOR TESTING SPROCKET WEAR………………………………………………………………………………………………. 638
TEST AND ADJUST TRACK TENSION…………………………………………………………………………………………………….. 639
METHOD FOR TESTING TRACK TENSION………………………………………………………………………………………………. 639
METHOD FOR ADJUSTING TRACK TENSION…………………………………………………………………………………………….. 639
HYDRAULIC SYSTEM……………………………………………………………………………………………………………………. 641
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM……………………………………………………………………………………. 641
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT……………………………………………………………………. 641
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT………………………………………………………………….. 644
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT…………………………………………………………………. 644
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…………………………………………………………….. 646
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS………………………………………………………. 649
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…………………………………………………….. 656
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT…………………………………………………………………………………….. 660
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT………………………………………………………………………………. 660
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT…………………………………………………………………………….. 661
TEST AND ADJUST PISTON PUMP CONTROL OIL PRESSURE……………………………………………………………………………………. 662
METHOD FOR TESTING TVC VALVE OUTLET PRESSURE……………………………………………………………………………………. 662
METHOD FOR TESTING CO VALVE + NC VALVE OUTLET PRESSURE OF NO. 1 AND NO. 2 PUMPS…………………………………………………….. 663
METHOD FOR TESTING CO VALVE + NC VALVE OUTLET PRESSURE OF NO. 3 PUMP………………………………………………………………. 664
METHOD FOR TESTING JET SENSOR OUTLET PRESSURE OF 4-SPOOL CONTROL VALVE ON THE RIGHT SIDE…………………………………………….. 665
METHOD FOR TESTING JET SENSOR OUTLET PRESSURE OF 4-SPOOL CONTROL VALVE FOR SWING……………………………………………………. 666
METHOD FOR ADJUSTING TVC VALVE………………………………………………………………………………………………… 667
METHOD FOR ADJUSTING CO VALVE + NC VALVE OF NO. 1 AND NO. 2 PUMPS…………………………………………………………………. 668
METHOD FOR ADJUSTING CO VALVE + NC VALVE OF NO. 3 PUMP…………………………………………………………………………… 669
METHOD FOR ADJUSTING JET SENSOR OF 4-SPOOL CONTROL VALVE ON THE RIGHT SIDE AND 5-SPOOL CONTROL VALVE ON THE LEFT SIDE…………………… 670
METHOD FOR ADJUSTING JET SENSOR OF 4-SPOOL CONTROL VALVE FOR SWING………………………………………………………………… 670
TEST SERVO PISTON STROKE…………………………………………………………………………………………………………. 671
METHOD FOR TESTING SERVO PISTON STROKE…………………………………………………………………………………………. 671
TEST OUTLET PRESSURE OF SOLENOID VALVE…………………………………………………………………………………………….. 673
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE…………………………………………………………………………….. 673
OPERATING CONDITION OF SOLENOID VALVE………………………………………………………………………………………….. 675
TEST PPC VALVE OUTLET PRESSURE……………………………………………………………………………………………………. 678
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE……………………………………………………………………………………. 678
TEST SWING PPC SHUTTLE VALVE OUTLET PRESSURE……………………………………………………………………………………….. 680
METHOD FOR TESTING SWING PPC SHUTTLE VALVE OUTLET PRESSURE……………………………………………………………………….. 680
ADJUST WORK EQUIPMENT AND SWING PPC VALVES…………………………………………………………………………………………. 682
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES………………………………………………………………….. 682
TEST TRAVEL DEVIATION……………………………………………………………………………………………………………. 683
METHOD FOR TESTING TRAVEL DEVIATION……………………………………………………………………………………………. 683
TEST COOLING FAN SPEED…………………………………………………………………………………………………………… 684
METHOD FOR TESTING COOLING FAN SPEED…………………………………………………………………………………………… 684
TEST AFTERCOOLER FAN SPEED……………………………………………………………………………………………………….. 685
METHOD FOR TESTING AFTERCOOLER FAN SPEED……………………………………………………………………………………….. 685
TEST OIL PRESSURE IN FAN PUMP CIRCUIT……………………………………………………………………………………………… 686
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT……………………………………………………………………………… 686
TEST AFTERCOOLER FAN PUMP CIRCUIT OIL PRESSURE……………………………………………………………………………………… 687
METHOD FOR TESTING AFTERCOOLER FAN PUMP CIRCUIT OIL PRESSURE……………………………………………………………………… 687
TEST FAN PUMP EPC ELECTRIC CURRENT………………………………………………………………………………………………… 688
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT………………………………………………………………………………… 688
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE……………………………………………………………………………………. 689
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE……………………………………………………………………. 689
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT…………………………………………………………………………….. 691
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER……………………………………………. 691
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER………………………………………………………………. 691
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE…………………………………………………………………. 692
TEST OIL LEAKAGE………………………………………………………………………………………………………………… 693
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER……………………………………………………………………………….. 693
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER………………………………………………………………………………… 694
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER……………………………………………………………………………… 694
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR…………………………………………………………………………………. 695
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR………………………………………………………………………………… 695
METHOD FOR TESTING OIL LEAKAGE OF SWIVEL JOINT………………………………………………………………………………….. 696
BLEED AIR FROM HYDRAULIC CIRCUIT………………………………………………………………………………………………….. 699
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT………………………………………………………………………………….. 700
CAB AND ITS ATTACHMENTS……………………………………………………………………………………………………………… 704
TEST CAB TIPPING STOPPER…………………………………………………………………………………………………………. 704
METHOD FOR TESTING CAB TIPPING STOPPER…………………………………………………………………………………………. 704
METHOD FOR ADJUSTING MIRRORS……………………………………………………………………………………………………… 705
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)……………………………………………………………………………. 705
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)………………………………………………………….. 706
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)…………………………………………………………………………… 707
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)…………………………………………………………. 708
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (C)…………………………………………………………………………… 709
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (C)…………………………………………………………. 710
ELECTRICAL SYSTEM…………………………………………………………………………………………………………………… 712
SET AND OPERATE MACHINE MONITOR…………………………………………………………………………………………………… 712
OPERATOR MODE……………………………………………………………………………………………………………….. 716
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN………………………………………………………………………. 716
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN…………………………………………………………………………. 716
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)……………………………………………………………………………….. 717
CHECKING FUNCTION OF SERVICE METER…………………………………………………………………………………………….. 717
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD………………………………………………………………………… 717
SERVICE MODE………………………………………………………………………………………………………………… 720
METHOD FOR OPERATING SERVICE MODE……………………………………………………………………………………………… 720
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION…………………………………………………………………………… 722
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION…………………………………………………………………………… 726
ABNORMALITY RECORD MENU………………………………………………………………………………………………………. 736
METHOD FOR CONFIRMING MAINTENANCE RECORD……………………………………………………………………………………….. 740
METHOD FOR OPERATING MAINTENANCE MODE SETTING…………………………………………………………………………………… 741
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING…………………………………………………………………………………. 745
DEFAULT MENU………………………………………………………………………………………………………………… 747
DIAGNOSTIC TESTS MENU………………………………………………………………………………………………………… 755
ADJUSTMENT MENU……………………………………………………………………………………………………………… 765
METHOD FOR PERFORMING NO-INJECTION CRANKING…………………………………………………………………………………….. 771
KOMTRAX SETTINGS MENU………………………………………………………………………………………………………… 774
METHOD FOR DISPLAYING SERVICE MESSAGE………………………………………………………………………………………….. 776
METHOD FOR HANDLING SNAP SHOT…………………………………………………………………………………………………. 777
START UP KOMTRAX TERMINAL………………………………………………………………………………………………………… 779
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER…………………………………………………………………………………………. 785
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER……………………………………………………………………………………… 785
SETTING DEFAULT OF WIRELESS LAN MODEM……………………………………………………………………………………………… 788
METHOD FOR SETTING DEFAULT OF WIRELESS LAN MODEM………………………………………………………………………………… 788
METHOD FOR CHECKING OF WIRELESS LAN MODEM COMMUNICATION………………………………………………………………………….. 789
DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA…………………………………………………………………………………………… 791
METHOD FOR DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA……………………………………………………………………………… 791
DOWNLOAD DATA FROM SERVICE CONNECTOR…………………………………………………………………………………………… 793
DOWNLOAD DATA FROM WIRELESS LAN (WIRELESS LAN SPEC)……………………………………………………………………………… 794
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED…………………………………………………………………………………….. 795
METHOD FOR ADJUSTING WHEN KOMTRAX Plus CONTROLLER IS REPLACED…………………………………………………………………….. 795
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED…………………………………………………………………………………………. 798
METHOD FOR ADJUSTING WHEN WIRELESS LAN MODEM IS REPLACED…………………………………………………………………………. 798
ADJUST KomVision CAMERA ANGLE…………………………………………………………………………………………………….. 801
METHOD FOR ADJUSTING KomVision CAMERA ANGLE…………………………………………………………………………………….. 802
ADJUST KomVision RELATED ITEMS……………………………………………………………………………………………………. 804
SETTING OF KomVision (MAIN SETTING)……………………………………………………………………………………………. 805
SETTING OF KomVision (CAMERA SETTING)………………………………………………………………………………………….. 807
SETTING OF KomVision (CAMERA CALIBRATION)………………………………………………………………………………………. 807
KomVision screen – Check 12 m visibility……………………………………………………………………………………….. 820
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER………………………………………………………………………………………… 823
HANDLE BATTERY DISCONNECT SWITCH………………………………………………………………………………………………….. 824
TEST DIODES…………………………………………………………………………………………………………………….. 825
METHOD FOR TESTING DIODE USING DIGITAL TESTER…………………………………………………………………………………… 825
METHOD FOR TESTING DIODE USING ANALOG TESTER……………………………………………………………………………………. 825
Pm CLINIC………………………………………………………………………………………………………………………….. 826
Pm CLINIC SERVICE……………………………………………………………………………………………………………….. 826
Pm CLINIC CHECK SHEET: PC1250-11………………………………………………………………………………………………. 831
Pm CLINIC CHECK SHEET: PC1250SP-11…………………………………………………………………………………………….. 844
Pm CLINIC CHECK SHEET: PC1250LC-11…………………………………………………………………………………………….. 857
PERFORMING QUICK Pm……………………………………………………………………………………………………………… 870
METHOD FOR PERFORMING QUICK Pm………………………………………………………………………………………………… 870
40 TROUBLESHOOTING……………………………………………………………………………………………………………………… 875
CONTENTS…………………………………………………………………………………………………………………………… 876
ABBREVIATION LIST…………………………………………………………………………………………………………………… 887
RELATED INFORMATION ON TROUBLESHOOTING………………………………………………………………………………………………… 893
GENERAL TROUBLESHOOTING POINTS……………………………………………………………………………………………………. 893
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEM……………………………………………………………………………………. 894
SEQUENCE OF EVENTS IN TROUBLESHOOTING……………………………………………………………………………………………… 901
CHECKS BEFORE TROUBLESHOOTING…………………………………………………………………………………………………….. 903
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING………………………………………………………………………………………… 905
WALK-AROUND CHECK……………………………………………………………………………………………………………. 905
TESTING IN ACCORDANCE WITH TESTING PROCEDURE……………………………………………………………………………………….. 907
CHECK FUEL LEVEL AND TYPE…………………………………………………………………………………………………….. 907
CHECK IMPURE INGREDIENT IN FUEL……………………………………………………………………………………………….. 908
CHECK FUEL PREFILTER…………………………………………………………………………………………………………. 908
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT………………………………………………………………………………. 909
FUEL PREFILTER CARTRIDGE – REPLACE…………………………………………………………………………………………….. 909
TEST FUEL MAIN FILTER………………………………………………………………………………………………………… 910
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)………………………………………………………………………………….. 912
CHECK COOLANT LEVEL (RESERVOIR TANK)…………………………………………………………………………………………… 913
CHECK CLOGGING OF AIR CLEANER…………………………………………………………………………………………………. 914
OUTER ELEMENT – CLEAN………………………………………………………………………………………………………… 914
ELEMENTS – REPLACE…………………………………………………………………………………………………………… 917
CHECK HYDRAULIC OIL LEVEL…………………………………………………………………………………………………….. 917
CHECK HYDRAULIC OIL STRAINER………………………………………………………………………………………………….. 919
CHECK HYDRAULIC FILTER……………………………………………………………………………………………………….. 920
CHECK OIL LEVEL IN SWING MACHINERY CASE………………………………………………………………………………………… 921
CHECK OIL LEVEL IN PTO CASE…………………………………………………………………………………………………… 923
CHECK PTO LUBRICATION FILTER STRAINER………………………………………………………………………………………….. 923
CHECK OIL LEVEL IN FINAL DRIVE CASE……………………………………………………………………………………………. 924
BLEED AIR FROM FUEL SYSTEM……………………………………………………………………………………………………. 924
BLEED AIR FROM HYDRAULIC SYSTEM……………………………………………………………………………………………….. 924
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod……………………………………………………………………………………. 924
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM………………………………………………………………………………… 930
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR………………………………………………………………………………. 930
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER…………………………………………………………………………….. 930
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER………………………………………………………………………………. 930
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL……………………………………………………………………………… 931
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX Plus CONTROLLER……………………………………………………………………….. 931
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER………………………………………………………………………….. 931
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK…………………………………………………………………………….. 931
PROCEDURE FOR TESTING AND TROUBLESHOOTING………………………………………………………………………………………….. 936
SYMPTOM AND TROUBLESHOOTING NUMBERS……………………………………………………………………………………………….. 939
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE……………………………………………………………………………………… 944
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM…………………………………………………….. 946
CONNECTORS LIST AND LAYOUT……………………………………………………………………………………………………….. 949
CONNECTOR LIST AND LAYOUT (LOADING SHOVEL SPECIFICATION)…………………………………………………………………………….. 965
CONNECTOR CONTACT IDENTIFICATION………………………………………………………………………………………………….. 982
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE…………………………………………………………………………………………….1022
FUSE LOCATION TABLE………………………………………………………………………………………………………………1028
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)…………………………………………………………………………..1031
PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES [CA1883], [CB1883], [CA3135] AND [CB3135])…………………………………………1035
FAILURE CODE TABLE……………………………………………………………………………………………………………….1037
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)……………………………………………………………………………………….1055
FAILURE CODE [879AKA]…………………………………………………………………………………………………………….1055
FAILURE CODE [879AKB]…………………………………………………………………………………………………………….1056
FAILURE CODE [879BKA]…………………………………………………………………………………………………………….1057
FAILURE CODE [879BKB]…………………………………………………………………………………………………………….1059
FAILURE CODE [879CKA]…………………………………………………………………………………………………………….1061
FAILURE CODE [879CKB]…………………………………………………………………………………………………………….1062
FAILURE CODE [879DKZ]…………………………………………………………………………………………………………….1063
FAILURE CODE [879EMC]…………………………………………………………………………………………………………….1065
FAILURE CODE [879FMC]…………………………………………………………………………………………………………….1066
FAILURE CODE [879GKX]…………………………………………………………………………………………………………….1067
FAILURE CODE [8800ZG]…………………………………………………………………………………………………………….1069
FAILURE CODE [989L00]…………………………………………………………………………………………………………….1070
FAILURE CODE [989M00]…………………………………………………………………………………………………………….1071
FAILURE CODE [989N00]…………………………………………………………………………………………………………….1072
FAILURE CODE [A1U0N3]…………………………………………………………………………………………………………….1073
FAILURE CODE [A1U0N4]…………………………………………………………………………………………………………….1075
FAILURE CODE [AA10NX]…………………………………………………………………………………………………………….1077
FAILURE CODE [AB00KE]…………………………………………………………………………………………………………….1079
FAILURE CODE [AQ00N3]…………………………………………………………………………………………………………….1081
FAILURE CODE [AQ00N4]…………………………………………………………………………………………………………….1082
FAILURE CODE [AQ10N3]…………………………………………………………………………………………………………….1083
FAILURE CODE [B@BAZG]…………………………………………………………………………………………………………….1084
FAILURE CODE [B@BAZK]…………………………………………………………………………………………………………….1085
FAILURE CODE [B@BCNS]…………………………………………………………………………………………………………….1087
FAILURE CODE [B@BCZK]…………………………………………………………………………………………………………….1088
FAILURE CODE [B@CBNS]…………………………………………………………………………………………………………….1090
FAILURE CODE [B@HANS]…………………………………………………………………………………………………………….1092
FAILURE CODE [CA115]……………………………………………………………………………………………………………..1093
FAILURE CODE [CA122]……………………………………………………………………………………………………………..1097
FAILURE CODE [CA123]……………………………………………………………………………………………………………..1099
FAILURE CODE [CA131]……………………………………………………………………………………………………………..1101
FAILURE CODE [CA132]……………………………………………………………………………………………………………..1103
FAILURE CODE [CA135]……………………………………………………………………………………………………………..1105
FAILURE CODE [CA141]……………………………………………………………………………………………………………..1107
FAILURE CODE [CA144]……………………………………………………………………………………………………………..1109
FAILURE CODE [CA145]……………………………………………………………………………………………………………..1111
FAILURE CODE [CA153]……………………………………………………………………………………………………………..1113
FAILURE CODE [CA154]……………………………………………………………………………………………………………..1115
FAILURE CODE [CA187]……………………………………………………………………………………………………………..1117
FAILURE CODE [CA212]……………………………………………………………………………………………………………..1119
FAILURE CODE [CA213]……………………………………………………………………………………………………………..1121
FAILURE CODE [CA221]……………………………………………………………………………………………………………..1123
FAILURE CODE [CA222]……………………………………………………………………………………………………………..1125
FAILURE CODE [CA227]……………………………………………………………………………………………………………..1127
FAILURE CODE [CA234]……………………………………………………………………………………………………………..1129
FAILURE CODE [CA238]……………………………………………………………………………………………………………..1130
FAILURE CODE [CA239]……………………………………………………………………………………………………………..1132
FAILURE CODE [CA271]……………………………………………………………………………………………………………..1134
FAILURE CODE [CA272]……………………………………………………………………………………………………………..1136
FAILURE CODE [CA273]……………………………………………………………………………………………………………..1137
FAILURE CODE [CA274]……………………………………………………………………………………………………………..1139
FAILURE CODE [CA322]……………………………………………………………………………………………………………..1140
FAILURE CODE [CA323]……………………………………………………………………………………………………………..1142
FAILURE CODE [CA324]……………………………………………………………………………………………………………..1144
FAILURE CODE [CA325]……………………………………………………………………………………………………………..1146
FAILURE CODE [CA331]……………………………………………………………………………………………………………..1148
FAILURE CODE [CA332]……………………………………………………………………………………………………………..1150
FAILURE CODE [CA343]……………………………………………………………………………………………………………..1152
FAILURE CODE [CA351]……………………………………………………………………………………………………………..1154
FAILURE CODE [CA352]……………………………………………………………………………………………………………..1156
FAILURE CODE [CA356]……………………………………………………………………………………………………………..1158
FAILURE CODE [CA357]……………………………………………………………………………………………………………..1160
FAILURE CODE [CA386]……………………………………………………………………………………………………………..1162
FAILURE CODE [CA441]……………………………………………………………………………………………………………..1164
FAILURE CODE [CA442]……………………………………………………………………………………………………………..1166
FAILURE CODE [CA449]……………………………………………………………………………………………………………..1168
FAILURE CODE [CA451]……………………………………………………………………………………………………………..1169
FAILURE CODE [CA452]……………………………………………………………………………………………………………..1171
FAILURE CODE [CA515]……………………………………………………………………………………………………………..1173
FAILURE CODE [CA516]……………………………………………………………………………………………………………..1174
FAILURE CODE [CA553]……………………………………………………………………………………………………………..1175
FAILURE CODE [CA555]……………………………………………………………………………………………………………..1176
FAILURE CODE [CA556]……………………………………………………………………………………………………………..1178
FAILURE CODE [CA559]……………………………………………………………………………………………………………..1180
FAILURE CODE [CA595]……………………………………………………………………………………………………………..1185
FAILURE CODE [CA687]……………………………………………………………………………………………………………..1187
FAILURE CODE [CA689]……………………………………………………………………………………………………………..1189
FAILURE CODE [CA691]……………………………………………………………………………………………………………..1191
FAILURE CODE [CA692]……………………………………………………………………………………………………………..1193
FAILURE CODE [CA697]……………………………………………………………………………………………………………..1195
FAILURE CODE [CA698]……………………………………………………………………………………………………………..1196
FAILURE CODE [CA731]……………………………………………………………………………………………………………..1197
FAILURE CODE [CA778]……………………………………………………………………………………………………………..1201
FAILURE CODE [CA1117]…………………………………………………………………………………………………………….1203
FAILURE CODE [CA1135]…………………………………………………………………………………………………………….1205
FAILURE CODE [CA1257]…………………………………………………………………………………………………………….1208
FAILURE CODE [CA1664]…………………………………………………………………………………………………………….1209
FAILURE CODE [CA1691]…………………………………………………………………………………………………………….1211
FAILURE CODE [CA1695]…………………………………………………………………………………………………………….1214
FAILURE CODE [CA1696]…………………………………………………………………………………………………………….1216
FAILURE CODE [CA1843]…………………………………………………………………………………………………………….1218
FAILURE CODE [CA1844]…………………………………………………………………………………………………………….1220
FAILURE CODE [CA1879]…………………………………………………………………………………………………………….1222
FAILURE CODE [CA1881]…………………………………………………………………………………………………………….1224
FAILURE CODE [CA1883]…………………………………………………………………………………………………………….1226
FAILURE CODE [CA1921]…………………………………………………………………………………………………………….1229
FAILURE CODE [CA1922]…………………………………………………………………………………………………………….1231
FAILURE CODE [CA1923]…………………………………………………………………………………………………………….1235
FAILURE CODE [CA1924]…………………………………………………………………………………………………………….1237
FAILURE CODE [CA1925]…………………………………………………………………………………………………………….1239
FAILURE CODE [CA1927]…………………………………………………………………………………………………………….1241
FAILURE CODE [CA1928]…………………………………………………………………………………………………………….1243
FAILURE CODE [CA1942]…………………………………………………………………………………………………………….1245
FAILURE CODE [CA1963]…………………………………………………………………………………………………………….1247
FAILURE CODE [CA1977]…………………………………………………………………………………………………………….1251
FAILURE CODE [CA1993]…………………………………………………………………………………………………………….1253
FAILURE CODE [CA2185]…………………………………………………………………………………………………………….1255
FAILURE CODE [CA2186]…………………………………………………………………………………………………………….1256
FAILURE CODE [CA2249]…………………………………………………………………………………………………………….1258
FAILURE CODE [CA2265]…………………………………………………………………………………………………………….1263
FAILURE CODE [CA2266]…………………………………………………………………………………………………………….1265
FAILURE CODE [CA2271]…………………………………………………………………………………………………………….1267
FAILURE CODE [CA2272]…………………………………………………………………………………………………………….1269
FAILURE CODE [CA2349]…………………………………………………………………………………………………………….1271
FAILURE CODE [CA2353]…………………………………………………………………………………………………………….1273
FAILURE CODE [CA2357]…………………………………………………………………………………………………………….1275
FAILURE CODE [CA2381]…………………………………………………………………………………………………………….1278
FAILURE CODE [CA2382]…………………………………………………………………………………………………………….1280
FAILURE CODE [CA2383]…………………………………………………………………………………………………………….1282
FAILURE CODE [CA2386]…………………………………………………………………………………………………………….1284
FAILURE CODE [CA2387]…………………………………………………………………………………………………………….1286
TROUBLESHOOTING FLOWCHART……………………………………………………………………………………………………..1290
FAILURE CODE [CA2555]…………………………………………………………………………………………………………….1291
FAILURE CODE [CA2556]…………………………………………………………………………………………………………….1293
FAILURE CODE [CA2637]…………………………………………………………………………………………………………….1295
FAILURE CODE [CA2639]…………………………………………………………………………………………………………….1298
FAILURE CODE [CA2732]…………………………………………………………………………………………………………….1300
FAILURE CODE [CA2733]…………………………………………………………………………………………………………….1302
FAILURE CODE [CA2741]…………………………………………………………………………………………………………….1304
FAILURE CODE [CA2765]…………………………………………………………………………………………………………….1305
FAILURE CODE [CA2777]…………………………………………………………………………………………………………….1306
FAILURE CODE [CA2878]…………………………………………………………………………………………………………….1308
FAILURE CODE [CA2881]…………………………………………………………………………………………………………….1311
FAILURE CODE [CA3133]…………………………………………………………………………………………………………….1315
FAILURE CODE [CA3134]…………………………………………………………………………………………………………….1317
FAILURE CODE [CA3135]…………………………………………………………………………………………………………….1319
FAILURE CODE [CA3167]…………………………………………………………………………………………………………….1322
FAILURE CODE [CA3251]…………………………………………………………………………………………………………….1325
FAILURE CODE [CA3253]…………………………………………………………………………………………………………….1327
FAILURE CODE [CA3254]…………………………………………………………………………………………………………….1332
FAILURE CODE [CA3255]…………………………………………………………………………………………………………….1335
FAILURE CODE [CA3256]…………………………………………………………………………………………………………….1338
FAILURE CODE [CA3311]…………………………………………………………………………………………………………….1340
FAILURE CODE [CA3312]…………………………………………………………………………………………………………….1342
FAILURE CODE [CA3313]…………………………………………………………………………………………………………….1344
FAILURE CODE [CA3314]…………………………………………………………………………………………………………….1345
FAILURE CODE [CA3315]…………………………………………………………………………………………………………….1346
FAILURE CODE [CA3316]…………………………………………………………………………………………………………….1349
FAILURE CODE [CA3317]…………………………………………………………………………………………………………….1350
FAILURE CODE [CA3318]…………………………………………………………………………………………………………….1351
FAILURE CODE [CA3319]…………………………………………………………………………………………………………….1354
FAILURE CODE [CA3321]…………………………………………………………………………………………………………….1355
FAILURE CODE [CA3322]…………………………………………………………………………………………………………….1356
FAILURE CODE [CA3419]…………………………………………………………………………………………………………….1359
FAILURE CODE [CA3421]…………………………………………………………………………………………………………….1361
FAILURE CODE [CA4151]…………………………………………………………………………………………………………….1363
FAILURE CODE [CA4158]…………………………………………………………………………………………………………….1366
FAILURE CODE [CA4161]…………………………………………………………………………………………………………….1367
FAILURE CODE [CA4162]…………………………………………………………………………………………………………….1369
FAILURE CODE [CA4163]…………………………………………………………………………………………………………….1371
FAILURE CODE [CA4259]…………………………………………………………………………………………………………….1373
FAILURE CODE [CA4952]…………………………………………………………………………………………………………….1375
FAILURE CODE [CA5383]…………………………………………………………………………………………………………….1377
FAILURE CODE [CB115]……………………………………………………………………………………………………………..1378
FAILURE CODE [CB187]……………………………………………………………………………………………………………..1381
FAILURE CODE [CB227]……………………………………………………………………………………………………………..1383
FAILURE CODE [CB238]……………………………………………………………………………………………………………..1384
FAILURE CODE [CB239]……………………………………………………………………………………………………………..1386
FAILURE CODE [CB271]……………………………………………………………………………………………………………..1388
FAILURE CODE [CB272]……………………………………………………………………………………………………………..1390
FAILURE CODE [CB273]……………………………………………………………………………………………………………..1391
FAILURE CODE [CB274]……………………………………………………………………………………………………………..1393
FAILURE CODE [CB343]……………………………………………………………………………………………………………..1394
FAILURE CODE [CB352]……………………………………………………………………………………………………………..1396
FAILURE CODE [CB386]……………………………………………………………………………………………………………..1398
FAILURE CODE [CB441]……………………………………………………………………………………………………………..1400
FAILURE CODE [CB442]……………………………………………………………………………………………………………..1402
FAILURE CODE [CB689]……………………………………………………………………………………………………………..1404
FAILURE CODE [CB697]……………………………………………………………………………………………………………..1406
FAILURE CODE [CB698]……………………………………………………………………………………………………………..1407
FAILURE CODE [CB731]……………………………………………………………………………………………………………..1408
FAILURE CODE [CB778]……………………………………………………………………………………………………………..1412
FAILURE CODE [CB1117]…………………………………………………………………………………………………………….1414
FAILURE CODE [CB1257]…………………………………………………………………………………………………………….1416
FAILURE CODE [CB1664]…………………………………………………………………………………………………………….1417
FAILURE CODE [CB1691]…………………………………………………………………………………………………………….1419
FAILURE CODE [CB1695]…………………………………………………………………………………………………………….1422
FAILURE CODE [CB1696]…………………………………………………………………………………………………………….1424
FAILURE CODE [CB1879]…………………………………………………………………………………………………………….1426
FAILURE CODE [CB1881]…………………………………………………………………………………………………………….1428
FAILURE CODE [CB1883]…………………………………………………………………………………………………………….1430
FAILURE CODE [CB1921]…………………………………………………………………………………………………………….1433
FAILURE CODE [CB1922]…………………………………………………………………………………………………………….1435
FAILURE CODE [CB1923]…………………………………………………………………………………………………………….1439
FAILURE CODE [CB1924]…………………………………………………………………………………………………………….1441
FAILURE CODE [CB1925]…………………………………………………………………………………………………………….1443
FAILURE CODE [CB1927]…………………………………………………………………………………………………………….1445
FAILURE CODE [CB1928]…………………………………………………………………………………………………………….1447
FAILURE CODE [CB1963]…………………………………………………………………………………………………………….1449
FAILURE CODE [CB1977]…………………………………………………………………………………………………………….1453
FAILURE CODE [CB1993]…………………………………………………………………………………………………………….1455
FAILURE CODE [CB2265]…………………………………………………………………………………………………………….1457
FAILURE CODE [CB2266]…………………………………………………………………………………………………………….1459
FAILURE CODE [CB2637]…………………………………………………………………………………………………………….1461
FAILURE CODE [CB2639]…………………………………………………………………………………………………………….1464
FAILURE CODE [CB2732]…………………………………………………………………………………………………………….1466
FAILURE CODE [CB2733]…………………………………………………………………………………………………………….1468
FAILURE CODE [CB2741]…………………………………………………………………………………………………………….1470
FAILURE CODE [CB2777]…………………………………………………………………………………………………………….1472
FAILURE CODE [CB2878]…………………………………………………………………………………………………………….1474
FAILURE CODE [CB2881]…………………………………………………………………………………………………………….1477
FAILURE CODE [CB3133]…………………………………………………………………………………………………………….1481
FAILURE CODE [CB3134]…………………………………………………………………………………………………………….1483
FAILURE CODE [CB3135]…………………………………………………………………………………………………………….1485
FAILURE CODE [CB3167]…………………………………………………………………………………………………………….1488
FAILURE CODE [CB3251]…………………………………………………………………………………………………………….1491
FAILURE CODE [CB3253]…………………………………………………………………………………………………………….1493
FAILURE CODE [CB3254]…………………………………………………………………………………………………………….1498
FAILURE CODE [CB3255]…………………………………………………………………………………………………………….1501
FAILURE CODE [CB3256]…………………………………………………………………………………………………………….1504
FAILURE CODE [CB3311]…………………………………………………………………………………………………………….1506
FAILURE CODE [CB3312]…………………………………………………………………………………………………………….1508
FAILURE CODE [CB3313]…………………………………………………………………………………………………………….1510
FAILURE CODE [CB3314]…………………………………………………………………………………………………………….1511
FAILURE CODE [CB3315]…………………………………………………………………………………………………………….1512
FAILURE CODE [CB3316]…………………………………………………………………………………………………………….1515
FAILURE CODE [CB3317]…………………………………………………………………………………………………………….1516
FAILURE CODE [CB3318]…………………………………………………………………………………………………………….1517
FAILURE CODE [CB3319]…………………………………………………………………………………………………………….1520
FAILURE CODE [CB3321]…………………………………………………………………………………………………………….1521
FAILURE CODE [CB3322]…………………………………………………………………………………………………………….1522
FAILURE CODE [CB4151]…………………………………………………………………………………………………………….1525
FAILURE CODE [CB4158]…………………………………………………………………………………………………………….1528
FAILURE CODE [CB4161]…………………………………………………………………………………………………………….1529
FAILURE CODE [CB4162]…………………………………………………………………………………………………………….1531
FAILURE CODE [CB4163]…………………………………………………………………………………………………………….1533
FAILURE CODE [CB4259]…………………………………………………………………………………………………………….1535
FAILURE CODE [CB4952]…………………………………………………………………………………………………………….1537
FAILURE CODE [CB5383]…………………………………………………………………………………………………………….1539
FAILURE CODE [D110KB]…………………………………………………………………………………………………………….1540
FAILURE CODE [D163KB]…………………………………………………………………………………………………………….1542
FAILURE CODE [D195KA]…………………………………………………………………………………………………………….1544
FAILURE CODE [D195KB]…………………………………………………………………………………………………………….1546
FAILURE CODE [D19JKZ]…………………………………………………………………………………………………………….1548
FAILURE CODE [D862KA]…………………………………………………………………………………………………………….1550
FAILURE CODE [D8AQKR]…………………………………………………………………………………………………………….1551
FAILURE CODE [DA20MC]…………………………………………………………………………………………………………….1555
FAILURE CODE [DA22KK]…………………………………………………………………………………………………………….1556
FAILURE CODE [DA25KP]…………………………………………………………………………………………………………….1558
FAILURE CODE [DA26KP]…………………………………………………………………………………………………………….1560
FAILURE CODE [DA29KQ]…………………………………………………………………………………………………………….1562
FAILURE CODE [DA2LKA]…………………………………………………………………………………………………………….1564
FAILURE CODE [DA2LKB]…………………………………………………………………………………………………………….1566
FAILURE CODE [DA2QKR]…………………………………………………………………………………………………………….1568
FAILURE CODE [DA2RKR]…………………………………………………………………………………………………………….1573
FAILURE CODE [DAF0KM]…………………………………………………………………………………………………………….1578
FAILURE CODE [DAF0MB]…………………………………………………………………………………………………………….1579
FAILURE CODE [DAF0MC]…………………………………………………………………………………………………………….1580
FAILURE CODE [DAF9KQ]…………………………………………………………………………………………………………….1581
FAILURE CODE [DAFGMC]…………………………………………………………………………………………………………….1582
FAILURE CODE [DAFLKA]…………………………………………………………………………………………………………….1583
FAILURE CODE [DAFLKB]…………………………………………………………………………………………………………….1586
FAILURE CODE [DAFQKR]…………………………………………………………………………………………………………….1588
FAILURE CODE [DAZ9KQ]…………………………………………………………………………………………………………….1593
FAILURE CODE [DAZQKR]…………………………………………………………………………………………………………….1594
FAILURE CODE [DB2QKR]…………………………………………………………………………………………………………….1597
FAILURE CODE [DB2RKR]…………………………………………………………………………………………………………….1604
FAILURE CODE [DBP0KM]…………………………………………………………………………………………………………….1610
FAILURE CODE [DBP0KT]…………………………………………………………………………………………………………….1611
FAILURE CODE [DBP5KB]…………………………………………………………………………………………………………….1612
FAILURE CODE [DBP5KY]…………………………………………………………………………………………………………….1614
FAILURE CODE [DBPQKR]…………………………………………………………………………………………………………….1616
FAILURE CODE [DBV0MC]…………………………………………………………………………………………………………….1621
FAILURE CODE [DBV1KK]…………………………………………………………………………………………………………….1622
FAILURE CODE [DBV5KB]…………………………………………………………………………………………………………….1624
FAILURE CODE [DBV6KB]…………………………………………………………………………………………………………….1628
FAILURE CODE [DBVLKA]…………………………………………………………………………………………………………….1630
FAILURE CODE [DBVLKB]…………………………………………………………………………………………………………….1632
FAILURE CODE [DBVQKR]…………………………………………………………………………………………………………….1634
FAILURE CODE [DBVRKR]…………………………………………………………………………………………………………….1638
FAILURE CODE [DBVVKR]…………………………………………………………………………………………………………….1642
FAILURE CODE [DBVWKR]…………………………………………………………………………………………………………….1643
FAILURE CODE [DDNRKA]…………………………………………………………………………………………………………….1644
FAILURE CODE [DDNRKY]…………………………………………………………………………………………………………….1646
FAILURE CODE [DDNS00]…………………………………………………………………………………………………………….1648
FAILURE CODE [DGE5KB]…………………………………………………………………………………………………………….1650
FAILURE CODE [DGH2KA]…………………………………………………………………………………………………………….1651
FAILURE CODE [DGH2KB]…………………………………………………………………………………………………………….1653
FAILURE CODE [DGT3KB]…………………………………………………………………………………………………………….1655
FAILURE CODE [DGT4KA]…………………………………………………………………………………………………………….1657
FAILURE CODE [DGT4KB]…………………………………………………………………………………………………………….1659
FAILURE CODE [DHA4KA]…………………………………………………………………………………………………………….1661
FAILURE CODE [DHAAMA]…………………………………………………………………………………………………………….1663
FAILURE CODE [DHABMA]…………………………………………………………………………………………………………….1664
FAILURE CODE [DHACMA]…………………………………………………………………………………………………………….1665
FAILURE CODE [DHADMA]…………………………………………………………………………………………………………….1666
FAILURE CODE [DHPAMA]…………………………………………………………………………………………………………….1667
FAILURE CODE [DHPAZL]…………………………………………………………………………………………………………….1669
FAILURE CODE [DHPBMA]…………………………………………………………………………………………………………….1670
FAILURE CODE [DHPBZL]…………………………………………………………………………………………………………….1672
FAILURE CODE [DHPGMA]…………………………………………………………………………………………………………….1673
FAILURE CODE [DHPGZL]…………………………………………………………………………………………………………….1675
FAILURE CODE [DHPSMA]…………………………………………………………………………………………………………….1676
FAILURE CODE [DHPTKA]…………………………………………………………………………………………………………….1678
FAILURE CODE [DHPTKB]…………………………………………………………………………………………………………….1680
FAILURE CODE [DHS3MA]…………………………………………………………………………………………………………….1682
FAILURE CODE [DHS4MA]…………………………………………………………………………………………………………….1685
FAILURE CODE [DHS8MA]…………………………………………………………………………………………………………….1688
FAILURE CODE [DHS9MA]…………………………………………………………………………………………………………….1691
FAILURE CODE [DHSAMA]…………………………………………………………………………………………………………….1694
FAILURE CODE [DHSBMA]…………………………………………………………………………………………………………….1697
FAILURE CODE [DHSCMA]…………………………………………………………………………………………………………….1700
FAILURE CODE [DHSDMA]…………………………………………………………………………………………………………….1703
FAILURE CODE [DHSFMA]…………………………………………………………………………………………………………….1706
FAILURE CODE [DHSGMA]…………………………………………………………………………………………………………….1709
FAILURE CODE [DHSHMA]…………………………………………………………………………………………………………….1712
FAILURE CODE [DHSJMA]…………………………………………………………………………………………………………….1715
FAILURE CODE [DKR2KA]…………………………………………………………………………………………………………….1718
FAILURE CODE [DKR2KB]…………………………………………………………………………………………………………….1720
FAILURE CODE [DKR2NX]…………………………………………………………………………………………………………….1722
FAILURE CODE [DKR3KA]…………………………………………………………………………………………………………….1724
FAILURE CODE [DKR3KB]…………………………………………………………………………………………………………….1726
FAILURE CODE [DKR3NX]…………………………………………………………………………………………………………….1728
FAILURE CODE [DKULKA]…………………………………………………………………………………………………………….1730
FAILURE CODE [DKULKB]…………………………………………………………………………………………………………….1732
FAILURE CODE [DKULKY]…………………………………………………………………………………………………………….1734
FAILURE CODE [DLM3KA]…………………………………………………………………………………………………………….1736
FAILURE CODE [DLM3KB]…………………………………………………………………………………………………………….1738
FAILURE CODE [DLM3MB]…………………………………………………………………………………………………………….1740
FAILURE CODE [DR10KA]…………………………………………………………………………………………………………….1741
FAILURE CODE [DR12KA]…………………………………………………………………………………………………………….1744
FAILURE CODE [DR20KA]…………………………………………………………………………………………………………….1746
FAILURE CODE [DR30KA]…………………………………………………………………………………………………………….1748
FAILURE CODE [DR40KA]…………………………………………………………………………………………………………….1750
FAILURE CODE [DUMBKA]…………………………………………………………………………………………………………….1752
FAILURE CODE [DUMBKB]…………………………………………………………………………………………………………….1755
FAILURE CODE [DV20KB]…………………………………………………………………………………………………………….1757
FAILURE CODE [DW41KA]…………………………………………………………………………………………………………….1759
FAILURE CODE [DW41KB]…………………………………………………………………………………………………………….1761
FAILURE CODE [DW41KY]…………………………………………………………………………………………………………….1762
FAILURE CODE [DW43KA]…………………………………………………………………………………………………………….1763
FAILURE CODE [DW43KB]…………………………………………………………………………………………………………….1765
FAILURE CODE [DW43KY]…………………………………………………………………………………………………………….1766
FAILURE CODE [DW45KA]…………………………………………………………………………………………………………….1767
FAILURE CODE [DW45KB]…………………………………………………………………………………………………………….1770
FAILURE CODE [DW45KY]…………………………………………………………………………………………………………….1773
FAILURE CODE [DW48KA]…………………………………………………………………………………………………………….1775
FAILURE CODE [DW48KB]…………………………………………………………………………………………………………….1777
FAILURE CODE [DW48KY]…………………………………………………………………………………………………………….1779
FAILURE CODE [DW4CKY]…………………………………………………………………………………………………………….1780
FAILURE CODE [DW7BKA]…………………………………………………………………………………………………………….1782
FAILURE CODE [DW7BKB]…………………………………………………………………………………………………………….1784
FAILURE CODE [DW7BKY]…………………………………………………………………………………………………………….1786
FAILURE CODE [DW91KA]…………………………………………………………………………………………………………….1787
FAILURE CODE [DW91KB]…………………………………………………………………………………………………………….1789
FAILURE CODE [DW91KY]…………………………………………………………………………………………………………….1790
FAILURE CODE [DWA5KA]…………………………………………………………………………………………………………….1791
FAILURE CODE [DWA5KB]…………………………………………………………………………………………………………….1793
FAILURE CODE [DWA5KY]…………………………………………………………………………………………………………….1795
FAILURE CODE [DWK0KA]…………………………………………………………………………………………………………….1797
FAILURE CODE [DWK0KB]…………………………………………………………………………………………………………….1799
FAILURE CODE [DWK0KY]…………………………………………………………………………………………………………….1801
FAILURE CODE [DWK2KA]…………………………………………………………………………………………………………….1802
FAILURE CODE [DWK2KB]…………………………………………………………………………………………………………….1804
FAILURE CODE [DWK2KY]…………………………………………………………………………………………………………….1806
FAILURE CODE [DWK8KA]…………………………………………………………………………………………………………….1807
FAILURE CODE [DWK8KB]…………………………………………………………………………………………………………….1809
FAILURE CODE [DWK8KY]…………………………………………………………………………………………………………….1811
FAILURE CODE [DX16KA]…………………………………………………………………………………………………………….1812
FAILURE CODE [DX16KB]…………………………………………………………………………………………………………….1814
FAILURE CODE [DXA0KA]…………………………………………………………………………………………………………….1816
FAILURE CODE [DXA0KB]…………………………………………………………………………………………………………….1819
FAILURE CODE [DXAXKA]…………………………………………………………………………………………………………….1821
FAILURE CODE [DXAXKB]…………………………………………………………………………………………………………….1823
FAILURE CODE [DY20KA]…………………………………………………………………………………………………………….1825
FAILURE CODE [DY20KA]…………………………………………………………………………………………………………….1827
FAILURE CODE [DY20MA]…………………………………………………………………………………………………………….1830
FAILURE CODE [DY20MA]…………………………………………………………………………………………………………….1832
FAILURE CODE [DY2CKB]…………………………………………………………………………………………………………….1835
FAILURE CODE [DY2DKB]…………………………………………………………………………………………………………….1837
FAILURE CODE [DY2DKB]…………………………………………………………………………………………………………….1839
FAILURE CODE [DY2EKB]…………………………………………………………………………………………………………….1842
FAILURE CODE [DY2EKB]…………………………………………………………………………………………………………….1844
FAILURE CODE [DY2FMA]…………………………………………………………………………………………………………….1847
FAILURE CODE [DY2GKM]…………………………………………………………………………………………………………….1849
FAILURE CODE [F@BYNR]…………………………………………………………………………………………………………….1851
FAILURE CODE [F@BYNS]…………………………………………………………………………………………………………….1852
FAILURE CODE [J100KA]…………………………………………………………………………………………………………….1853
FAILURE CODE [J100KB]…………………………………………………………………………………………………………….1855
FAILURE CODE [J100L6]…………………………………………………………………………………………………………….1857
FAILURE CODE [J190KA]…………………………………………………………………………………………………………….1858
FAILURE CODE [J190KB]…………………………………………………………………………………………………………….1860
FAILURE CODE [J190L6]…………………………………………………………………………………………………………….1862
FAILURE CODE [LA10ZL]…………………………………………………………………………………………………………….1863
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…………………………………………………………………………………………..1864
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)……………………………………………………………………………………1864
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK………………………………………………………………………………………….1871
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK……………………………………………………………………………………….1874
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP………………………………………………………………….1876
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING……………………………………………………..1878
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW………………………1881
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW…………………1882
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING……………………………………………………….1883
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING………………………………………………………..1884
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING…………………………………………………………..1885
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…………………………………………………………………….1886
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING………………………………………………………………………1887
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING………………………………………………………..1888
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING………………………………………………………………1889
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…………………………………………………………1890
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM…………………………………………………………………………1891
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL…………………………………………………………………………….1893
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM……………………………………………………..1894
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE…………………………………………………1895
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM………………………………………………………1896
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE……………………………………………………..1898
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED…………………………………………………………………………..1899
E-23 FUNCTION SWITCH DOES NOT OPERATE………………………………………………………………………………………………1900
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)…………………………………………………………………………1901
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF……………………………….1902
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER………………………………………………………………………….1903
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED………………………………………………..1904
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED…………………………………………………..1905
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE…………………………………………………………1906
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE………………………………………………………..1907
E-31 ALARM BUZZER CANNOT BE CANCELED……………………………………………………………………………………………….1908
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION…………………………………………………………..1909
E-33 SERVICE MODE CANNOT BE SELECTED……………………………………………………………………………………………….1910
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE…………………………………………………………………..1911
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK……………………………………………………………………1914
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING……………………………………………………..1916
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE……………………………………….1919
E-38 ALARM DOES NOT SOUND DURING TRAVEL…………………………………………………………………………………………….1921
E-39 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED……………………………………………………………………………1923
E-40 HORN DOES NOT SOUND………………………………………………………………………………………………………….1924
E-41 HORN DOES NOT STOP…………………………………………………………………………………………………………..1927
E-42 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF…………………………………………………………..1929
E-43 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED (SINGLE WIPER SPECIFICATION)…………………………………………………..1930
E-44 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED (DOUBLE WIPER SPECIFICATION)…………………………………………………..1932
E-45 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY……………………………………………………………………………1934
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE……………………………………………………………..1937
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION……………………………………………………………1938
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION……………………………………………………………1939
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION………………………………………………………………1940
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION……………………………………………………………….1941
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…………………………………………………………..1942
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…………………………………………………………..1943
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION………………………………………………………………..1944
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION……………………………………………………………….1945
E-55 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY……………………………………………………………………………………….1946
E-56 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED…………………………………………………………………………………….1947
E-57 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE………………………………………………………………………………………1949
E-58 STEP LIGHT DOES NOT LIGHT UP………………………………………………………………………………………………….1950
E-59 STEP LIGHT DOES NOT GO OUT……………………………………………………………………………………………………1953
E-60 BOOM SHOCKLESS FUNCTION CANNOT BE CANCELED……………………………………………………………………………………..1955
E-61 BOOM SHOCKLESS FUNCTION DOES NOT WORK………………………………………………………………………………………….1957
E-62 BOTTOM DUMP CANNOT BE OPERATED………………………………………………………………………………………………..1958
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)…………………………………………………………………………….1961
H-1 ALL WORK EQUIPMENT, TRAVEL, SWING SPEED OR POWER IS LOW…………………………………………………………………………..1961
H-2 ENGINE SPEED DROPS SIGNIFICANTLY OR ENGINE STALLS………………………………………………………………………………..1963
H-3 ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK………………………………………………………………………………..1964
H-4 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT PUMP……………………………………………………………………………1966
H-5 BOOM SPEED OR POWER IS LOW IN NORMAL MODE……………………………………………………………………………………….1967
H-6 BOOM RAISE SPEED OR POWER IS LOW IN HEAVY LIFT MODE………………………………………………………………………………1968
H-7 BOOM LOWER SPEED OR POWER IS LOW IN MACHINE PUSH UP MODE………………………………………………………………………….1969
H-8 ARM SPEED OR POWER IS LOW……………………………………………………………………………………………………..1970
H-9 BUCKET SPEED OR POWER IS LOW…………………………………………………………………………………………………..1971
H-10 BOOM DOES NOT OPERATE………………………………………………………………………………………………………..1972
H-11 ARM DOES NOT OPERATE…………………………………………………………………………………………………………1973
H-12 BUCKET DOES NOT OPERATE………………………………………………………………………………………………………1974
H-13 HYDRAULIC DRIFT OF BOOM IS LARGE………………………………………………………………………………………………1975
H-14 HYDRAULIC DRIFT OF ARM IS LARGE……………………………………………………………………………………………….1976
H-15 HYDRAULIC DRIFT OF BUCKET IS LARGE…………………………………………………………………………………………….1977
H-16 TIME LAG OF BOOM IS LARGE…………………………………………………………………………………………………….1978
H-17 TIME LAG OF ARM IS LARGE……………………………………………………………………………………………………..1979
H-18 TIME LAG OF BUCKET IS LARGE…………………………………………………………………………………………………..1980
H-19 BOOM SHOCKLESS FUNCTION DOES NOT WORK OR CANNOT BE RELEASED………………………………………………………………………1981
H-20 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS (IT TURNS IN THE SAME DIRECTION WHEN TRAVELING FORWARD AND REVERSE)……….1982
H-21 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS (IT TURNS IN THE DIFFERENT DIRECTIONS WHEN TRAVELING FORWARD AND REVERSE)….1984
H-22 ONLY WHEN OPERATING THE TRAVEL LEVER FULLY, TRAVEL DEVIATION IS LARGE AT START OF TRAVELING………………………………………….1985
H-23 REGARDLESS OF THE STROKE OF THE TRAVEL LEVER, TRAVEL DEVIATION IS LARGE AT START OF TRAVELING………………………………………..1986
H-24 TRAVEL DEVIATION IS LARGE AT COMBINED OPERATION…………………………………………………………………………………1987
H-25 TRAVEL SPEED OR POWER IS LOW………………………………………………………………………………………………….1988
H-26 ONLY THE ONE SIDE TRACK CAN OPERATE (MACHINE DOES NOT TRAVEL EITHER FORWARD OR REVERSE)……………………………………………..1989
H-27 ONLY THE ONE SIDE TRACK CAN OPERATE (MACHINE CAN TRAVEL ONLY FORWARD OR REVERSE)……………………………………………………1990
H-28 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST…………………………………………………………………1991
H-29 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT………………………………………………………………………..1992
H-30 SWINGS ONLY IN ONE DIRECTION………………………………………………………………………………………………….1993
H-31 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)……………………………………………………….1994
H-32 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION…………………………………………………1995
H-33 IN COMBINED OPERATION OF WORK EQUIPMENT, SWING SPEED OR POWER IS LOW………………………………………………………………1996
H-34 WHILE COMBINED OPERATION WITH BOOM IN SWING PRIORITY MODE, SWING SPEED IS LOW OR SWING ACCELERATION PERFORMANCE IS POOR…………………1997
H-35 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)…………………………………………………..1998
H-36 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)…………………………………1999
H-37 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING (BOTH RIGHT AND LEFT)…………………………………………………………..2000
H-38 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING………………………………………………………………………………2001
H-39 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING (BOTH RIGHT AND LEFT)………………………………………………2002
H-40 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING IN ONLY ONE DIRECTION………………………………………………2003
H-41 SWING DRIFT ON A SLOPE IS LARGE……………………………………………………………………………………………….2004
H-42 FAN SPEED IS ABNORMAL (SUCH AS EXCESSIVE NOISE OR VIBRATION OF FAN, OR OVERHEATING)…………………………………………………2005
H-43 BOTTOM DUMP CANNOT BE MOVED…………………………………………………………………………………………………..2006
TROUBLESHOOTING OF ENGINE (S-MODE)…………………………………………………………………………………………………….2007
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)………………………………………………………………………………2007
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION……………………………………………………………..2008
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT………………………………………………………………………………………2009
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)………………………………………..2010
S-4 ENGINE STARTABILITY IS POOR……………………………………………………………………………………………………2011
S-5 ENGINE DOES NOT PICK UP SMOOTHLY……………………………………………………………………………………………….2013
S-6 ENGINE STOPS DURING OPERATION………………………………………………………………………………………………….2015
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE……………………………………………………………………………………………….2017
S-8 ENGINE LACKS POWER……………………………………………………………………………………………………………2018
S-9 KDPF GETS CLOGGED IN A SHORT TIME………………………………………………………………………………………………2020
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE……………………………………………………………………………………………2022
S-11 OIL BECOMES CONTAMINATED QUICKLY………………………………………………………………………………………………2023
S-12 FUEL CONSUMPTION IS EXCESSIVE…………………………………………………………………………………………………2024
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)……………………………………………………………..2025
S-14 OIL PRESSURE DROPS…………………………………………………………………………………………………………..2026
S-15 FUEL MIXES INTO ENGINE OIL……………………………………………………………………………………………………2028
S-16 WATER MIXES INTO ENGINE OIL (MILKY)……………………………………………………………………………………………2029
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)………………………………………………………………………………..2030
S-18 UNUSUAL NOISE IS HEARD……………………………………………………………………………………………………….2032
S-19 VIBRATION IS EXCESSIVE……………………………………………………………………………………………………….2033
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT…………………………………………………………………………………………..2034
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY……………………………………………………………………………………..2035
S-22 ACTIVE REGENERATION TAKES TIME………………………………………………………………………………………………..2036
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION……………………………………………………………………………..2037
50 DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………………2039
CONTENTS……………………………………………………………………………………………………………………………2040
ABBREVIATION LIST……………………………………………………………………………………………………………………2045
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………………2051
HOW TO READ THIS MANUAL…………………………………………………………………………………………………………..2051
COATING MATERIALS LIST……………………………………………………………………………………………………………2053
SPECIAL TOOLS LIST……………………………………………………………………………………………………………….2057
SKETCHES OF SPECIAL TOOLS…………………………………………………………………………………………………………2067
ENGINE AND COOLING SYSTEM…………………………………………………………………………………………………………….2074
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY…………………………………………………………………………………………….2074
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY………………………………………………………………………………………..2074
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY………………………………………………………………………………………2086
REMOVE AND INSTALL INJECTOR ASSEMBLY……………………………………………………………………………………………….2100
METHOD FOR REMOVING INJECTOR ASSEMBLY…………………………………………………………………………………………..2101
METHOD FOR INSTALLING INJECTOR ASSEMBLY…………………………………………………………………………………………2111
REMOVE AND INSTALL FUEL DOSER ASSEMBLY……………………………………………………………………………………………..2124
METHOD FOR REMOVING FUEL DOSER ASSEMBLY…………………………………………………………………………………………2124
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY……………………………………………………………………………………….2127
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY…………………………………………………………………………………………..2130
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY………………………………………………………………………………………2131
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY…………………………………………………………………………………….2170
REMOVE AND INSTALL EGR VALVE ASSEMBLY………………………………………………………………………………………………2221
METHOD FOR REMOVING EGR VALVE ASSEMBLY………………………………………………………………………………………….2221
METHOD FOR INSTALLING EGR VALVE ASSEMBLY………………………………………………………………………………………..2225
REMOVE AND INSTALL EGR COOLER ASSEMBLY……………………………………………………………………………………………..2229
METHOD FOR REMOVING EGR COOLER ASSEMBLY…………………………………………………………………………………………2229
METHOD FOR INSTALLING EGR COOLER ASSEMBLY……………………………………………………………………………………….2235
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY………………………………………………………………………………………….2244
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY……………………………………………………………………………………..2244
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY……………………………………………………………………………………2244
REMOVE AND INSTALL ALTERNATOR BELT…………………………………………………………………………………………………2246
METHOD FOR REMOVING ALTERNATOR BELT…………………………………………………………………………………………….2246
METHOD FOR INSTALLING ALTERNATOR BELT…………………………………………………………………………………………..2247
REMOVE AND INSTALL RADIATOR ASSEMBLY……………………………………………………………………………………………….2249
METHOD FOR REMOVING RADIATOR ASSEMBLY…………………………………………………………………………………………..2249
METHOD FOR INSTALLING RADIATOR ASSEMBLY…………………………………………………………………………………………2253
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY…………………………………………………………………………………….2258
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY………………………………………………………………………………..2258
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY………………………………………………………………………………2263
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY…………………………………………………………………………………………….2269
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY………………………………………………………………………………………..2269
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY………………………………………………………………………………………2275
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY……………………………………………………………………………………….2281
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY…………………………………………………………………………………..2281
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY…………………………………………………………………………………2294
REMOVE AND INSTALL ENGINE PTO AND HYDRAULIC ASSEMBLY…………………………………………………………………………………2306
METHOD FOR REMOVING ENGINE PTO AND HYDRAULIC ASSEMBLY…………………………………………………………………………….2306
METHOD FOR INSTALLING ENGINE PTO AND HYDRAULIC ASSEMBLY…………………………………………………………………………..2322
REMOVE AND INSTALL ENGINE FRONT OIL SEAL……………………………………………………………………………………………2338
METHOD FOR REMOVING ENGINE FRONT OIL SEAL……………………………………………………………………………………….2338
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL……………………………………………………………………………………..2341
REMOVE AND INSTALL ENGINE REAR OIL SEAL…………………………………………………………………………………………….2345
METHOD FOR REMOVING ENGINE REAR OIL SEAL………………………………………………………………………………………..2345
METHOD FOR INSTALLING ENGINE REAR OIL SEAL………………………………………………………………………………………2346
REMOVE AND INSTALL FUEL COOLER ASSEMBLY…………………………………………………………………………………………….2350
METHOD FOR REMOVING FUEL COOLER ASSEMBLY………………………………………………………………………………………..2350
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY………………………………………………………………………………………2351
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY…………………………………………………………………………………………….2353
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY………………………………………………………………………………………..2353
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY………………………………………………………………………………………2359
REMOVE AND INSTALL FUEL TANK ASSEMBLY………………………………………………………………………………………………2366
METHOD FOR REMOVING FUEL TANK ASSEMBLY………………………………………………………………………………………….2366
METHOD FOR INSTALLING FUEL TANK ASSEMBLY………………………………………………………………………………………..2371
REMOVE AND INSTALL KDPF ASSEMBLY…………………………………………………………………………………………………..2376
METHOD FOR REMOVING KDPF ASSEMBLY………………………………………………………………………………………………2376
METHOD FOR INSTALLING KDPF ASSEMBLY…………………………………………………………………………………………….2382
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY…………………………………………………………………………………………..2389
METHOD FOR DISASSEMBLING KDPF ASSEMBLY………………………………………………………………………………………….2390
METHOD FOR ASSEMBLING KDPF ASSEMBLY…………………………………………………………………………………………….2395
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY……………………………………………………………………………………………2403
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY……………………………………………………………………………………….2403
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY……………………………………………………………………………………..2407
REMOVE AND INSTALL KCCV ASSEMBLY…………………………………………………………………………………………………..2411
METHOD FOR REMOVING KCCV ASSEMBLY………………………………………………………………………………………………2411
METHOD FOR INSTALLING KCCV ASSEMBLY…………………………………………………………………………………………….2413
REMOVE AND INSTALL AIR CLEANER ASSEMBLY…………………………………………………………………………………………….2415
METHOD FOR REMOVING AIR CLEANER ASSEMBLY………………………………………………………………………………………..2415
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY………………………………………………………………………………………2415
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY……………………………………………………………………………….2417
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY…………………………………………………………………………..2417
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY…………………………………………………………………………2418
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY………………………………………………………………………………..2420
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY……………………………………………………………………………2420
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY………………………………………………………………………….2421
POWER TRAIN…………………………………………………………………………………………………………………………2424
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY………………………………………………………………………………………………2424
METHOD FOR DISASSEMBLING PTO ASSEMBLY…………………………………………………………………………………………..2424
METHOD FOR ASSEMBLING PTO ASSEMBLY……………………………………………………………………………………………..2426
REMOVE AND INSTALL PTO ASSEMBLY……………………………………………………………………………………………………2430
METHOD FOR REMOVING PTO ASSEMBLY……………………………………………………………………………………………….2430
METHOD FOR INSTALLING PTO ASSEMBLY……………………………………………………………………………………………..2432
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY……………………………………………………………………………..2435
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…………………………………………………………………………2435
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY……………………………………………………………………….2436
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY……………………………………………………………………………………….2437
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY……………………………………………………………………………………2437
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY………………………………………………………………………………………2442
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY…………………………………………………………………………..2450
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY………………………………………………………………………2450
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY…………………………………………………………………….2452
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY……………………………………………………………………………………2455
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY………………………………………………………………………………..2455
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY…………………………………………………………………………………..2459
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY……………………………………………………………………………………………2465
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY……………………………………………………………………………………….2465
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY……………………………………………………………………………………..2466
UNDERCARRIAGE AND FRAME………………………………………………………………………………………………………………2467
REMOVE AND INSTALL IDLER ASSEMBLY………………………………………………………………………………………………….2467
METHOD FOR REMOVING IDLER ASSEMBLY……………………………………………………………………………………………..2467
METHOD FOR INSTALLING IDLER ASSEMBLY……………………………………………………………………………………………2468
DISASSEMBLE AND ASSEMBLE RECOIL SPRING……………………………………………………………………………………………..2469
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING…………………………………………………………………………….2469
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY…………………………………………………………………………………….2470
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY……………………………………………………………………………………………2471
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY……………………………………………………………………………………….2471
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY……………………………………………………………………………………..2472
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY………………………………………………………………………………………….2474
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY……………………………………………………………………………………..2474
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY……………………………………………………………………………………2475
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD…………………………………………………………………………….2476
METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD…………………………………………………………………………2478
METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD……………………………………………………………………………2479
SEPARATION AND CONNECTION OF TRACK ASSEMBLY…………………………………………………………………………………………2482
METHOD FOR SEPARATING TRACK ASSEMBLY……………………………………………………………………………………………2483
METHOD FOR INSTALLING TRACK ASSEMBLY……………………………………………………………………………………………2484
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY…………………………………………………………………………………………….2485
METHOD FOR DISASSEMBLING IDLER ASSEMBLY…………………………………………………………………………………………2485
METHOD FOR ASSEMBLING IDLER ASSEMBLY……………………………………………………………………………………………2487
DISASSEMBLE AND ASSEMBLE AIDLER ADJUSTMENT CYLINDER ASSEMBLY………………………………………………………………………….2490
METHOD FOR DISASSEMBLING AIDLER ADJUSTMENT CYLINDER ASSEMBLY………………………………………………………………………2490
METHOD FOR ASSEMBLING AIDLER ADJUSTMENT CYLINDER ASSEMBLY…………………………………………………………………………2491
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY………………………………………………………………………………………2492
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY…………………………………………………………………………………..2492
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY……………………………………………………………………………………..2493
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY……………………………………………………………………………………..2496
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY…………………………………………………………………………………2496
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY……………………………………………………………………………………2497
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY…………………………………………………………………………………………2499
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY…………………………………………………………………………………….2499
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY…………………………………………………………………………………..2500
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY…………………………………………………………………………………………..2502
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY………………………………………………………………………………………2502
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY…………………………………………………………………………………….2504
HYDRAULIC SYSTEM…………………………………………………………………………………………………………………….2506
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY……………………………………………………………………………………..2506
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY…………………………………………………………………………………2506
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY……………………………………………………………………………….2507
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY………………………………………………………………………………..2509
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY…………………………………………………………………………….2510
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY……………………………………………………………………………….2511
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY………………………………………………………………………………………….2512
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY……………………………………………………………………………………..2512
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY……………………………………………………………………………………2516
REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY………………………………………………………………………………………….2521
METHOD FOR REMOVING HYDRAULIC PUMP ASSEMBLY……………………………………………………………………………………..2521
METHOD FOR INSTALLING HYDRAULIC PUMP ASSEMBLY……………………………………………………………………………………2533
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY…………………………………………………………………………………………..2544
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY………………………………………………………………………………………2544
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY…………………………………………………………………………………….2549
REMOVE AND INSTALL SWING MOTOR ASSEMBLY…………………………………………………………………………………………….2556
METHOD FOR REMOVING SWING MOTOR ASSEMBLY………………………………………………………………………………………..2556
METHOD FOR INSTALLING SWING MOTOR ASSEMBLY………………………………………………………………………………………2557
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY……………………………………………………………………………2559
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY………………………………………………………………………..2559
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY…………………………………………………………………………..2560
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY…………………………………………………………………………………..2562
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY……………………………………………………………………………….2562
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY………………………………………………………………………………….2563
DISASSEMBLE AND ASSEMBLE GREASE GUN ASSEMBLY………………………………………………………………………………………..2565
METHOD FOR DISASSEMBLING GREASE GUN ASSEMBLY…………………………………………………………………………………….2565
METHOD FOR ASSEMBLING GREASE GUN ASSEMBLY……………………………………………………………………………………….2565
WORK EQUIPMENT………………………………………………………………………………………………………………………2566
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY…………………………………………………………………………………………2566
METHOD FOR REMOVING BUCKET CYLINDER ASSEMBLY…………………………………………………………………………………….2566
METHOD FOR INSTALLING BUCKET CYLINDER ASSEMBLY…………………………………………………………………………………..2567
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)……………………………………………………………..2569
REMOVE BUCKET CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)…………………………………………………………………….2569
INSTALL BUCKET CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)……………………………………………………………………2570
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY……………………………………………………………………………………………2572
METHOD FOR REMOVING ARM CYLINDER ASSEMBLY……………………………………………………………………………………….2572
METHOD FOR INSTALLING ARM CYLINDER ASSEMBLY……………………………………………………………………………………..2574
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)………………………………………………………………..2576
REMOVE ARM CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)……………………………………………………………………….2576
INSTALL ARM CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)………………………………………………………………………2578
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY…………………………………………………………………………………………..2580
METHOD FOR REMOVING BOOM CYLINDER ASSEMBLY………………………………………………………………………………………2580
METHOD FOR INSTALLING BOOM CYLINDER ASSEMBLY…………………………………………………………………………………….2581
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)……………………………………………………………….2583
REMOVE BOOM CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)………………………………………………………………………2583
INSTALL BOOM CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)……………………………………………………………………..2584
REMOVE AND INSTALL BUCKET ASSEMBLY…………………………………………………………………………………………………2587
METHOD FOR REMOVING BUCKET ASSEMBLY…………………………………………………………………………………………….2588
METHOD FOR INSTALLING BUCKET ASSEMBLY…………………………………………………………………………………………..2589
REMOVE AND INSTALL BUCKET ASSEMBLY (LOADING SHOVEL SPECIFICATION)……………………………………………………………………..2591
REMOVE BUCKET ASSEMBLY (LOADING SHOVEL SPECIFICATION)…………………………………………………………………………….2591
INSTALL BUCKET ASSEMBLY (LOADING SHOVEL SPECIFICATION)……………………………………………………………………………2592
REMOVE AND INSTALL ARM ASSEMBLY……………………………………………………………………………………………………2594
METHOD FOR REMOVING ARM ASSEMBLY……………………………………………………………………………………………….2594
METHOD FOR INSTALLING ARM ASSEMBLY……………………………………………………………………………………………..2595
REMOVE AND INSTALL ARM ASSEMBLY (LOADING SHOVEL SPECIFICATION)………………………………………………………………………..2597
REMOVE ARM ASSEMBLY (LOADING SHOVEL SPECIFICATION)……………………………………………………………………………….2597
INSTALL ARM ASSEMBLY (LOADING SHOVEL SPECIFICATION)………………………………………………………………………………2598
REMOVE AND INSTALL BOOM ASSEMBLY…………………………………………………………………………………………………..2600
METHOD FOR REMOVING BOOM ASSEMBLY………………………………………………………………………………………………2600
METHOD FOR INSTALLING BOOM ASSEMBLY…………………………………………………………………………………………….2602
REMOVE AND INSTALL BOOM ASSEMBLY (LOADING SHOVEL SPECIFICATION)……………………………………………………………………….2604
REMOVE BOOM ASSEMBLY (LOADING SHOVEL SPECIFICATION)………………………………………………………………………………2604
INSTALL BOOM ASSEMBLY (LOADING SHOVEL SPECIFICATION)……………………………………………………………………………..2606
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY…………………………………………………………………………….2608
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY…………………………………………………………………………2609
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY……………………………………………………………………………2611
DISASSEMBLE AND ASSEMBLE BOTTOM DUMP CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)……………………………………………………2616
DISASSEMBLE BOTTOM DUMP CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)……………………………………………………………2616
ASSEMBLE BOTTOM DUMP CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)………………………………………………………………2622
CAB AND ITS ATTACHMENTS………………………………………………………………………………………………………………2627
REMOVE AND INSTALL TOP GUARD ASSEMBLY………………………………………………………………………………………………2627
METHOD FOR REMOVING TOP GUARD ASSEMBLY………………………………………………………………………………………….2627
METHOD FOR INSTALLING TOP GUARD ASSEMBLY………………………………………………………………………………………..2629
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY………………………………………………………………………………………….2631
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY……………………………………………………………………………………….2631
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY……………………………………………………………………………………..2640
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)………………………………………………………………………………..2650
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)……………………………………………………………………………2652
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)………………………………………………………………………….2652
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY……………………………………………………………………………………………2662
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY……………………………………………………………………………………….2662
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY……………………………………………………………………………………..2665
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY…………………………………………………………………………………………….2671
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY………………………………………………………………………………………..2671
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY………………………………………………………………………………………2677
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY…………………………………………………………………………………….2684
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY………………………………………………………………………………..2684
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY………………………………………………………………………………2689
REMOVE AND INSTALL OPERATOR’S SEAT…………………………………………………………………………………………………2696
METHOD FOR REMOVING OPERATOR’S SEAT…………………………………………………………………………………………….2696
METHOD FOR INSTALLING OPERATOR’S SEAT…………………………………………………………………………………………..2698
REMOVE AND INSTALL SEAT BELT………………………………………………………………………………………………………2701
METHOD FOR REMOVING SEAT BELT………………………………………………………………………………………………….2701
METHOD FOR INSTALLING SEAT BELT………………………………………………………………………………………………..2701
REMOVE AND INSTALL FRONT WIPER ASSEMBLY…………………………………………………………………………………………….2703
METHOD FOR REMOVING FRONT WIPER ASSEMBLY………………………………………………………………………………………..2703
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY………………………………………………………………………………………2708
ELECTRICAL SYSTEM……………………………………………………………………………………………………………………2717
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY……………………………………………………………………………………….2717
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY…………………………………………………………………………………..2717
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY…………………………………………………………………………………2719
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY…………………………………………………………………………………………2722
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY…………………………………………………………………………………….2722
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY…………………………………………………………………………………..2724
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY…………………………………………………………………………………….2727
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY………………………………………………………………………………..2727
METHOD FOR INSTALLING KomVision CONTROLLER………………………………………………………………………………………2728
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY…………………………………………………………………………………………2729
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY…………………………………………………………………………………….2729
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY…………………………………………………………………………………..2731
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR………………………………………………………………………………2735
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR………………………………………………………………………….2735
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR………………………………………………………………………..2736
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR……………………………………………………………………………………2738
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR……………………………………………………………………………….2738
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR……………………………………………………………………………..2739
REMOVE AND INSTALL KomVision CAMERA………………………………………………………………………………………………..2741
METHOD FOR REMOVING KomVision CAMERA……………………………………………………………………………………………2741
METHOD FOR INSTALLING KomVision CAMERA………………………………………………………………………………………….2742
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY………………………………………………………………………………………..2744
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY……………………………………………………………………………………2744
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY………………………………………………………………………………….2746
REMOVE AND INSTALL KOMTRAX Plus CONTROLLER ASSEMBLY………………………………………………………………………………….2748
METHOD FOR REMOVING KOMTRAX Plus CONTROLLER ASSEMBLY……………………………………………………………………………..2748
METHOD FOR INSTALLING KOMTRAX Plus CONTROLLER ASSEMBLY……………………………………………………………………………2749
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY……………………………………………………………………………………….2750
METHOD FOR REMOVING WIRELESS LAN UNIT ASSEMBLY…………………………………………………………………………………..2750
METHOD FOR NSTALLING WIRELESS LAN UNIT ASSEMBLY………………………………………………………………………………….2751
60 MAINTENANCE STANDARD………………………………………………………………………………………………………………….2755
CONTENTS……………………………………………………………………………………………………………………………2756
ABBREVIATION LIST……………………………………………………………………………………………………………………2757
ENGINE AND COOLING SYSTEM…………………………………………………………………………………………………………….2763
MAINTENANCE STANDARD OF ENGINE MOUNT……………………………………………………………………………………………….2763
MAINTENANCE STANDARD FOR PTO………………………………………………………………………………………………………2765
MAINTENANCE STANDARD OF COOLING SYSTEM……………………………………………………………………………………………..2766
MAINTENANCE STANDARD OF COOLING FAN PUMP……………………………………………………………………………………………2768
MAINTENANCE STANDARD OF EPC VALVE OF COOLING FAN PUMP…………………………………………………………………………….2770
MAINTENANCE STANDARD OF COOLING FAN MOTOR…………………………………………………………………………………………..2771
POWER TRAIN…………………………………………………………………………………………………………………………2773
MAINTENANCE STANDARD OF SWING CIRCLE……………………………………………………………………………………………….2773
MAINTENANCE STANDARD OF SWING MACHINERY…………………………………………………………………………………………….2774
MAINTENANCE STANDARD OF FINAL DRIVE………………………………………………………………………………………………..2776
MAINTENANCE STANDARD OF SPROCKET…………………………………………………………………………………………………..2778
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING……………………………………………………………………..2779
UNDERCARRIAGE AND FRAME………………………………………………………………………………………………………………2781
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION………………………………………………………………………………..2781
MAINTENANCE STANDARD OF IDLER……………………………………………………………………………………………………..2783
MAINTENANCE STANDARD OF TRACK ROLLER……………………………………………………………………………………………….2785
MAINTENANCE STANDARD OF CARRIER ROLLER……………………………………………………………………………………………..2786
MAINTENANCE STANDARD OF TRACK SHOE…………………………………………………………………………………………………2787
MAINTENANCE STANDARD OF DOUBLE SHOE………………………………………………………………………………………………..2790
HYDRAULIC SYSTEM…………………………………………………………………………………………………………………….2791
MAINTENANCE STANDARD OF MAIN PUMP………………………………………………………………………………………………….2791
MAINTENANCE STANDARD OF SWING MOTOR………………………………………………………………………………………………..2795
MAINTENANCE STANDARD OF CONTROL VALVE………………………………………………………………………………………………2798
MAINTENANCE STANDARD OF STRAIGHT TRAVEL VALVE OF CONTROL VALVE…………………………………………………………………….2809
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE VALVE…………………………………………………………………………………2810
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE……………………………………………………………………………2811
MAINTENANCE STANDARD OF TRAVEL PPC VALVE……………………………………………………………………………………………2814
MAINTENANCE STANDARD OF SOLENOID VALVE……………………………………………………………………………………………..2816
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT…………………………………………………………………………………………2817
WORK EQUIPMENT………………………………………………………………………………………………………………………2818
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE………………………………………………………………………………………2818
DIMENSION OF ARM……………………………………………………………………………………………………………..2821
DIMENSIONS OF BUCKET………………………………………………………………………………………………………….2823
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE (LOADING SHOVEL SPECIFICATION)…………………………………………………………..2825
DIMENSIONS OF ARM (LOADING SHOVEL SPECIFICATION)…………………………………………………………………………………2828
DIMENSIONS OF BUCKET (LOADING SHOVEL SPECIFICATION)………………………………………………………………………………2830
MAINTENANCE STANDARD OF BOOM CYLINDER………………………………………………………………………………………………2832
MAINTENANCE STANDARD OF BOOM CYLINDER (LOADING SHOVEL SPECIFICATION)…………………………………………………………………..2833
MAINTENANCE STANDARD OF ARM CYLINDER……………………………………………………………………………………………….2834
MAINTENANCE STANDARD OF ARM CYLINDER (LOADING SHOVEL SPECIFICATION)……………………………………………………………………2835
MAINTENANCE STANDARD OF BUCKET CYLINDER…………………………………………………………………………………………….2836
MAINTENANCE STANDARD OF BUCKET CYLINDER (LOADING SHOVEL SPECIFICATION)…………………………………………………………………2837
MAINTENANCE STANDARD OF BOTTOM DUMP CYLINDER (LOADING SHOVEL SPECIFICATION)…………………………………………………………….2838
80 APPENDIX…………………………………………………………………………………………………………………………….2839
CONTENTS……………………………………………………………………………………………………………………………2840
ABBREVIATION LIST……………………………………………………………………………………………………………………2842
AIR CONDITIONER SYSTEM……………………………………………………………………………………………………………….2848
PRECAUTIONS FOR REFRIGERANT……………………………………………………………………………………………………….2848
AIR CONDITIONER COMPONENT…………………………………………………………………………………………………………2849
SPECIFICATIONS OF AIR CONDITIONER………………………………………………………………………………………………….2851
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE……………………………………………………………………………………2852
OUTLINE OF REFRIGERATION CYCLE…………………………………………………………………………………………………….2853
COMPONENT PARTS OF AIR CONDITIONER SYSTEM………………………………………………………………………………………………2855
AIR CONDITIONER UNIT……………………………………………………………………………………………………………..2855
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT……………………………………………………………………………………2855
FUNCTION OF AIR CONDITIONER UNIT……………………………………………………………………………………………….2857
COMPONENT PARTS OF AIR CONDITIONER UNIT…………………………………………………………………………………………….2859
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT………………………………………………………………………….2860
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………………………2860
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………2860
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………………………2860
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………………….2861
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT……………………………………………………………………..2861
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………………………2861
FUNCTION OF DUAL PRESSURE SWITCH……………………………………………………………………………………………….2862
AIR CONDITIONER CONTROLLER………………………………………………………………………………………………………..2863
STRUCTURE OF AIR CONDITIONER CONTROLLER…………………………………………………………………………………………2863
COMPRESSOR………………………………………………………………………………………………………………………2864
STRUCTURE OF COMPRESSOR……………………………………………………………………………………………………….2864
SPECIFICATIONS OF COMPRESSOR…………………………………………………………………………………………………..2864
FUNCTION OF COMPRESSOR………………………………………………………………………………………………………..2864
CONDENSER……………………………………………………………………………………………………………………….2865
STRUCTURE OF CONDENSER………………………………………………………………………………………………………..2865
SPECIFICATIONS OF CONDENSER……………………………………………………………………………………………………2865
FUNCTION OF CONDENSER…………………………………………………………………………………………………………2865
RECEIVER DRIER…………………………………………………………………………………………………………………..2866
STRUCTURE OF RECEIVER DRIER……………………………………………………………………………………………………2866
SPECIFICATIONS OF RECEIVER DRIER……………………………………………………………………………………………….2866
FUNCTION OF RECEIVER DRIER…………………………………………………………………………………………………….2866
SENSORS FOR AIR CONDITIONER SYSTEM…………………………………………………………………………………………………2867
STRUCTURE OF SUNLIGHT SENSOR…………………………………………………………………………………………………..2867
FUNCTION OF SUNLIGHT SENSOR……………………………………………………………………………………………………2867
STRUCTURE OF AMBIENT TEMPERATURE SENSOR…………………………………………………………………………………………2867
FUNCTION OF AMBIENT TEMPERATURE SENSOR………………………………………………………………………………………….2867
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER………………………………………………………………..2869
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER……………………………………………………………………..2871
AIR CONDITIONER SYSTEM DIAGRAM………………………………………………………………………………………………………..2873
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER……………………………………………………………………………….2874
FUNCTION OF AIR CONDITIONER CONTROLLER………………………………………………………………………………………….2875
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS………………………………………………………………2876
TESTING AIR LEAKAGE (DUCT)……………………………………………………………………………………………………………2880
METHOD FOR TESTING AIR LEAKAGE (DUCT)………………………………………………………………………………………………2880
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION……………………………………………………………………………………2882
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR……………………………………………2883
TEST VENT (MODE) CHANGEOVER…………………………………………………………………………………………………………..2884
METHOD FOR TESTING VENT (MODE) CHANGEOVER…………………………………………………………………………………………..2884
TESTING FRESH/RECIRC AIR CHANGEOVER……………………………………………………………………………………………………2886
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER………………………………………………………………………………………2886
TEST SUNLIGHT SENSOR…………………………………………………………………………………………………………………2887
METHOD FOR TESTING SUNLIGHT SENSOR…………………………………………………………………………………………………2887
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT…………………………………………………………………………………………….2888
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT…………………………………………………………………………….2888
TEST RELAYS…………………………………………………………………………………………………………………………2889
METHOD FOR TESTING RELAYS…………………………………………………………………………………………………………2889
AIR CONDITIONER TROUBLESHOOTING CHART 1………………………………………………………………………………………………..2890
AIR CONDITIONER TROUBLESHOOTING CHART 2………………………………………………………………………………………………..2891
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE………………………………………………………………………………………….2894
FAILURE CODE [879AKA]………………………………………………………………………………………………………………..2896
FAILURE CODE [879AKB]………………………………………………………………………………………………………………..2897
FAILURE CODE [879BKA]………………………………………………………………………………………………………………..2898
FAILURE CODE [879BKB]………………………………………………………………………………………………………………..2900
FAILURE CODE [879CKA]………………………………………………………………………………………………………………..2902
FAILURE CODE [879CKB]………………………………………………………………………………………………………………..2903
FAILURE CODE [879DKZ]………………………………………………………………………………………………………………..2904
FAILURE CODE [879EMC]………………………………………………………………………………………………………………..2906
FAILURE CODE [879FMC]………………………………………………………………………………………………………………..2907
FAILURE CODE [879GKX]………………………………………………………………………………………………………………..2908
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)……………………………………………………………..2910
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)………………………………………………………………2912
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)………………………………………………………2915
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER……………………………………………………………………………………..2917
TROUBLESHOOTING USING GAUGE PRESSURE…………………………………………………………………………………………………..2919
CONNECTION OF SERVICE TOOL……………………………………………………………………………………………………………2922
METHOD FOR CONNECTING SERVICE TOOL…………………………………………………………………………………………………2922
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS……………………………………………………..2924
HANDLE COMPRESSOR OIL………………………………………………………………………………………………………………..2926
90 CIRCUIT DIAGRAMS……………………………………………………………………………………………………………………..2929
CONTENTS……………………………………………………………………………………………………………………………2930
ABBREVIATION LIST……………………………………………………………………………………………………………………2931
HYDRAULIC CIRCUIT DIAGRAM…………………………………………………………………………………………………………….2937
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM…………………………………………………………………………………………..2937
HYDRAULIC CIRCUIT DIAGRAM…………………………………………………………………………………………………………2941
HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL SPECIFICATION)……………………………………………………………………………..2943
ELECTRICAL CIRCUIT DIAGRAM……………………………………………………………………………………………………………2945
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM………………………………………………………………………………………….2945
ELECTRICAL CIRCUIT DIAGRAM (1/14)………………………………………………………………………………………………….2949
ELECTRICAL CIRCUIT DIAGRAM (2/14)………………………………………………………………………………………………….2951
ELECTRICAL CIRCUIT DIAGRAM (3/14)………………………………………………………………………………………………….2953
ELECTRICAL CIRCUIT DIAGRAM (4/14)………………………………………………………………………………………………….2955
ELECTRICAL CIRCUIT DIAGRAM (5/14)………………………………………………………………………………………………….2957
ELECTRICAL CIRCUIT DIAGRAM (6/14)………………………………………………………………………………………………….2959
ELECTRICAL CIRCUIT DIAGRAM (7/14)………………………………………………………………………………………………….2961
ELECTRICAL CIRCUIT DIAGRAM (8/14)………………………………………………………………………………………………….2963
ELECTRICAL CIRCUIT DIAGRAM (9/14)………………………………………………………………………………………………….2965
ELECTRICAL CIRCUIT DIAGRAM (10/14)…………………………………………………………………………………………………2967
ELECTRICAL CIRCUIT DIAGRAM (11/14)…………………………………………………………………………………………………2969
ELECTRICAL CIRCUIT DIAGRAM (12/14)…………………………………………………………………………………………………2971
ELECTRICAL CIRCUIT DIAGRAM (13/14)…………………………………………………………………………………………………2973
ELECTRICAL CIRCUIT DIAGRAM (14/14)…………………………………………………………………………………………………2975
ELECTRICAL CIRCUIT DIAGRAM (1/14) (LOADING SHOVEL SPECIFICATION)………………………………………………………………………2977
ELECTRICAL CIRCUIT DIAGRAM (2/14) (LOADING SHOVEL SPECIFICATION)………………………………………………………………………2979
ELECTRICAL CIRCUIT DIAGRAM (3/14) (LOADING SHOVEL SPECIFICATION)………………………………………………………………………2981
ELECTRICAL CIRCUIT DIAGRAM (4/14) (LOADING SHOVEL SPECIFICATION)………………………………………………………………………2983
ELECTRICAL CIRCUIT DIAGRAM (5/14) (LOADING SHOVEL SPECIFICATION)………………………………………………………………………2985
ELECTRICAL CIRCUIT DIAGRAM (6/14) (LOADING SHOVEL SPECIFICATION)………………………………………………………………………2987
ELECTRICAL CIRCUIT DIAGRAM (7/14) (LOADING SHOVEL SPECIFICATION)………………………………………………………………………2989
ELECTRICAL CIRCUIT DIAGRAM (8/14) (LOADING SHOVEL SPECIFICATION)………………………………………………………………………2991
ELECTRICAL CIRCUIT DIAGRAM (9/14) (LOADING SHOVEL SPECIFICATION)………………………………………………………………………2993
ELECTRICAL CIRCUIT DIAGRAM (10/14) (LOADING SHOVEL SPECIFICATION)……………………………………………………………………..2995
ELECTRICAL CIRCUIT DIAGRAM (11/14) (LOADING SHOVEL SPECIFICATION)……………………………………………………………………..2997
ELECTRICAL CIRCUIT DIAGRAM (12/14) (LOADING SHOVEL SPECIFICATION)……………………………………………………………………..2999
ELECTRICAL CIRCUIT DIAGRAM (13/14) (LOADING SHOVEL SPECIFICATION)……………………………………………………………………..3001
ELECTRICAL CIRCUIT DIAGRAM (14/14) (LOADING SHOVEL SPECIFICATION)……………………………………………………………………..3003
INDEX…………………………………………………………………………………………………………………………………..3005