Komatsu PC2000-11 Hydraulic Excavator Shop Manual SEN06651-08 – PDF DOWNLOAD

Komatsu PC2000-11 Hydraulic Excavator Shop Manual SEN06651-08 – PDF DOWNLOAD

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Komatsu PC2000-11 Hydraulic Excavator Shop Manual SEN06651-08 – PDF DOWNLOAD

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Komatsu PC2000-11 Hydraulic Excavator Shop Manual SEN06651-08 – PDF DOWNLOAD

SERIAL NUMBERS 30001 and up

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

TABLE OF CONTENTS:

Komatsu PC2000-11 Hydraulic Excavator Shop Manual SEN06651-08 – PDF DOWNLOAD

COVER………………………………………………………………………………………………………………………………….. 1
00 INDEX AND FOREWORD…………………………………………………………………………………………………………………… 3
INDEX……………………………………………………………………………………………………………………………… 4
ABBREVIATION LIST…………………………………………………………………………………………………………………… 25
FOREWORD, SAFETY, BASIC INFORMATION…………………………………………………………………………………………………… 31
HOW TO READ THE SHOP MANUAL………………………………………………………………………………………………………. 31
SAFETY NOTICE FOR OPERATION………………………………………………………………………………………………………. 33
PRECAUTIONS TO PREVENT FIRE………………………………………………………………………………………………………. 41
ACTIONS IF FIRE OCCURS…………………………………………………………………………………………………………… 43
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS……………………………………………………………………………………….. 44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT……………………………………………………………………………………….. 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS……………………………………………………………………………… 48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT………………………………………………………………………………………. 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT……………………………………………………………………………………… 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT……………………………………………………………………………………. 57
PRACTICAL USE OF KOMTRAX…………………………………………………………………………………………………………. 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER………………………………………………………………………………………. 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER……………………………………………………………… 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER……………………………………………………………… 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER……………………………………………………………… 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS…………………………………………………………………………… 63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR……………………………………………………………………………. 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR…………………………………………………………………….. 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL…………………………………………………………………… 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH…………………………………………………………………… 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE………………………………………………………………. 73
HOW TO READ ELECTRICAL WIRE CODE………………………………………………………………………………………………….. 74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD………………………………………………………………………………………. 78
STANDARD TIGHTENING TORQUE TABLE………………………………………………………………………………………………….. 81
CONVERSION TABLE………………………………………………………………………………………………………………… 88
01 SPECIFICATIONS………………………………………………………………………………………………………………………. 93
CONTENTS…………………………………………………………………………………………………………………………… 94
ABBREVIATION LIST…………………………………………………………………………………………………………………… 95
SPECIFICATIONS……………………………………………………………………………………………………………………… 101
SPECIFICATION DRAWING……………………………………………………………………………………………………………. 101
SPECIFICATION DRAWING: PC2000-11………………………………………………………………………………………………. 101
WORKING RANGE DRAWINGS…………………………………………………………………………………………………………… 103
WORKING RANGE: PC2000-11……………………………………………………………………………………………………… 103
SPECIFICATIONS………………………………………………………………………………………………………………….. 104
SPECIFICATIONS: PC2000-11…………………………………………………………………………………………………….. 104
WEIGHT TABLE……………………………………………………………………………………………………………………. 107
WEIGHT TABLE: PC2000-11………………………………………………………………………………………………………. 107
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA)………………………………………………………………………………………. 111
USE OF FUEL, COOLANT AND LUBRICANTS TO ACCORDING TO AMBIENT TEMPERATURE……………………………………………………………. 111
10 STRUCTURE AND FUNCTION……………………………………………………………………………………………………………….. 115
CONTENTS…………………………………………………………………………………………………………………………… 116
ABBREVIATION LIST…………………………………………………………………………………………………………………… 120
BOOT-UP SYSTEM……………………………………………………………………………………………………………………… 126
LAYOUT DRAWING OF BOOT-UP SYSTEM………………………………………………………………………………………………….. 126
SYSTEM OPERATING LAMP SYSTEM……………………………………………………………………………………………………… 127
SYSTEM OPERATING LAMP SYSTEM DIAGRAM…………………………………………………………………………………………… 127
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM……………………………………………………………………………………….. 127
BATTERY ISOLATOR………………………………………………………………………………………………………………… 129
LAYOUT DRAWING OF BATTERY ISOLATOR…………………………………………………………………………………………….. 129
FUNCTION OF BATTERY ISOLATOR………………………………………………………………………………………………….. 129
FUNCTION OF STARTING MOTOR ISOLATOR SWITCH……………………………………………………………………………………… 130
ENGINE SYSTEM………………………………………………………………………………………………………………………. 131
LAYOUT DRAWING OF ENGINE SYSTEM…………………………………………………………………………………………………… 131
FUNCTION OF ENGINE SYSTEM…………………………………………………………………………………………………….. 132
ENGINE CONTROL SYSTEM……………………………………………………………………………………………………………. 133
ENGINE CONTROL SYSTEM DIAGRAM…………………………………………………………………………………………………. 133
OPERATION OF ENGINE CONTROL SYSTEM…………………………………………………………………………………………….. 134
AUTO-DECELERATION SYSTEM…………………………………………………………………………………………………………. 135
AUTO-DECELERATION SYSTEM DIAGRAM………………………………………………………………………………………………. 135
FUNCTION OF AUTO-DECELERATION SYSTEM…………………………………………………………………………………………… 136
OPERATION OF AUTO-DECELERATION SYSTEM………………………………………………………………………………………….. 136
AUTOMATIC LOW IDLE SYSTEM………………………………………………………………………………………………………… 137
AUTOMATIC LOW IDLE SYSTEM DIAGRAM……………………………………………………………………………………………… 137
FUNCTION OF AUTOMATIC LOW IDLE SYSTEM………………………………………………………………………………………….. 137
OPERATION OF AUTOMATIC LOW IDLE SYSTEM…………………………………………………………………………………………. 138
ENGINE AUTOMATIC WARM-UP SYSTEM…………………………………………………………………………………………………… 139
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM………………………………………………………………………………………… 139
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM…………………………………………………………………………………….. 140
OVERHEAT PREVENTION SYSTEM……………………………………………………………………………………………………….. 141
OVERHEAT PREVENTION SYSTEM DIAGRAM…………………………………………………………………………………………….. 141
FUNCTION OF OVERHEAT PREVENTION SYSTEM…………………………………………………………………………………………. 142
TURBOCHARGER PROTECTION SYSTEM……………………………………………………………………………………………………. 143
TURBOCHARGER PROTECTION SYSTEM DIAGRAM…………………………………………………………………………………………. 143
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM……………………………………………………………………………………… 143
MULTIPLE INJECTION CONTROL SYSTEM…………………………………………………………………………………………………. 145
FUNCTION OF MULTIPLE INJECTION CONTROL SYSTEM…………………………………………………………………………………… 145
COMPONENT PARTS OF ENGINE SYSTEM………………………………………………………………………………………………….. 146
PTO………………………………………………………………………………………………………………………… 146
VGT………………………………………………………………………………………………………………………… 149
EGR SYSTEM………………………………………………………………………………………………………………….. 153
EGR VALVE…………………………………………………………………………………………………………………… 157
EGR COOLER………………………………………………………………………………………………………………….. 159
KCCV SYSTEM…………………………………………………………………………………………………………………. 160
KCCV VENTILATOR……………………………………………………………………………………………………………… 163
KDPF……………………………………………………………………………………………………………………….. 165
COOLING SYSTEM……………………………………………………………………………………………………………………… 169
LAYOUT DRAWING OF COOLING SYSTEM………………………………………………………………………………………………….. 169
SPECIFICATIONS OF COOLING SYSTEM………………………………………………………………………………………………. 170
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN………………………………………………………………………………………….. 171
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN……………………………………………………………………………….. 171
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN……………………………………………………………………………. 172
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN………………………………………………………………………………………. 173
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN……………………………………………………………………………. 173
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN………………………………………………………………………… 173
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN……………………………………………………………………………………….. 174
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN…………………………………………………………………………….. 174
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN…………………………………………………………………………. 174
COMPONENT PARTS OF COOLING SYSTEM…………………………………………………………………………………………………. 175
COOLING FAN PUMP…………………………………………………………………………………………………………….. 175
COOLING FAN MOTOR……………………………………………………………………………………………………………. 190
CONTROL SYSTEM……………………………………………………………………………………………………………………… 197
LAYOUT DRAWING OF CONTROL SYSTEM………………………………………………………………………………………………….. 197
MACHINE MONITOR SYSTEM…………………………………………………………………………………………………………… 199
MACHINE MONITOR SYSTEM DIAGRAM………………………………………………………………………………………………… 199
KOMTRAX Plus SYSTEM……………………………………………………………………………………………………………… 201
KOMTRAX Plus SYSTEM DIAGRAM…………………………………………………………………………………………………… 201
FUNCTION OF KOMTRAX Plus SYSTEM……………………………………………………………………………………………….. 201
COMPONENT PARTS OF CONTROL SYSTEM…………………………………………………………………………………………………. 206
MACHINE MONITOR……………………………………………………………………………………………………………… 206
KOMTRAX TERMINAL…………………………………………………………………………………………………………….. 222
KOMTRAX Plus CONTROLLER………………………………………………………………………………………………………. 224
WIRELESS LAN UNIT……………………………………………………………………………………………………………. 229
PUMP CONTROLLER……………………………………………………………………………………………………………… 230
VALVE CONTROLLER 1…………………………………………………………………………………………………………… 234
VALVE CONTROLLER 2…………………………………………………………………………………………………………… 238
RESISTOR FOR PUMP SECONDARY DRIVE……………………………………………………………………………………………… 242
CAN TERMINATING RESISTOR……………………………………………………………………………………………………… 243
ENGINE CONTROLLER……………………………………………………………………………………………………………. 244
FUEL CONTROL DIAL……………………………………………………………………………………………………………. 258
FUEL FEED PUMP………………………………………………………………………………………………………………. 259
FUEL FEED PUMP SWITCH………………………………………………………………………………………………………… 260
HYDRAULIC SYSTEM……………………………………………………………………………………………………………………. 261
LAYOUT DRAWING OF HYDRAULIC SYSTEM………………………………………………………………………………………………… 261
ELECTRONIC OLSS…………………………………………………………………………………………………………………. 264
STRUCTURE OF ELECTRONIC OLSS………………………………………………………………………………………………….. 264
FUNCTION OF ELECTRONIC OLSS…………………………………………………………………………………………………… 265
ENGINE AND PUMP COMBINED CONTROL SYSTEM……………………………………………………………………………………………. 267
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM…………………………………………………………………………………. 267
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM……………………………………………………………………………… 268
COMPONENT PARTS OF HYDRAULIC SYSTEM……………………………………………………………………………………………….. 271
HYDRAULIC TANK………………………………………………………………………………………………………………. 271
MAIN PUMP…………………………………………………………………………………………………………………… 273
CONTROL VALVE……………………………………………………………………………………………………………….. 292
VARIABLE BACK PRESSURE VALVE………………………………………………………………………………………………….. 325
WORK EQUIPMENT SYSTEM……………………………………………………………………………………………………………….. 328
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM……………………………………………………………………………………………. 328
WORK EQUIPMENT SYSTEM DIAGRAM…………………………………………………………………………………………………….. 334
MACHINE PUSH-UP SYSTEM…………………………………………………………………………………………………………… 335
MACHINE PUSH-UP SYSTEM DIAGRAM………………………………………………………………………………………………… 335
FUNCTION OF MACHINE PUSH-UP SYSTEM…………………………………………………………………………………………….. 335
HEAVY LIFT SYSTEM……………………………………………………………………………………………………………….. 337
HEAVY LIFT SYSTEM DIAGRAM…………………………………………………………………………………………………….. 337
FUNCTION OF HEAVY LIFT SYSTEM…………………………………………………………………………………………………. 337
OPERATION OF HEAVY LIFT SYSTEM………………………………………………………………………………………………… 338
BOOM SHOCKLESS CONTROL FUNCTION…………………………………………………………………………………………………… 339
BOOM SHOCKLESS CONTROL FUNCTION SYSTEM DIAGRAM………………………………………………………………………………….. 339
OPERATION OF BOOM SHOCKLESS CONTROL FUNCTION……………………………………………………………………………………. 339
PPC LOCK SYSTEM…………………………………………………………………………………………………………………. 340
PPC LOCK SYSTEM DIAGRAM………………………………………………………………………………………………………. 340
FUNCTION OF PPC LOCK SYSTEM…………………………………………………………………………………………………… 340
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM…………………………………………………………………………………….. 341
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM………………………………………………………………………….. 341
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM………………………………………………………………………. 341
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM……………………………………………………………………… 341
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM…………………………………………………………………………………………… 343
WORK EQUIPMENT AND SWING PPC VALVE…………………………………………………………………………………………….. 343
SUCTION SELECTOR VALVE……………………………………………………………………………………………………….. 349
PPC CUT-OFF VALVE……………………………………………………………………………………………………………. 352
SOLENOID VALVE………………………………………………………………………………………………………………. 357
PILOT CIRCUIT ACCUMULATOR…………………………………………………………………………………………………….. 360
SWING SYSTEM……………………………………………………………………………………………………………………….. 361
LAYOUT DRAWING OF SWING SYSTEM……………………………………………………………………………………………………. 361
SWING CONTROL SYSTEM DIAGRAM……………………………………………………………………………………………………… 364
FUNCTION OF SWING CONTROL SYSTEM………………………………………………………………………………………………. 364
SWING PRIORITY SYSTEM DIAGRAM…………………………………………………………………………………………………….. 367
OPERATION OF SWING PRIORITY SYSTEM…………………………………………………………………………………………….. 368
COMPONENT PARTS OF SWING SYSTEM…………………………………………………………………………………………………… 369
SWING MOTOR…………………………………………………………………………………………………………………. 369
SWING MACHINERY……………………………………………………………………………………………………………… 379
SWING CIRCLE………………………………………………………………………………………………………………… 381
TRAVEL SYSTEM………………………………………………………………………………………………………………………. 382
LAYOUT DRAWING OF TRAVEL SYSTEM…………………………………………………………………………………………………… 382
TRAVEL CONTROL SYSTEM DIAGRAM…………………………………………………………………………………………………….. 386
TRAVEL STRAIGHT SYSTEM DIAGRAM……………………………………………………………………………………………………. 387
OPERATION OF TRAVEL STRAIGHT SYSTEM……………………………………………………………………………………………. 388
HIC SYSTEM……………………………………………………………………………………………………………………… 390
LAYOUT DRAWING OF HIC SYSTEM………………………………………………………………………………………………….. 390
HIC SYSTEM DIAGRAM…………………………………………………………………………………………………………… 391
OPERATION OF HIC SYSTEM………………………………………………………………………………………………………. 391
COMPONENT PARTS OF TRAVEL SYSTEM………………………………………………………………………………………………….. 394
TRAVEL MOTOR………………………………………………………………………………………………………………… 394
FINAL DRIVE…………………………………………………………………………………………………………………. 407
TRAVEL PPC VALVE…………………………………………………………………………………………………………….. 409
CENTER SWIVEL JOINT………………………………………………………………………………………………………….. 413
ACCUMULATOR FOR HIC SYSTEM……………………………………………………………………………………………………….. 414
STRUCTURE OF ACCUMULATOR FOR HIC SYSTEM………………………………………………………………………………………… 414
SPECIFICATIONS OF ACCUMULATOR FOR HIC SYSTEM……………………………………………………………………………………. 414
LIFTING SYSTEM……………………………………………………………………………………………………………………… 415
HYDRAULICALLY OPERATED STAIRWAY SYSTEM…………………………………………………………………………………………….. 415
LAYOUT DRAWING OF HYDRAULICALLY OPERATED STAIRWAY SYSTEM…………………………………………………………………………. 415
HYDRAULICALLY OPERATED STAIRWAY SYSTEM DIAGRAM………………………………………………………………………………….. 416
FUNCTION OF HYDRAULICALLY OPERATED STAIRWAY SYSTEM………………………………………………………………………………. 416
COMPONENT PARTS OF LIFTING SYSTEM…………………………………………………………………………………………………. 417
SWITCH BOX………………………………………………………………………………………………………………….. 417
PROXIMITY SWITCH PART………………………………………………………………………………………………………… 417
CONTROL VALVE ASSEMBLY……………………………………………………………………………………………………….. 418
SERVICE CENTER SYSTEM……………………………………………………………………………………………………………….. 419
LAYOUT DRAWING OF SERVICE CENTER SYSTEM……………………………………………………………………………………………. 419
SERVICE CENTER SYSTEM DIAGRAM…………………………………………………………………………………………………….. 421
FUNCTION OF SERVICE CENTER SYSTEM……………………………………………………………………………………………… 421
COMPONENT PARTS OF SERVICE CENTER SYSTEM…………………………………………………………………………………………… 423
RAISE/LOWER SWITCH…………………………………………………………………………………………………………… 423
PROXIMITY SWITCH PART………………………………………………………………………………………………………… 423
CONTROL VALVE ASSEMBLY……………………………………………………………………………………………………….. 424
LEFT CONSOLE BOX SECTION IN CAB……………………………………………………………………………………………….. 425
SERVICE PANEL PART…………………………………………………………………………………………………………… 425
GREASE LUBRICATION SYSTEM……………………………………………………………………………………………………………. 428
GREASE LUBRICATION SYSTEM DIAGRAM…………………………………………………………………………………………………. 428
FUNCTION OF GREASE LUBRICATION SYSTEM………………………………………………………………………………………….. 430
SPECIFICATIONS OF GREASE LUBRICATION SYSTEM…………………………………………………………………………………….. 431
COMPONENT PARTS OF GREASE LUBRICATION SYSTEM……………………………………………………………………………………….. 432
GREASE PUMP…………………………………………………………………………………………………………………. 432
GREASE GUN………………………………………………………………………………………………………………….. 434
HOSE REEL…………………………………………………………………………………………………………………… 434
INJECTOR DISTRIBUTION VALVE…………………………………………………………………………………………………… 435
UNDERCARRIAGE AND FRAME……………………………………………………………………………………………………………… 438
LAYOUT DRAWING OF UNDERCARRIAGE…………………………………………………………………………………………………… 438
SPECIFICATIONS OF UNDERCARRIAGE……………………………………………………………………………………………….. 438
WORK EQUIPMENT……………………………………………………………………………………………………………………… 439
STRUCTURE OF WORK EQUIPMENT………………………………………………………………………………………………………. 439
FUNCTION OF WORK EQUIPMENT……………………………………………………………………………………………………….. 440
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM…………………………………………………………………………………………… 441
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM…………………………………………………………………………….. 441
CAB AND ITS ATTACHMENTS……………………………………………………………………………………………………………… 442
CAB……………………………………………………………………………………………………………………………. 442
STRUCTURE OF CAB…………………………………………………………………………………………………………….. 442
WIPER SYSTEM……………………………………………………………………………………………………………………. 443
LAYOUT DRAWING OF WIPER SYSTEM………………………………………………………………………………………………… 443
WIPER SYSTEM DIAGRAM…………………………………………………………………………………………………………. 444
FUNCTION OF WIPER SYSTEM……………………………………………………………………………………………………… 444
CAB MOUNT………………………………………………………………………………………………………………………. 447
STRUCTURE OF CAB MOUNT……………………………………………………………………………………………………….. 447
FUNCTION OF CAB MOUNT………………………………………………………………………………………………………… 447
20 STANDARD VALUE TABLE…………………………………………………………………………………………………………………. 449
CONTENTS…………………………………………………………………………………………………………………………… 450
ABBREVIATION LIST…………………………………………………………………………………………………………………… 451
STANDARD VALUE TABLE FOR ENGINE………………………………………………………………………………………………………. 457
STANDARD VALUE TABLE FOR ENGINE: PC2000-11…………………………………………………………………………………………. 457
STANDARD VALUE TABLE FOR MACHINE……………………………………………………………………………………………………… 462
STANDARD VALUE TABLE FOR MACHINE: PC2000-11………………………………………………………………………………………… 462
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE……………………………………………………………………………… 479
30 TESTING AND ADJUSTING………………………………………………………………………………………………………………… 483
CONTENTS…………………………………………………………………………………………………………………………… 484
ABBREVIATION LIST…………………………………………………………………………………………………………………… 488
RELATED INFORMATION ON TESTING AND ADJUSTING…………………………………………………………………………………………… 494
TOOLS FOR TESTING AND ADJUSTING…………………………………………………………………………………………………… 494
ENGINE AND COOLING SYSTEM……………………………………………………………………………………………………………. 502
TEST ENGINE SPEED……………………………………………………………………………………………………………….. 502
METHOD FOR TESTING ENGINE SPEED……………………………………………………………………………………………….. 502
TEST BOOST PRESSURE……………………………………………………………………………………………………………… 505
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR…………………………………………………………………………….. 505
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL……………………………………………………………………………….. 506
TEST EXHAUST GAS TEMPERATURE……………………………………………………………………………………………………… 509
METHOD FOR TESTING EXHAUST GAS TEMPERATURE……………………………………………………………………………………… 509
TEST EXHAUST GAS COLOR…………………………………………………………………………………………………………… 510
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER………………………………………………………………………. 510
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER……………………………………………………………………………… 513
TEST AND ADJUST VALVE CLEARANCE…………………………………………………………………………………………………… 516
METHOD FOR TESTING VALVE CLEARANCE…………………………………………………………………………………………….. 516
METHOD FOR ADJUSTING VALVE CLEARANCE…………………………………………………………………………………………… 517
TEST COMPRESSION PRESSURE………………………………………………………………………………………………………… 519
METHOD FOR TESTING COMPRESSION PRESSURE………………………………………………………………………………………… 519
TEST BLOWBY PRESSURE…………………………………………………………………………………………………………….. 523
METHOD FOR TESTING BLOWBY PRESSURE BY TESTING TOOL………………………………………………………………………………. 523
TEST ENGINE OIL PRESSURE…………………………………………………………………………………………………………. 529
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR………………………………………………………………………… 529
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL…………………………………………………………………………… 529
TEST EGR VALVE AND VGT OIL PRESSURE……………………………………………………………………………………………….. 531
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE……………………………………………………………………………….. 531
TEST FUEL PRESSURE………………………………………………………………………………………………………………. 533
METHOD FOR TESTING FUEL PRESSURE………………………………………………………………………………………………. 533
TEST FUEL RETURN RATE AND LEAKAGE…………………………………………………………………………………………………. 535
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE…………………………………………………………………………………. 536
BLEED AIR FROM FUEL SYSTEM……………………………………………………………………………………………………….. 542
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM……………………………………………………………………………………….. 543
TEST FUEL CIRCUIT FOR LEAKAGE…………………………………………………………………………………………………….. 545
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE…………………………………………………………………………………….. 545
TEST SUPPLY PUMP………………………………………………………………………………………………………………… 547
METHOD FOR TESTING SUPPLY PUMP………………………………………………………………………………………………… 547
HANDLE CYLINDER CUT-OUT MODE OPERATION…………………………………………………………………………………………….. 551
TEST ALTERNATOR…………………………………………………………………………………………………………………. 552
METHOD FOR TESTING ALTERNATOR…………………………………………………………………………………………………. 552
TEST AND ADJUST ALTERNATOR BELT TENSION……………………………………………………………………………………………. 553
METHOD FOR TESTING ALTERNATOR BELT TENSION……………………………………………………………………………………… 553
METHOD FOR ADJUSTING ALTERNATOR BELT TENSION……………………………………………………………………………………. 554
HANDLE NO-INJECTION CRANKING OPERATION…………………………………………………………………………………………….. 555
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION……………………………………………………………………………… 556
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION……………………………………………………………………….. 556
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION……………………………………………………………………… 557
CLEAN FUEL DOSER………………………………………………………………………………………………………………… 558
METHOD FOR CLEANING FUEL DOSER………………………………………………………………………………………………… 558
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER………………………………………………………………………………. 561
METHOD FOR WRITING INJECTOR COMPENSATION VALUE………………………………………………………………………………….. 561
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER……………………………………………………………………….. 568
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER………………………………………………………… 568
POWER TRAIN………………………………………………………………………………………………………………………… 569
TEST SWING CIRCLE BEARING CLEARANCE……………………………………………………………………………………………….. 569
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE……………………………………………………………………………….. 569
RELEASE REMAINING PRESSURE FROM HIC CIRCUIT………………………………………………………………………………………… 570
METHOD FOR RELEASING REMAINING PRESSURE FROM HIC CIRCUIT…………………………………………………………………………. 570
TEST AND CHARGE HIC CIRCUIT ACCUMULATOR NITROGEN GAS PRESSURE………………………………………………………………………… 571
METHOD FOR TESTING HIC CIRCUIT ACCUMULATOR NITROGEN GAS………………………………………………………………………….. 571
METHOD FOR CHARGING HIC CIRCUIT ACCUMULATOR NITROGEN GAS…………………………………………………………………………. 574
BLEED AIR FROM HIC CIRCUIT……………………………………………………………………………………………………….. 577
METHOD FOR BLEEDING AIR FROM HIC CIRCUIT……………………………………………………………………………………….. 577
UNDERCARRIAGE AND FRAME……………………………………………………………………………………………………………… 579
TEST SPROCKET WEAR………………………………………………………………………………………………………………. 579
METHOD FOR TESTING SPROCKET WEAR………………………………………………………………………………………………. 579
TEST AND ADJUST TRACK TENSION…………………………………………………………………………………………………….. 580
METHOD FOR TESTING TRACK TENSION………………………………………………………………………………………………. 580
METHOD FOR ADJUSTING TRACK TENSION…………………………………………………………………………………………….. 580
HYDRAULIC SYSTEM……………………………………………………………………………………………………………………. 583
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM……………………………………………………………………………………. 583
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT……………………………………………………………………. 583
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK………………………………………………………………………. 583
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT……………………………………………………………… 583
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT………………………………………………………………….. 583
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT…………………………………………………………………. 584
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…………………………………………………………….. 585
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS………………………………………………………. 588
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…………………………………………………….. 595
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT…………………………………………………………………………………….. 600
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT………………………………………………………………………………. 600
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT…………………………………………………………………………….. 601
TEST PUMP EPC SOLENOID VALVE OUTLET PRESSURE……………………………………………………………………………………….. 602
METHOD FOR TESTING OF PUMP EPC SOLENOID VALVE OUTLET PRESSURE…………………………………………………………………….. 602
METHOD FOR TESTING OF PUMP EPC SOLENOID VALVE ELECTRIC CURRENT……………………………………………………………………. 603
TEST AND ADJUST JET SENSOR DIFFERENTIAL PRESSURE……………………………………………………………………………………. 604
METHOD FOR TESTING JET SENSOR DIFFERENTIAL PRESSURE WITH MACHINE MONITOR…………………………………………………………… 604
METHOD FOR TESTING JET SENSOR DIFFERENTIAL PRESSURE BY TESTING TOOL……………………………………………………………….. 605
METHOD FOR TESTING JET SENSOR DIFFERENTIAL PRESSURE……………………………………………………………………………… 606
METHOD FOR ADJUSTING JET SENSOR DIFFERENTIAL PRESSURE……………………………………………………………………………. 606
TEST OUTLET PRESSURE OF SOLENOID VALVE…………………………………………………………………………………………….. 608
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE…………………………………………………………………………….. 608
OPERATING CONDITION OF SOLENOID VALVE………………………………………………………………………………………….. 610
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE…………………………………………………………………………….. 612
METHOD FOR TESTING OF EPC SOLENOID VALVE OUTLET PRESSURE…………………………………………………………………………. 612
TEST PPC VALVE OUTLET PRESSURE……………………………………………………………………………………………………. 614
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE……………………………………………………………………………………. 615
ADJUST WORK EQUIPMENT AND SWING PPC VALVES…………………………………………………………………………………………. 617
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES………………………………………………………………….. 617
TEST TRAVEL DEVIATION……………………………………………………………………………………………………………. 618
METHOD FOR TESTING TRAVEL DEVIATION……………………………………………………………………………………………. 618
METHOD FOR ADJUSTING TRAVEL DEVIATION………………………………………………………………………………………….. 618
TEST FAN SPEED………………………………………………………………………………………………………………….. 619
METHOD FOR CHECKING OF RADIATOR FAN SPEED………………………………………………………………………………………. 619
METHOD FOR TESTING OF OIL COOLER FAN SPEED……………………………………………………………………………………… 619
TEST OIL PRESSURE IN FAN PUMP CIRCUIT……………………………………………………………………………………………… 620
METHOD OF TESTING RADIATOR FAN PUMP CIRCUIT OIL PRESSURE BY MACHINE MONITOR………………………………………………………… 620
METHOD OF TESTING RADIATOR FAN PUMP CIRCUIT OIL PRESSURE BY TESTING TOOL…………………………………………………………… 620
METHOD OF TESTING OIL COOLER FAN PUMP CIRCUIT OIL PRESSURE BY MACHINE MONITOR………………………………………………………. 621
METHOD OF TESTING OIL COOLER FAN PUMP CIRCUIT OIL PRESSURE BY TESTING TOOL…………………………………………………………. 621
TEST FAN PUMP EPC ELECTRIC CURRENT………………………………………………………………………………………………… 623
METHOD FOR TESTING OF RADIATOR FAN PUMP EPC ELECTRIC CURRENT……………………………………………………………………… 623
METHOD FOR TESTING OF OIL COOLER FAN PUMP EPC ELECTRIC CURRENT……………………………………………………………………. 623
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE……………………………………………………………………………………. 624
METHOD FOR TESTING OF RADIATOR FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE…………………………………………………………. 624
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE OF OIL COOLER FAN PUMP…………………………………………………….. 625
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT…………………………………………………………………………….. 626
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER……………………………………………. 626
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER………………………………………………………………. 626
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE…………………………………………………………………. 627
TEST OIL LEAKAGE………………………………………………………………………………………………………………… 628
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER……………………………………………………………………………….. 628
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER………………………………………………………………………………… 629
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER……………………………………………………………………………… 629
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR…………………………………………………………………………………. 630
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR………………………………………………………………………………… 630
METHOD FOR TESTING OIL LEAKAGE OF SWIVEL JOINT………………………………………………………………………………….. 631
BLEED AIR FROM HYDRAULIC CIRCUIT………………………………………………………………………………………………….. 633
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT………………………………………………………………………………….. 634
CAB AND ITS ATTACHMENTS……………………………………………………………………………………………………………… 641
METHOD FOR ADJUSTING MIRRORS……………………………………………………………………………………………………… 641
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)……………………………………………………………………………. 641
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)………………………………………………………….. 642
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (B)……………………………………………………………………………. 643
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (B)………………………………………………………….. 643
PROCEDURE FOR ADJUSTING MACHINE LEFT REAR MIRROR (C)…………………………………………………………………………….. 644
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT REAR MIRROR (C)…………………………………………………………… 645
PROCEDURE FOR ADJUSTING MACHINE RIGHT CENTER MIRROR (D)………………………………………………………………………….. 646
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT CENTER MIRROR (D)………………………………………………………… 647
AUTOMATIC LUBRICATION SYSTEM…………………………………………………………………………………………………………. 650
TESTING AND ADJUSTING AUTOMATIC LUBRICATION SYSTEM………………………………………………………………………………….. 650
METHOD FOR TESTING AUTOMATIC LUBRICATION SYSTEM…………………………………………………………………………………. 650
METHOD FOR ADJUSTING AUTOMATIC LUBRICATION SYSTEM……………………………………………………………………………….. 652
LIFTING SYSTEM……………………………………………………………………………………………………………………… 654
TEST AND ADJUST HYDRAULICALLY OPERATED STAIRWAY PROXIMITY SWITCH……………………………………………………………………… 654
METHOD FOR TESTING CLEARANCE OF HYDRAULICALLY OPERATED STAIRWAY PROXIMITY SWITCH……………………………………………………. 654
METHOD FOR ADJUSTING CLEARANCE OF HYDRAULICALLY OPERATED STAIRWAY PROXIMITY SWITCH………………………………………………….. 655
METHOD FOR TESTING POSITION OF HYDRAULICALLY OPERATED STAIRWAY POSITION DETECTING PLATE……………………………………………… 656
METHOD FOR ADJUSTING POSITION OF HYDRAULICALLY OPERATED STAIRWAY POSITION DETECTING PLATE……………………………………………. 656
SERVICE CENTER SYSTEM……………………………………………………………………………………………………………….. 658
TEST AND ADJUST SERVICE ARM PROXIMITY SWITCH……………………………………………………………………………………….. 658
METHOD FOR TESTING CLEARANCE OF SERVICE ARM PROXIMITY SWITCH……………………………………………………………………… 658
METHOD FOR ADJUSTING CLEARANCE OF SERVICE ARM PROXIMITY SWITCH……………………………………………………………………. 658
ELECTRICAL SYSTEM…………………………………………………………………………………………………………………… 659
SET AND OPERATE MACHINE MONITOR…………………………………………………………………………………………………… 659
OPERATOR MODE……………………………………………………………………………………………………………….. 663
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN………………………………………………………………………. 663
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN…………………………………………………………………………. 663
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)……………………………………………………………………………….. 664
CHECKING FUNCTION OF SERVICE METER…………………………………………………………………………………………….. 664
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD………………………………………………………………………… 664
SERVICE MODE………………………………………………………………………………………………………………… 667
METHOD FOR OPERATING SERVICE MODE……………………………………………………………………………………………… 667
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION…………………………………………………………………………… 670
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION…………………………………………………………………………… 680
ABNORMALITY RECORD MENU………………………………………………………………………………………………………. 695
METHOD FOR CONFIRMING MAINTENANCE RECORD……………………………………………………………………………………….. 699
METHOD FOR OPERATING MAINTENANCE MODE SETTING…………………………………………………………………………………… 700
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING…………………………………………………………………………………. 704
DEFAULT MENU………………………………………………………………………………………………………………… 706
DIAGNOSTIC TESTS MENU………………………………………………………………………………………………………… 714
ADJUSTMENT MENU……………………………………………………………………………………………………………… 726
METHOD FOR PERFORMING NO-INJECTION CRANKING…………………………………………………………………………………….. 744
MACHINE CONFIGURATION MENU……………………………………………………………………………………………………. 746
KOMTRAX SETTINGS MENU………………………………………………………………………………………………………… 749
METHOD FOR DISPLAYING SERVICE MESSAGE………………………………………………………………………………………….. 751
METHOD FOR HANDLING SNAP SHOT…………………………………………………………………………………………………. 752
METHOD FOR HANDLING SNAP SHOT (Quick Pm)……………………………………………………………………………………….. 753
METHOD FOR STARTING UP KOMTRAX TERMINAL……………………………………………………………………………………………. 755
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER…………………………………………………………………………………………. 760
METHOD FOR SETTING WITH DEFAULT SETTING OF KOMTRAX Plus CONTROLLER………………………………………………………………… 760
SETTING DEFAULT OF WIRELESS LAN MODEM……………………………………………………………………………………………… 763
METHOD FOR SETTING DEFAULT OF WIRELESS LAN MODEM………………………………………………………………………………… 763
METHOD FOR CHECKING OF WIRELESS LAN MODEM COMMUNICATION………………………………………………………………………….. 764
DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA…………………………………………………………………………………………… 766
METHOD FOR DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA……………………………………………………………………………… 766
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED…………………………………………………………………………………….. 769
METHOD FOR ADJUSTING WHEN KOMTRAX Plus CONTROLLER IS REPLACED…………………………………………………………………….. 769
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED…………………………………………………………………………………………. 772
METHOD FOR ADJUSTING WHEN WIRELESS LAN MODEM IS REPLACED…………………………………………………………………………. 772
ADJUST KomVision CAMERA ANGLE…………………………………………………………………………………………………….. 775
METHOD FOR ADJUSTING KomVision CAMERA ANGLE…………………………………………………………………………………….. 775
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER………………………………………………………………………………………… 778
HANDLE BATTERY ISOLATOR AND STARTING MOTOR ISOLATOR…………………………………………………………………………………. 779
TEST DIODES…………………………………………………………………………………………………………………….. 780
METHOD FOR TESTING DIODE USING DIGITAL TESTER…………………………………………………………………………………… 780
METHOD FOR TESTING DIODE USING ANALOG TESTER……………………………………………………………………………………. 780
Pm CLINIC………………………………………………………………………………………………………………………….. 781
Pm CLINIC SERVICE……………………………………………………………………………………………………………….. 781
Pm CLINIC CHECK SHEET: PC2000-11………………………………………………………………………………………………. 786
PERFORMING QUICK Pm……………………………………………………………………………………………………………… 802
METHOD FOR PERFORMING QUICK Pm………………………………………………………………………………………………… 802
40 TROUBLESHOOTING……………………………………………………………………………………………………………………… 807
CONTENTS…………………………………………………………………………………………………………………………… 808
ABBREVIATION LIST…………………………………………………………………………………………………………………… 821
RELATED INFORMATION ON TROUBLESHOOTING………………………………………………………………………………………………… 827
GENERAL TROUBLESHOOTING POINTS……………………………………………………………………………………………………. 827
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEM……………………………………………………………………………………. 828
SEQUENCE OF EVENTS IN TROUBLESHOOTING……………………………………………………………………………………………… 835
CHECKS BEFORE TROUBLESHOOTING…………………………………………………………………………………………………….. 837
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING………………………………………………………………………………………… 839
WALK-AROUND CHECK……………………………………………………………………………………………………………. 839
TESTING IN ACCORDANCE WITH TESTING PROCEDURE……………………………………………………………………………………….. 841
CHECK FUEL LEVEL AND TYPE…………………………………………………………………………………………………….. 841
CHECK IMPURE INGREDIENT IN FUEL……………………………………………………………………………………………….. 841
CHECK FUEL PREFILTER…………………………………………………………………………………………………………. 842
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT………………………………………………………………………………. 842
FUEL PREFILTER CARTRIDGE – REPLACE…………………………………………………………………………………………….. 843
TEST FUEL MAIN FILTER………………………………………………………………………………………………………… 844
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)………………………………………………………………………………….. 846
CHECK COOLANT LEVEL (RESERVOIR TANK)…………………………………………………………………………………………… 848
CHECK CLOGGING OF AIR CLEANER…………………………………………………………………………………………………. 848
OUTER ELEMENT – CLEAN………………………………………………………………………………………………………… 848
ELEMENTS – REPLACE…………………………………………………………………………………………………………… 851
CHECK HYDRAULIC OIL LEVEL…………………………………………………………………………………………………….. 851
CHECK HYDRAULIC OIL STRAINER………………………………………………………………………………………………….. 853
CHECK HYDRAULIC FILTER……………………………………………………………………………………………………….. 853
CHECK OIL LEVEL IN SWING MACHINERY CASE………………………………………………………………………………………… 854
CHECK OIL LEVEL IN PTO CASE…………………………………………………………………………………………………… 856
CHECK PTO LUBRICATION FILTER STRAINER………………………………………………………………………………………….. 856
CHECK OIL LEVEL IN FINAL DRIVE CASE……………………………………………………………………………………………. 857
BLEED AIR FROM FUEL SYSTEM……………………………………………………………………………………………………. 857
BLEED AIR FROM HYDRAULIC SYSTEM……………………………………………………………………………………………….. 857
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod……………………………………………………………………………………. 857
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM………………………………………………………………………………… 863
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR………………………………………………………………………………. 863
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER…………………………………………………………………………….. 863
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER………………………………………………………………………………. 863
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX Plus CONTROLLER……………………………………………………………………….. 864
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER………………………………………………………………………….. 864
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK……………………………………………………………….. 864
PROCEDURE FOR TESTING AND TROUBLESHOOTING………………………………………………………………………………………….. 869
SYMPTOM AND TROUBLESHOOTING NUMBERS……………………………………………………………………………………………….. 872
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE……………………………………………………………………………………… 877
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM…………………………………………………….. 879
CONNECTORS LIST AND LAYOUT……………………………………………………………………………………………………….. 882
CONNECTOR CONTACT IDENTIFICATION………………………………………………………………………………………………….. 905
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE……………………………………………………………………………………………. 947
FUSE LOCATION TABLE……………………………………………………………………………………………………………… 953
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)………………………………………………………………………….. 960
PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES [CA1883], [CB1883], [CA3135] AND [CB3135])………………………………………… 964
FAILURE CODES TABLE……………………………………………………………………………………………………………… 966
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)………………………………………………………………………………………. 990
FAILURE CODE [7@HAZL]……………………………………………………………………………………………………………. 990
FAILURE CODE [7@HBZL]……………………………………………………………………………………………………………. 992
FAILURE CODE [7@HCZL]……………………………………………………………………………………………………………. 993
FAILURE CODE [7@HDZL]……………………………………………………………………………………………………………. 994
FAILURE CODE [8800ZG]……………………………………………………………………………………………………………. 995
FAILURE CODE [989L00]……………………………………………………………………………………………………………. 996
FAILURE CODE [989M00]……………………………………………………………………………………………………………. 997
FAILURE CODE [989N00]……………………………………………………………………………………………………………. 998
FAILURE CODE [A1U0N3]……………………………………………………………………………………………………………. 999
FAILURE CODE [A1U0N4]…………………………………………………………………………………………………………….1001
FAILURE CODE [A900FR]…………………………………………………………………………………………………………….1003
FAILURE CODE [A900N6]…………………………………………………………………………………………………………….1004
FAILURE CODE [A900NY]…………………………………………………………………………………………………………….1005
FAILURE CODE [AA10NX]…………………………………………………………………………………………………………….1006
FAILURE CODE [AQ10N3]…………………………………………………………………………………………………………….1007
FAILURE CODE [B@BAZG]…………………………………………………………………………………………………………….1008
FAILURE CODE [B@BAZK]…………………………………………………………………………………………………………….1009
FAILURE CODE [B@BCNS]…………………………………………………………………………………………………………….1010
FAILURE CODE [B@BCQA]…………………………………………………………………………………………………………….1011
FAILURE CODE [B@BCZK]…………………………………………………………………………………………………………….1013
FAILURE CODE [B@HAZK]…………………………………………………………………………………………………………….1015
FAILURE CODE [CA115]……………………………………………………………………………………………………………..1016
FAILURE CODE [CA122]……………………………………………………………………………………………………………..1020
FAILURE CODE [CA123]……………………………………………………………………………………………………………..1022
FAILURE CODE [CA131]……………………………………………………………………………………………………………..1024
FAILURE CODE [CA132]……………………………………………………………………………………………………………..1026
FAILURE CODE [CA135]……………………………………………………………………………………………………………..1028
FAILURE CODE [CA141]……………………………………………………………………………………………………………..1030
FAILURE CODE [CA144]……………………………………………………………………………………………………………..1032
FAILURE CODE [CA145]……………………………………………………………………………………………………………..1034
FAILURE CODE [CA153]……………………………………………………………………………………………………………..1036
FAILURE CODE [CA154]……………………………………………………………………………………………………………..1039
FAILURE CODE [CA187]……………………………………………………………………………………………………………..1042
FAILURE CODE [CA212]……………………………………………………………………………………………………………..1044
FAILURE CODE [CA213]……………………………………………………………………………………………………………..1046
FAILURE CODE [CA221]……………………………………………………………………………………………………………..1048
FAILURE CODE [CA222]……………………………………………………………………………………………………………..1050
FAILURE CODE [CA227]……………………………………………………………………………………………………………..1052
FAILURE CODE [CA234]……………………………………………………………………………………………………………..1054
FAILURE CODE [CA238]……………………………………………………………………………………………………………..1055
FAILURE CODE [CA239]……………………………………………………………………………………………………………..1057
FAILURE CODE [CA271]……………………………………………………………………………………………………………..1059
FAILURE CODE [CA272]……………………………………………………………………………………………………………..1061
FAILURE CODE [CA273]……………………………………………………………………………………………………………..1062
FAILURE CODE [CA274]……………………………………………………………………………………………………………..1064
FAILURE CODE [CA322]……………………………………………………………………………………………………………..1065
FAILURE CODE [CA323]……………………………………………………………………………………………………………..1067
FAILURE CODE [CA324]……………………………………………………………………………………………………………..1069
FAILURE CODE [CA325]……………………………………………………………………………………………………………..1071
FAILURE CODE [CA331]……………………………………………………………………………………………………………..1073
FAILURE CODE [CA332]……………………………………………………………………………………………………………..1075
FAILURE CODE [CA343]……………………………………………………………………………………………………………..1077
FAILURE CODE [CA351]……………………………………………………………………………………………………………..1085
FAILURE CODE [CA352]……………………………………………………………………………………………………………..1087
FAILURE CODE [CA356]……………………………………………………………………………………………………………..1089
FAILURE CODE [CA357]……………………………………………………………………………………………………………..1091
FAILURE CODE [CA386]……………………………………………………………………………………………………………..1093
FAILURE CODE [CA441]……………………………………………………………………………………………………………..1095
FAILURE CODE [CA442]……………………………………………………………………………………………………………..1097
FAILURE CODE [CA449]……………………………………………………………………………………………………………..1099
FAILURE CODE [CA451]……………………………………………………………………………………………………………..1100
FAILURE CODE [CA452]……………………………………………………………………………………………………………..1102
FAILURE CODE [CA515]……………………………………………………………………………………………………………..1104
FAILURE CODE [CA516]……………………………………………………………………………………………………………..1105
FAILURE CODE [CA553]……………………………………………………………………………………………………………..1106
FAILURE CODE [CA555]……………………………………………………………………………………………………………..1107
FAILURE CODE [CA556]……………………………………………………………………………………………………………..1109
FAILURE CODE [CA559]……………………………………………………………………………………………………………..1111
FAILURE CODE [CA595]……………………………………………………………………………………………………………..1117
FAILURE CODE [CA687]……………………………………………………………………………………………………………..1119
FAILURE CODE [CA689]……………………………………………………………………………………………………………..1121
FAILURE CODE [CA691]……………………………………………………………………………………………………………..1123
FAILURE CODE [CA692]……………………………………………………………………………………………………………..1125
FAILURE CODE [CA697]……………………………………………………………………………………………………………..1127
FAILURE CODE [CA698]……………………………………………………………………………………………………………..1128
FAILURE CODE [CA731]……………………………………………………………………………………………………………..1129
FAILURE CODE [CA778]……………………………………………………………………………………………………………..1133
FAILURE CODE [CA1117]…………………………………………………………………………………………………………….1136
FAILURE CODE [CA1135]…………………………………………………………………………………………………………….1138
FAILURE CODE [CA1257]…………………………………………………………………………………………………………….1141
FAILURE CODE [CA1664]…………………………………………………………………………………………………………….1142
FAILURE CODE [CA1691]…………………………………………………………………………………………………………….1144
FAILURE CODE [CA1695]…………………………………………………………………………………………………………….1147
FAILURE CODE [CA1696]…………………………………………………………………………………………………………….1149
FAILURE CODE [CA1843]…………………………………………………………………………………………………………….1151
FAILURE CODE [CA1844]…………………………………………………………………………………………………………….1153
FAILURE CODE [CA1879]…………………………………………………………………………………………………………….1155
FAILURE CODE [CA1881]…………………………………………………………………………………………………………….1157
FAILURE CODE [CA1883]…………………………………………………………………………………………………………….1159
FAILURE CODE [CA1921]…………………………………………………………………………………………………………….1162
FAILURE CODE [CA1922]…………………………………………………………………………………………………………….1164
FAILURE CODE [CA1923]…………………………………………………………………………………………………………….1167
FAILURE CODE [CA1924]…………………………………………………………………………………………………………….1169
FAILURE CODE [CA1925]…………………………………………………………………………………………………………….1172
FAILURE CODE [CA1927]…………………………………………………………………………………………………………….1174
FAILURE CODE [CA1928]…………………………………………………………………………………………………………….1176
FAILURE CODE [CA1942]…………………………………………………………………………………………………………….1178
FAILURE CODE [CA1963]…………………………………………………………………………………………………………….1180
FAILURE CODE [CA1977]…………………………………………………………………………………………………………….1184
FAILURE CODE [CA1993]…………………………………………………………………………………………………………….1186
FAILURE CODE [CA2185]…………………………………………………………………………………………………………….1188
FAILURE CODE [CA2186]…………………………………………………………………………………………………………….1190
FAILURE CODE [CA2249]…………………………………………………………………………………………………………….1192
FAILURE CODE [CA2265]…………………………………………………………………………………………………………….1197
FAILURE CODE [CA2266]…………………………………………………………………………………………………………….1199
FAILURE CODE [CA2271]…………………………………………………………………………………………………………….1201
FAILURE CODE [CA2272]…………………………………………………………………………………………………………….1203
FAILURE CODE [CA2349]…………………………………………………………………………………………………………….1205
FAILURE CODE [CA2353]…………………………………………………………………………………………………………….1207
FAILURE CODE [CA2357]…………………………………………………………………………………………………………….1209
FAILURE CODE [CA2381]…………………………………………………………………………………………………………….1212
FAILURE CODE [CA2382]…………………………………………………………………………………………………………….1214
FAILURE CODE [CA2383]…………………………………………………………………………………………………………….1216
FAILURE CODE [CA2386]…………………………………………………………………………………………………………….1218
FAILURE CODE [CA2387]…………………………………………………………………………………………………………….1220
FAILURE CODE [CA2555]…………………………………………………………………………………………………………….1223
FAILURE CODE [CA2556]…………………………………………………………………………………………………………….1225
FAILURE CODE [CA2637]…………………………………………………………………………………………………………….1227
FAILURE CODE [CA2639]…………………………………………………………………………………………………………….1229
FAILURE CODE [CA2732]…………………………………………………………………………………………………………….1231
FAILURE CODE [CA2733]…………………………………………………………………………………………………………….1233
FAILURE CODE [CA2741]…………………………………………………………………………………………………………….1235
FAILURE CODE [CA2765]…………………………………………………………………………………………………………….1237
FAILURE CODE [CA2777]…………………………………………………………………………………………………………….1238
FAILURE CODE [CA2878]…………………………………………………………………………………………………………….1240
FAILURE CODE [CA2881]…………………………………………………………………………………………………………….1243
FAILURE CODE [CA3133]…………………………………………………………………………………………………………….1247
FAILURE CODE [CA3134]…………………………………………………………………………………………………………….1249
FAILURE CODE [CA3135]…………………………………………………………………………………………………………….1251
FAILURE CODE [CA3167]…………………………………………………………………………………………………………….1254
FAILURE CODE [CA3251]…………………………………………………………………………………………………………….1257
FAILURE CODE [CA3253]…………………………………………………………………………………………………………….1259
FAILURE CODE [CA3254]…………………………………………………………………………………………………………….1264
FAILURE CODE [CA3255]…………………………………………………………………………………………………………….1267
FAILURE CODE [CA3256]…………………………………………………………………………………………………………….1270
FAILURE CODE [CA3311]…………………………………………………………………………………………………………….1272
FAILURE CODE [CA3312]…………………………………………………………………………………………………………….1274
FAILURE CODE [CA3313]…………………………………………………………………………………………………………….1276
FAILURE CODE [CA3314]…………………………………………………………………………………………………………….1277
FAILURE CODE [CA3315]…………………………………………………………………………………………………………….1278
FAILURE CODE [CA3316]…………………………………………………………………………………………………………….1281
FAILURE CODE [CA3317]…………………………………………………………………………………………………………….1282
FAILURE CODE [CA3318]…………………………………………………………………………………………………………….1283
FAILURE CODE [CA3319]…………………………………………………………………………………………………………….1286
FAILURE CODE [CA3321]…………………………………………………………………………………………………………….1287
FAILURE CODE [CA3322]…………………………………………………………………………………………………………….1288
FAILURE CODE [CA3419]…………………………………………………………………………………………………………….1291
FAILURE CODE [CA3421]…………………………………………………………………………………………………………….1293
FAILURE CODE [CA4151]…………………………………………………………………………………………………………….1295
FAILURE CODE [CA4158]…………………………………………………………………………………………………………….1298
FAILURE CODE [CA4161]…………………………………………………………………………………………………………….1299
FAILURE CODE [CA4162]…………………………………………………………………………………………………………….1301
FAILURE CODE [CA4163]…………………………………………………………………………………………………………….1303
FAILURE CODE [CA4259]…………………………………………………………………………………………………………….1305
FAILURE CODE [CA4952]…………………………………………………………………………………………………………….1308
FAILURE CODE [CA5383]…………………………………………………………………………………………………………….1310
FAILURE CODE [CB115]……………………………………………………………………………………………………………..1311
FAILURE CODE [CB123]……………………………………………………………………………………………………………..1315
FAILURE CODE [CB187]……………………………………………………………………………………………………………..1317
FAILURE CODE [CB227]……………………………………………………………………………………………………………..1319
FAILURE CODE [CB238]……………………………………………………………………………………………………………..1321
FAILURE CODE [CB239]……………………………………………………………………………………………………………..1323
FAILURE CODE [CB271]……………………………………………………………………………………………………………..1325
FAILURE CODE [CB272]……………………………………………………………………………………………………………..1327
FAILURE CODE [CB273]……………………………………………………………………………………………………………..1328
FAILURE CODE [CB274]……………………………………………………………………………………………………………..1330
FAILURE CODE [CB343]……………………………………………………………………………………………………………..1331
FAILURE CODE [CB351]……………………………………………………………………………………………………………..1333
FAILURE CODE [CB352]……………………………………………………………………………………………………………..1335
FAILURE CODE [CB356]……………………………………………………………………………………………………………..1337
FAILURE CODE [CB357]……………………………………………………………………………………………………………..1339
FAILURE CODE [CB386]……………………………………………………………………………………………………………..1341
FAILURE CODE [CB441]……………………………………………………………………………………………………………..1343
FAILURE CODE [CB442]……………………………………………………………………………………………………………..1345
FAILURE CODE [CB449]……………………………………………………………………………………………………………..1347
FAILURE CODE [CB451]……………………………………………………………………………………………………………..1348
FAILURE CODE [CB452]……………………………………………………………………………………………………………..1350
FAILURE CODE [CB515]……………………………………………………………………………………………………………..1352
FAILURE CODE [CB516]……………………………………………………………………………………………………………..1353
FAILURE CODE [CB553]……………………………………………………………………………………………………………..1354
FAILURE CODE [CB555]……………………………………………………………………………………………………………..1355
FAILURE CODE [CB556]……………………………………………………………………………………………………………..1357
FAILURE CODE [CB559]……………………………………………………………………………………………………………..1359
FAILURE CODE [CB595]……………………………………………………………………………………………………………..1364
FAILURE CODE [CB689]……………………………………………………………………………………………………………..1366
FAILURE CODE [CB687]……………………………………………………………………………………………………………..1368
FAILURE CODE [CB697]……………………………………………………………………………………………………………..1370
FAILURE CODE [CB698]……………………………………………………………………………………………………………..1371
FAILURE CODE [CB731]……………………………………………………………………………………………………………..1372
FAILURE CODE [CB778]……………………………………………………………………………………………………………..1376
FAILURE CODE [CB1117]…………………………………………………………………………………………………………….1379
FAILURE CODE [CB1257]…………………………………………………………………………………………………………….1381
FAILURE CODE [CB1548]…………………………………………………………………………………………………………….1382
FAILURE CODE [CB1549]…………………………………………………………………………………………………………….1384
FAILURE CODE [CB1551]…………………………………………………………………………………………………………….1386
FAILURE CODE [CB1552]…………………………………………………………………………………………………………….1388
FAILURE CODE [CB1553]…………………………………………………………………………………………………………….1390
FAILURE CODE [CB1622]…………………………………………………………………………………………………………….1392
FAILURE CODE [CB1664]…………………………………………………………………………………………………………….1394
FAILURE CODE [CB1691]…………………………………………………………………………………………………………….1396
FAILURE CODE [CB1695]…………………………………………………………………………………………………………….1399
FAILURE CODE [CB1696]…………………………………………………………………………………………………………….1401
FAILURE CODE [CB1843]…………………………………………………………………………………………………………….1403
FAILURE CODE [CB1844]…………………………………………………………………………………………………………….1405
FAILURE CODE [CB1879]…………………………………………………………………………………………………………….1407
FAILURE CODE [CB1881]…………………………………………………………………………………………………………….1409
FAILURE CODE [CB1883]…………………………………………………………………………………………………………….1411
FAILURE CODE [CB1921]…………………………………………………………………………………………………………….1414
FAILURE CODE [CB1922]…………………………………………………………………………………………………………….1416
FAILURE CODE [CB1923]…………………………………………………………………………………………………………….1419
FAILURE CODE [CB1924]…………………………………………………………………………………………………………….1421
FAILURE CODE [CB1925]…………………………………………………………………………………………………………….1424
FAILURE CODE [CB1927]…………………………………………………………………………………………………………….1426
FAILURE CODE [CB1928]…………………………………………………………………………………………………………….1428
FAILURE CODE [CB1942]…………………………………………………………………………………………………………….1430
FAILURE CODE [CB1963]…………………………………………………………………………………………………………….1432
FAILURE CODE [CB1977]…………………………………………………………………………………………………………….1437
FAILURE CODE [CB1993]…………………………………………………………………………………………………………….1439
FAILURE CODE [CB2249]…………………………………………………………………………………………………………….1441
FAILURE CODE [CB2265]…………………………………………………………………………………………………………….1446
FAILURE CODE [CB2266]…………………………………………………………………………………………………………….1448
FAILURE CODE [CB2271]…………………………………………………………………………………………………………….1450
FAILURE CODE [CB2272]…………………………………………………………………………………………………………….1452
FAILURE CODE [CB2349]…………………………………………………………………………………………………………….1454
FAILURE CODE [CB2353]…………………………………………………………………………………………………………….1456
FAILURE CODE [CB2357]…………………………………………………………………………………………………………….1458
FAILURE CODE [CB2381]…………………………………………………………………………………………………………….1461
FAILURE CODE [CB2382]…………………………………………………………………………………………………………….1463
FAILURE CODE [CB2383]…………………………………………………………………………………………………………….1465
FAILURE CODE [CB2386]…………………………………………………………………………………………………………….1467
FAILURE CODE [CB2387]…………………………………………………………………………………………………………….1469
FAILURE CODE [CB2637]…………………………………………………………………………………………………………….1472
FAILURE CODE [CB2639]…………………………………………………………………………………………………………….1474
FAILURE CODE [CB2732]…………………………………………………………………………………………………………….1476
FAILURE CODE [CB2733]…………………………………………………………………………………………………………….1478
FAILURE CODE [CB2741]…………………………………………………………………………………………………………….1480
FAILURE CODE [CB2777]…………………………………………………………………………………………………………….1482
FAILURE CODE [CB2878]…………………………………………………………………………………………………………….1484
FAILURE CODE [CB2881]…………………………………………………………………………………………………………….1487
FAILURE CODE [CB3313]…………………………………………………………………………………………………………….1491
FAILURE CODE [CB3133]…………………………………………………………………………………………………………….1492
FAILURE CODE [CB3134]…………………………………………………………………………………………………………….1494
FAILURE CODE [CB3135]…………………………………………………………………………………………………………….1496
FAILURE CODE [CB3167]…………………………………………………………………………………………………………….1499
FAILURE CODE [CB3251]…………………………………………………………………………………………………………….1502
FAILURE CODE [CB3253]…………………………………………………………………………………………………………….1504
FAILURE CODE [CB3254]…………………………………………………………………………………………………………….1509
FAILURE CODE [CB3255]…………………………………………………………………………………………………………….1512
FAILURE CODE [CB3256]…………………………………………………………………………………………………………….1515
FAILURE CODE [CB3311]…………………………………………………………………………………………………………….1517
FAILURE CODE [CB3312]…………………………………………………………………………………………………………….1519
FAILURE CODE [CB3313]…………………………………………………………………………………………………………….1521
FAILURE CODE [CB3314]…………………………………………………………………………………………………………….1522
FAILURE CODE [CB3315]…………………………………………………………………………………………………………….1523
FAILURE CODE [CB3316]…………………………………………………………………………………………………………….1526
FAILURE CODE [CB3317]…………………………………………………………………………………………………………….1527
FAILURE CODE [CB3318]…………………………………………………………………………………………………………….1528
FAILURE CODE [CB3319]…………………………………………………………………………………………………………….1531
FAILURE CODE [CB3321]…………………………………………………………………………………………………………….1532
FAILURE CODE [CB3322]…………………………………………………………………………………………………………….1533
FAILURE CODE [CB3419]…………………………………………………………………………………………………………….1536
FAILURE CODE [CB3421]…………………………………………………………………………………………………………….1538
FAILURE CODE [CB4151]…………………………………………………………………………………………………………….1540
FAILURE CODE [CB4158]…………………………………………………………………………………………………………….1544
FAILURE CODE [CB4161]…………………………………………………………………………………………………………….1545
FAILURE CODE [CB4162]…………………………………………………………………………………………………………….1547
FAILURE CODE [CB4163]…………………………………………………………………………………………………………….1549
FAILURE CODE [CB4259]…………………………………………………………………………………………………………….1552
FAILURE CODE [CB4952]…………………………………………………………………………………………………………….1555
FAILURE CODE [CB5383]…………………………………………………………………………………………………………….1557
FAILURE CODE [D110KB]…………………………………………………………………………………………………………….1558
FAILURE CODE [D163KB]…………………………………………………………………………………………………………….1560
FAILURE CODE [D195KA]…………………………………………………………………………………………………………….1562
FAILURE CODE [D195KB]…………………………………………………………………………………………………………….1565
FAILURE CODE [D19JKZ]…………………………………………………………………………………………………………….1567
FAILURE CODE [D1E7KA]…………………………………………………………………………………………………………….1569
FAILURE CODE [D1E7KB]…………………………………………………………………………………………………………….1570
FAILURE CODE [D1E7KY]…………………………………………………………………………………………………………….1571
FAILURE CODE [D1E9KB]…………………………………………………………………………………………………………….1572
FAILURE CODE [D1EAKB]…………………………………………………………………………………………………………….1575
FAILURE CODE [D1EBKB]…………………………………………………………………………………………………………….1577
FAILURE CODE [D1ECKB]…………………………………………………………………………………………………………….1580
FAILURE CODE [D1F0KA]…………………………………………………………………………………………………………….1582
FAILURE CODE [D1F0KB]…………………………………………………………………………………………………………….1583
FAILURE CODE [D1F0KY]…………………………………………………………………………………………………………….1584
FAILURE CODE [D8AQKR]…………………………………………………………………………………………………………….1585
FAILURE CODE [DA20MC]…………………………………………………………………………………………………………….1589
FAILURE CODE [DA22KK]…………………………………………………………………………………………………………….1590
FAILURE CODE [DA25KP]…………………………………………………………………………………………………………….1593
FAILURE CODE [DA26KP]…………………………………………………………………………………………………………….1595
FAILURE CODE [DA29KQ]…………………………………………………………………………………………………………….1597
FAILURE CODE [DA2LKA]…………………………………………………………………………………………………………….1599
FAILURE CODE [DA2LKB]…………………………………………………………………………………………………………….1602
FAILURE CODE [DA2QKR]…………………………………………………………………………………………………………….1604
FAILURE CODE [DA2RKR]…………………………………………………………………………………………………………….1610
FAILURE CODE [DAF0KM]…………………………………………………………………………………………………………….1615
FAILURE CODE [DAF0MB]…………………………………………………………………………………………………………….1616
FAILURE CODE [DAF0MC]…………………………………………………………………………………………………………….1617
FAILURE CODE [DAF9KQ]…………………………………………………………………………………………………………….1618
FAILURE CODE [DAFGMC]…………………………………………………………………………………………………………….1619
FAILURE CODE [DAFLKA]…………………………………………………………………………………………………………….1620
FAILURE CODE [DAFLKB]…………………………………………………………………………………………………………….1623
FAILURE CODE [DAFQKR]…………………………………………………………………………………………………………….1625
FAILURE CODE [DB2QKR]…………………………………………………………………………………………………………….1630
FAILURE CODE [DB2RKR]…………………………………………………………………………………………………………….1639
FAILURE CODE [DBP0KM]…………………………………………………………………………………………………………….1647
FAILURE CODE [DBP0KT]…………………………………………………………………………………………………………….1648
FAILURE CODE [DBP0MC]…………………………………………………………………………………………………………….1649
FAILURE CODE [DBP0NR]…………………………………………………………………………………………………………….1650
FAILURE CODE [DBP5KP]…………………………………………………………………………………………………………….1651
FAILURE CODE [DBPLKA]…………………………………………………………………………………………………………….1654
FAILURE CODE [DBPLKB]…………………………………………………………………………………………………………….1657
FAILURE CODE [DBPRKR]…………………………………………………………………………………………………………….1659
FAILURE CODE [DBV0MC]…………………………………………………………………………………………………………….1665
FAILURE CODE [DBV1KK]…………………………………………………………………………………………………………….1666
FAILURE CODE [DBV5KB]…………………………………………………………………………………………………………….1668
FAILURE CODE [DBV6KB]…………………………………………………………………………………………………………….1670
FAILURE CODE [DBV8KB]…………………………………………………………………………………………………………….1672
FAILURE CODE [DBVLKA]…………………………………………………………………………………………………………….1677
FAILURE CODE [DBVLKB]…………………………………………………………………………………………………………….1679
FAILURE CODE [[DBVQKR]……………………………………………………………………………………………………………1681
FAILURE CODE [DBVRKR]…………………………………………………………………………………………………………….1685
FAILURE CODE [DBVVKR]…………………………………………………………………………………………………………….1689
FAILURE CODE [DBVWKR]…………………………………………………………………………………………………………….1690
FAILURE CODE [DBWQKR]…………………………………………………………………………………………………………….1691
FAILURE CODE [DBWRKR]…………………………………………………………………………………………………………….1697
FAILURE CODE [DBX0MC]…………………………………………………………………………………………………………….1703
FAILURE CODE [DBX2KK]…………………………………………………………………………………………………………….1704
FAILURE CODE [DBX5KP]…………………………………………………………………………………………………………….1706
FAILURE CODE [DBX6KP]…………………………………………………………………………………………………………….1708
FAILURE CODE [DBX9KQ]…………………………………………………………………………………………………………….1710
FAILURE CODE [DBXLKA]…………………………………………………………………………………………………………….1712
FAILURE CODE [DBXLKB]…………………………………………………………………………………………………………….1715
FAILURE CODE [DBXQKR]…………………………………………………………………………………………………………….1717
FAILURE CODE [DBXRKR]…………………………………………………………………………………………………………….1723
FAILURE CODE [DBY0MC]…………………………………………………………………………………………………………….1729
FAILURE CODE [DBY2KK]…………………………………………………………………………………………………………….1730
FAILURE CODE [DBY5KP]…………………………………………………………………………………………………………….1732
FAILURE CODE [DBY6KP]…………………………………………………………………………………………………………….1734
FAILURE CODE [DBY9KQ]…………………………………………………………………………………………………………….1736
FAILURE CODE [DBYLKA]…………………………………………………………………………………………………………….1738
FAILURE CODE [DBYLKB]…………………………………………………………………………………………………………….1741
FAILURE CODE [DDNRKA]…………………………………………………………………………………………………………….1743
FAILURE CODE [DDNRKY]…………………………………………………………………………………………………………….1745
FAILURE CODE [DDNS00]…………………………………………………………………………………………………………….1747
FAILURE CODE [DDXAL4]…………………………………………………………………………………………………………….1749
FAILURE CODE [DGE5KB]…………………………………………………………………………………………………………….1751
FAILURE CODE [DGH2KA]…………………………………………………………………………………………………………….1753
FAILURE CODE [DGH2KB]…………………………………………………………………………………………………………….1755
FAILURE CODE [DGT3KB]…………………………………………………………………………………………………………….1757
FAILURE CODE [DGT5KA]…………………………………………………………………………………………………………….1759
FAILURE CODE [DGT5KB]…………………………………………………………………………………………………………….1761
FAILURE CODE [DGT6KA]…………………………………………………………………………………………………………….1763
FAILURE CODE [DGT6KB]…………………………………………………………………………………………………………….1765
FAILURE CODE [DH25MA]…………………………………………………………………………………………………………….1767
FAILURE CODE [DH26MA]…………………………………………………………………………………………………………….1769
FAILURE CODE [DH27MA]…………………………………………………………………………………………………………….1771
FAILURE CODE [DH28MA]…………………………………………………………………………………………………………….1773
FAILURE CODE [DHA4KA]…………………………………………………………………………………………………………….1775
FAILURE CODE [DHA5KA]…………………………………………………………………………………………………………….1776
FAILURE CODE [DHAAMA]…………………………………………………………………………………………………………….1777
FAILURE CODE [DHABMA]…………………………………………………………………………………………………………….1778
FAILURE CODE [DHACMA]…………………………………………………………………………………………………………….1779
FAILURE CODE [DHADMA]…………………………………………………………………………………………………………….1780
FAILURE CODE [DHPEMA]…………………………………………………………………………………………………………….1781
FAILURE CODE [DHPFMA]…………………………………………………………………………………………………………….1783
FAILURE CODE [DHPGMA]…………………………………………………………………………………………………………….1785
FAILURE CODE [DHPSMA]…………………………………………………………………………………………………………….1787
FAILURE CODE [DHPHMA]…………………………………………………………………………………………………………….1789
FAILURE CODE [DHPTMA]…………………………………………………………………………………………………………….1791
FAILURE CODE [DHPUMA]…………………………………………………………………………………………………………….1793
FAILURE CODE [DHS3MA]…………………………………………………………………………………………………………….1795
FAILURE CODE [DHS4MA]…………………………………………………………………………………………………………….1798
FAILURE CODE [DHS8MA]…………………………………………………………………………………………………………….1801
FAILURE CODE [DHS9MA]…………………………………………………………………………………………………………….1804
FAILURE CODE [DHSAMA]…………………………………………………………………………………………………………….1807
FAILURE CODE [DHSBMA]…………………………………………………………………………………………………………….1810
FAILURE CODE [DHSCMA]…………………………………………………………………………………………………………….1813
FAILURE CODE [DHSDMA]…………………………………………………………………………………………………………….1816
FAILURE CODE [DHSFMA]…………………………………………………………………………………………………………….1819
FAILURE CODE [DHSGMA]…………………………………………………………………………………………………………….1822
FAILURE CODE [DHSHMA]…………………………………………………………………………………………………………….1825
FAILURE CODE [DHSJMA]…………………………………………………………………………………………………………….1828
FAILURE CODE [DKR0MA]…………………………………………………………………………………………………………….1831
FAILURE CODE [DKR1MA]…………………………………………………………………………………………………………….1834
FAILURE CODE [DKR2KA]…………………………………………………………………………………………………………….1837
FAILURE CODE [DKR2KB]…………………………………………………………………………………………………………….1838
FAILURE CODE [DKR2NX]…………………………………………………………………………………………………………….1839
FAILURE CODE [DKR3KA]…………………………………………………………………………………………………………….1841
FAILURE CODE [DKR3KB]…………………………………………………………………………………………………………….1842
FAILURE CODE [DKR3NX]…………………………………………………………………………………………………………….1843
FAILURE CODE [DKR4KA]…………………………………………………………………………………………………………….1845
FAILURE CODE [DKR4KB]…………………………………………………………………………………………………………….1846
FAILURE CODE [DKR4NX]…………………………………………………………………………………………………………….1847
FAILURE CODE [DKR5MA]…………………………………………………………………………………………………………….1849
FAILURE CODE [DKR6MA]…………………………………………………………………………………………………………….1852
FAILURE CODE [[DKTKKX]……………………………………………………………………………………………………………1855
FAILURE CODE [DKULKA]…………………………………………………………………………………………………………….1857
FAILURE CODE [DKULKB]…………………………………………………………………………………………………………….1859
FAILURE CODE [DKULKY]…………………………………………………………………………………………………………….1861
FAILURE CODE [DKVEL8]…………………………………………………………………………………………………………….1863
FAILURE CODE [DKVEMA]…………………………………………………………………………………………………………….1865
FAILURE CODE [DKVFL8]…………………………………………………………………………………………………………….1867
FAILURE CODE [DKVFMA]…………………………………………………………………………………………………………….1869
FAILURE CODE [DKVGL8]…………………………………………………………………………………………………………….1871
FAILURE CODE [DKVGMA]…………………………………………………………………………………………………………….1873
FAILURE CODE [DKVHL8]…………………………………………………………………………………………………………….1875
FAILURE CODE [DKVHMA]…………………………………………………………………………………………………………….1877
FAILURE CODE [DKVJL8]…………………………………………………………………………………………………………….1879
FAILURE CODE [DKVJMA]…………………………………………………………………………………………………………….1881
FAILURE CODE [DLM3KA]…………………………………………………………………………………………………………….1883
FAILURE CODE [DLM3KB]…………………………………………………………………………………………………………….1885
FAILURE CODE [DLM3MB]…………………………………………………………………………………………………………….1887
FAILURE CODE [DLM8KA]…………………………………………………………………………………………………………….1891
FAILURE CODE [DLM8KB]…………………………………………………………………………………………………………….1892
FAILURE CODE [DLM8MB]…………………………………………………………………………………………………………….1893
FAILURE CODE [DMU6KB]…………………………………………………………………………………………………………….1894
FAILURE CODE [DMU6KB]…………………………………………………………………………………………………………….1896
FAILURE CODE [DMU6KB]…………………………………………………………………………………………………………….1898
FAILURE CODE [DPQ1LD]…………………………………………………………………………………………………………….1900
FAILURE CODE [DPQ4KB]…………………………………………………………………………………………………………….1901
FAILURE CODE [DPQ4KT]…………………………………………………………………………………………………………….1902
FAILURE CODE [DR10KA]…………………………………………………………………………………………………………….1903
FAILURE CODE [DR20KA]…………………………………………………………………………………………………………….1905
FAILURE CODE [DR21KX]…………………………………………………………………………………………………………….1907
FAILURE CODE [DR30KA]…………………………………………………………………………………………………………….1909
FAILURE CODE [DR40KA]…………………………………………………………………………………………………………….1911
FAILURE CODE [DR50KA]…………………………………………………………………………………………………………….1913
FAILURE CODE [DR60KA]…………………………………………………………………………………………………………….1915
FAILURE CODE [DR90KA]…………………………………………………………………………………………………………….1917
FAILURE CODE [DV20KB]…………………………………………………………………………………………………………….1919
FAILURE CODE [DW45KA]…………………………………………………………………………………………………………….1921
FAILURE CODE [DW45KB]…………………………………………………………………………………………………………….1924
FAILURE CODE [DW45KY]…………………………………………………………………………………………………………….1927
FAILURE CODE [DW7BKA]…………………………………………………………………………………………………………….1929
FAILURE CODE [DW7BKB]…………………………………………………………………………………………………………….1931
FAILURE CODE [DW7BKY]…………………………………………………………………………………………………………….1933
FAILURE CODE [DW7HKA]…………………………………………………………………………………………………………….1934
FAILURE CODE [DW7HKB]…………………………………………………………………………………………………………….1936
FAILURE CODE [DW7HKY]…………………………………………………………………………………………………………….1938
FAILURE CODE [DWA5KA]…………………………………………………………………………………………………………….1940
FAILURE CODE [DWA5KB]…………………………………………………………………………………………………………….1942
FAILURE CODE [DWA5KY]…………………………………………………………………………………………………………….1944
FAILURE CODE [DWACKA]…………………………………………………………………………………………………………….1945
FAILURE CODE [DWACKB]…………………………………………………………………………………………………………….1947
FAILURE CODE [DWACKY]…………………………………………………………………………………………………………….1949
FAILURE CODE [DWK0KA]…………………………………………………………………………………………………………….1950
FAILURE CODE [DWK0KB]…………………………………………………………………………………………………………….1952
FAILURE CODE [DWK0KY]…………………………………………………………………………………………………………….1954
FAILURE CODE [DWK2KA]…………………………………………………………………………………………………………….1956
FAILURE CODE [DWK2KB]…………………………………………………………………………………………………………….1958
FAILURE CODE [DWK2KY]…………………………………………………………………………………………………………….1960
FAILURE CODE [DWM1KA]…………………………………………………………………………………………………………….1962
FAILURE CODE [DWM1KB]…………………………………………………………………………………………………………….1964
FAILURE CODE [DWM1KY]…………………………………………………………………………………………………………….1966
FAILURE CODE [DWN5KA]…………………………………………………………………………………………………………….1968
FAILURE CODE [DWN5KB]…………………………………………………………………………………………………………….1969
FAILURE CODE [DWNCKA]…………………………………………………………………………………………………………….1970
FAILURE CODE [DWNCKB]…………………………………………………………………………………………………………….1971
FAILURE CODE [DWNPKA]…………………………………………………………………………………………………………….1972
FAILURE CODE [DWNPKB]…………………………………………………………………………………………………………….1974
FAILURE CODE [DWNPKY]…………………………………………………………………………………………………………….1976
FAILURE CODE [DWNQKA]…………………………………………………………………………………………………………….1977
FAILURE CODE [DWNQKB]…………………………………………………………………………………………………………….1979
FAILURE CODE [DWNQKY]…………………………………………………………………………………………………………….1981
FAILURE CODE [DWNRKA]…………………………………………………………………………………………………………….1982
FAILURE CODE [DWNRKB]…………………………………………………………………………………………………………….1984
FAILURE CODE [DWNRKY]…………………………………………………………………………………………………………….1986
FAILURE CODE [DXR9KY]…………………………………………………………………………………………………………….1988
FAILURE CODE [DXAAKA]…………………………………………………………………………………………………………….1989
FAILURE CODE [DXAAKB]…………………………………………………………………………………………………………….1991
FAILURE CODE [DXABKA]…………………………………………………………………………………………………………….1993
FAILURE CODE [DXABKB]…………………………………………………………………………………………………………….1995
FAILURE CODE [DXACKA]…………………………………………………………………………………………………………….1997
FAILURE CODE [DXACKB]…………………………………………………………………………………………………………….1999
FAILURE CODE [DXADKA]…………………………………………………………………………………………………………….2001
FAILURE CODE [DXADKB]…………………………………………………………………………………………………………….2003
FAILURE CODE [DXR6KA]…………………………………………………………………………………………………………….2005
FAILURE CODE [DXR6KB]…………………………………………………………………………………………………………….2006
FAILURE CODE [DXR6KY]…………………………………………………………………………………………………………….2007
FAILURE CODE [DXR9KA]…………………………………………………………………………………………………………….2008
FAILURE CODE [DXR9KB]…………………………………………………………………………………………………………….2009
FAILURE CODE [DXR9KY]…………………………………………………………………………………………………………….2010
FAILURE CODE [DXRAKA]…………………………………………………………………………………………………………….2011
FAILURE CODE [DXRAKB]…………………………………………………………………………………………………………….2012
FAILURE CODE [DXRAKY]…………………………………………………………………………………………………………….2013
FAILURE CODE [DXRCKA]…………………………………………………………………………………………………………….2014
FAILURE CODE [DXRCKB]…………………………………………………………………………………………………………….2015
FAILURE CODE [DXRCKY]…………………………………………………………………………………………………………….2016
FAILURE CODE [DXRDKA]…………………………………………………………………………………………………………….2017
FAILURE CODE [DXRDKB]…………………………………………………………………………………………………………….2018
FAILURE CODE [DXRDKY]…………………………………………………………………………………………………………….2019
FAILURE CODE [DXRFKA]…………………………………………………………………………………………………………….2020
FAILURE CODE [DXRFKB]…………………………………………………………………………………………………………….2021
FAILURE CODE [DXRFKY]…………………………………………………………………………………………………………….2022
FAILURE CODE [DXRJKA]…………………………………………………………………………………………………………….2023
FAILURE CODE [DXRJKB]…………………………………………………………………………………………………………….2024
FAILURE CODE [DXRJKY]…………………………………………………………………………………………………………….2025
FAILURE CODE [DY20MA]…………………………………………………………………………………………………………….2026
FAILURE CODE [DY2CKA]…………………………………………………………………………………………………………….2029
FAILURE CODE [DY2CKY]…………………………………………………………………………………………………………….2031
FAILURE CODE [DY2FMA]…………………………………………………………………………………………………………….2033
FAILURE CODE [F7FQKR]…………………………………………………………………………………………………………….2036
FAILURE CODE [F7G0MC]…………………………………………………………………………………………………………….2038
FAILURE CODE [LA10ZL]…………………………………………………………………………………………………………….2039
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…………………………………………………………………………………………..2040
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)……………………………………………………………………………………2040
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK………………………………………………………………………………………….2047
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK……………………………………………………………………………………….2050
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP………………………………………………………………….2052
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING……………………………………………………..2054
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW………………………2057
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW…………………2058
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING……………………………………………………….2059
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING………………………………………………………..2060
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING…………………………………………………………..2061
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…………………………………………………………………….2062
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING………………………………………………………………………2063
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING………………………………………………………..2064
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING………………………………………………………………2065
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…………………………………………………………2066
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM…………………………………………………………………………2067
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL…………………………………………………………………………….2069
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM……………………………………………………..2070
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE…………………………………………………2071
E-20 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED…………………………………………………………………………..2072
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM………………………………………………………2073
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE……………………………………………………..2075
E-23 FUNCTION SWITCH DOES NOT OPERATE………………………………………………………………………………………………2076
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)…………………………………………………………………………2077
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF……………………………….2078
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER………………………………………………………………………….2079
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED………………………………………………..2080
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED…………………………………………………..2081
E-29 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION…………………………………………………………..2082
E-30 SERVICE MODE CANNOT BE SELECTED……………………………………………………………………………………………….2083
E-31 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE…………………………………………………………………..2084
E-32 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK……………………………………………………………………2087
E-33 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING……………………………………………………..2089
E-34 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE……………………………………….2091
E-35 HORN DOES NOT SOUND………………………………………………………………………………………………………….2093
E-36 HORN DOES NOT STOP SOUNDING…………………………………………………………………………………………………..2096
E-37 ALARM DOES NOT SOUND DURING TRAVEL…………………………………………………………………………………………….2098
E-38 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED……………………………………………………………………………2100
E-39 ALARM BUZZER CANNOT BE CANCELED……………………………………………………………………………………………….2101
E-40 NONE OF ROOM LAMP, HEADLAMP, OR WORKING LAMP DOES NOT LIGHT UP……………………………………………………………………2102
E-41 HEADLAMP OR WORKING LAMP DOES NOT LIGHT UP……………………………………………………………………………………..2105
E-42 ROOM LAMP DOES NOT LIGHT UP…………………………………………………………………………………………………..2109
E-43 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF…………………………………………………………..2111
E-44 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED (UPPER WIPER SPECIFICATION)……………………………………………………2112
E-45 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED (LOWER WIPER SPECIFICATION)……………………………………………………2115
E-46 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY……………………………………………………………………………2118
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE……………………………………………………………..2122
E-48 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION………………………………………………………………2123
E-49 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION……………………………………………………………….2124
E-50 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…………………………………………………………..2125
E-51 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…………………………………………………………..2126
E-52 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION………………………………………………………………..2127
E-53 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION……………………………………………………………….2128
E-54 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION……………………………………………………………2129
E-55 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION……………………………………………………………2130
E-56 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY……………………………………………………………………………………….2131
E-57 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED…………………………………………………………………………………….2132
E-58 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE………………………………………………………………………………………2134
E-59 STEP LIGHT DOES NOT LIGHT UP………………………………………………………………………………………………….2135
E-60 STEP LIGHT DOES NOT GO OUT……………………………………………………………………………………………………2138
E-61 BOOM SHOCKLESS FUNCTION CANNOT BE CANCELED……………………………………………………………………………………..2140
E-62 BOOM SHOCKLESS FUNCTION DOES NOT WORK………………………………………………………………………………………….2142
E-63 AIR CONDITIONER CONTROL PANEL DOES NOT TURN ON………………………………………………………………………………….2143
E-64 WIND DOES NOT COME OUT FROM THE AIR CONDITIONER…………………………………………………………………………………2145
E-65 AIR CONDITIONER IS WEAK IN COLD(ELECTRIC CAPACITOR DOES NOT MOVE OR ONLY HI ROTATION MOVES)………………………………………….2147
E-66 AIR CONDITIONER DOES NOT GET COLD(COMPRESSOR DOES NOT MOVE)………………………………………………………………………2149
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)…………………………………………………………………………….2152
H-1 ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK………………………………………………………………………………..2152
H-2 ALL WORK EQUIPMENT, TRAVEL, SWING SPEED OR POWER IS LOW…………………………………………………………………………..2153
H-3 ENGINE SPEED DROPS SIGNIFICANTLY OR ENGINE STALLS………………………………………………………………………………..2155
H-4 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT PUMP……………………………………………………………………………2156
H-5 BOOM SPEED OR POWER IS LOW IN NORMAL MODE……………………………………………………………………………………….2157
H-6 BOOM RAISE SPEED OR POWER IS LOW IN HEAVY LIFT MODE………………………………………………………………………………2158
H-7 BOOM LOWER SPEED OR POWER IS LOW IN MACHINE PUSH UP MODE………………………………………………………………………….2159
H-8 ARM SPEED OR POWER IS LOW……………………………………………………………………………………………………..2160
H-9 BUCKET SPEED OR POWER IS LOW…………………………………………………………………………………………………..2161
H-10 BOOM DOES NOT OPERATE………………………………………………………………………………………………………..2162
H-11 ARM DOES NOT OPERATE…………………………………………………………………………………………………………2163
H-12 BUCKET DOES NOT OPERATE………………………………………………………………………………………………………2164
H-13 HYDRAULIC DRIFT OF BOOM IS LARGE………………………………………………………………………………………………2165
H-14 HYDRAULIC DRIFT OF ARM IS LARGE……………………………………………………………………………………………….2166
H-15 HYDRAULIC DRIFT OF BUCKET IS LARGE…………………………………………………………………………………………….2167
H-16 TIME LAG OF BOOM IS LARGE…………………………………………………………………………………………………….2168
H-17 TIME LAG OF ARM IS LARGE……………………………………………………………………………………………………..2169
H-18 TIME LAG OF BUCKET IS LARGE…………………………………………………………………………………………………..2170
H-19 BOOM SHOCKLESS FUNCTION DOES NOT WORK OR CANNOT BE RELEASED………………………………………………………………………2171
H-20 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS (IT TURNS IN THE SAME DIRECTION WHEN TRAVELING FORWARD AND REVERSE)……….2172
H-21 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS (IT TURNS IN THE DIFFERENT DIRECTIONS WHEN TRAVELING FORWARD AND REVERSE)….2174
H-22 ONLY WHEN OPERATING THE TRAVEL LEVER FULLY, TRAVEL DEVIATION IS LARGE AT START OF TRAVELING………………………………………….2175
H-23 REGARDLESS OF THE STROKE OF THE TRAVEL LEVER, TRAVEL DEVIATION IS LARGE AT START OF TRAVELING………………………………………..2176
H-24 TRAVEL DEVIATION IS LARGE AT COMBINED OPERATION…………………………………………………………………………………2177
H-25 TRAVEL SPEED OR POWER IS LOW………………………………………………………………………………………………….2178
H-26 ONLY THE ONE SIDE TRACK CAN OPERATE (MACHINE DOES NOT TRAVEL EITHER FORWARD OR REVERSE)……………………………………………..2179
H-27 ONLY THE ONE SIDE TRACK CAN OPERATE (MACHINE CAN TRAVEL ONLY FORWARD OR REVERSE)……………………………………………………2180
H-28 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST…………………………………………………………………2181
H-29 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT………………………………………………………………………..2182
H-30 SWINGS ONLY IN ONE DIRECTION………………………………………………………………………………………………….2183
H-31 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)……………………………………………………….2184
H-32 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION…………………………………………………2185
H-33 IN COMBINED OPERATION OF WORK EQUIPMENT, SWING SPEED OR POWER IS LOW………………………………………………………………2186
H-34 WHILE COMBINED OPERATION WITH BOOM SWING SPEED IS LOW OR SWING ACCELERATION PERFORMANCE IS POOR………………………………………2187
H-35 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)…………………………………………………..2188
H-36 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)…………………………………2189
H-37 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING (BOTH RIGHT AND LEFT)…………………………………………………………..2190
H-38 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING………………………………………………………………………………2191
H-39 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING (BOTH RIGHT AND LEFT)………………………………………………2192
H-40 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING IN ONLY ONE DIRECTION………………………………………………2193
H-41 SWING DRIFT ON A SLOPE IS LARGE……………………………………………………………………………………………….2194
H-42 FAN SPEED IS ABNORMAL (SUCH AS EXCESSIVE NOISE OR VIBRATION OF FAN, OR OVERHEATING)…………………………………………………2195
TROUBLESHOOTING OF ENGINE (S-MODE)…………………………………………………………………………………………………….2196
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)………………………………………………………………………………2196
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO…………………………………………………………………………..2197
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT………………………………………………………………………………………2198
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING:ENGINE CRANKS BUT DOES NOT START)…………………………………………2199
S-4 ENGINE STARTABILITY IS POOR……………………………………………………………………………………………………2200
S-5 ENGINE DOES NOT PICK UP SMOOTHLY……………………………………………………………………………………………….2202
S-6 ENGINE STOPS DURING OPERATION………………………………………………………………………………………………….2204
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE……………………………………………………………………………………………….2206
S-8 ENGINE LACKS POWER……………………………………………………………………………………………………………2207
S-9 KDPF GETS CLOGGED IN A SHORT TIME………………………………………………………………………………………………2209
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE……………………………………………………………………………………………2211
S-11 OIL BECOMES CONTAMINATED QUICKLY………………………………………………………………………………………………2212
S-12 FUEL CONSUMPTION IS EXCESSIVE…………………………………………………………………………………………………2213
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT…………………………………………………………………………….2214
S-14 OIL PRESSURE DROPS…………………………………………………………………………………………………………..2215
S-15 FUEL MIXES INTO ENGINE OIL……………………………………………………………………………………………………2217
S-16 WATER MIXES INTO ENGINE OIL (MILKY)……………………………………………………………………………………………2218
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)………………………………………………………………………………..2219
S-18 UNUSUAL NOISE IS HEARD……………………………………………………………………………………………………….2221
S-19 VIBRATION IS EXCESSIVE……………………………………………………………………………………………………….2222
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT…………………………………………………………………………………………..2223
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY……………………………………………………………………………………..2224
S-22 ACTIVE REGENERATION TAKES TIME………………………………………………………………………………………………..2225
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION……………………………………………………………………………..2226
50 DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………………2227
CONTENTS……………………………………………………………………………………………………………………………2228
ABBREVIATION LIST……………………………………………………………………………………………………………………2233
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………………2239
HOW TO READ THIS MANUAL…………………………………………………………………………………………………………..2239
COATING MATERIALS LIST……………………………………………………………………………………………………………2241
SPECIAL TOOLS LIST……………………………………………………………………………………………………………….2245
SKETCHES OF SPECIAL TOOLS…………………………………………………………………………………………………………2263
ENGINE AND COOLING SYSTEM…………………………………………………………………………………………………………….2266
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (RIGHT BANK)…………………………………………………………………………………2266
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY (RIGHT BANK)…………………………………………………………………………….2266
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY (RIGHT BANK)…………………………………………………………………………..2279
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (LEFT BANK)………………………………………………………………………………….2301
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY (LEFT BANK)……………………………………………………………………………..2301
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY (LEFT BANK)……………………………………………………………………………2310
REMOVE AND INSTALL INJECTOR ASSEMBLY (RIGHT BANK)……………………………………………………………………………………2324
METHOD FOR REMOVING INJECTOR ASSEMBLY…………………………………………………………………………………………..2324
METHOD FOR INSTALLING INJECTOR ASSEMBLY…………………………………………………………………………………………2337
REMOVE AND INSTALL INJECTOR ASSEMBLY (LEFT BANK)…………………………………………………………………………………….2355
METHOD FOR REMOVING INJECTOR ASSEMBLY (LEFT BANK)………………………………………………………………………………..2355
METHOD FOR INSTALLING INJECTOR ASSEMBLY (LEFT BANK)………………………………………………………………………………2369
REMOVE AND INSTALL FUEL DOSER ASSEMBLY (RIGHT BANK)………………………………………………………………………………….2388
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY (RIGHT BANK)……………………………………………………………………………2388
METHOD FOR REMOVING FUEL DOSER ASSEMBLY (RIGHT BANK)……………………………………………………………………………..2391
REMOVE AND INSTALL FUEL DOSER ASSEMBLY (LEFT BANK)…………………………………………………………………………………..2395
METHOD FOR REMOVING FUEL DOSER ASSEMBLY (LEFT BANK)………………………………………………………………………………2395
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY (LEFT BANK)…………………………………………………………………………….2398
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY (RIGHT BANK)……………………………………………………………………………….2402
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY (RIGHT BANK)…………………………………………………………………………..2402
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY (RIGHT BANK)…………………………………………………………………………2436
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY (LEFT BANK)………………………………………………………………………………..2486
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY (LEFT BANK)……………………………………………………………………………2486
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY (LEFT BANK)………………………………………………………………………….2526
REMOVE AND INSTALL EGR VALVE ASSEMBLY (RIGHT BANK)…………………………………………………………………………………..2586
METHOD FOR REMOVING EGR VALVE ASSEMBLY (RIGHT BANK)………………………………………………………………………………2586
METHOD FOR INSTALLING EGR VALVE ASSEMBLY (RIGHT BANK)…………………………………………………………………………….2598
REMOVE AND INSTALL EGR VALVE ASSEMBLY (LEFT BANK)……………………………………………………………………………………2614
METHOD FOR REMOVING EGR VALVE ASSEMBLY (LEFT BANK)……………………………………………………………………………….2614
METHOD FOR INSTALLING EGR VALVE ASSEMBLY (LEFT BANK)……………………………………………………………………………..2626
REMOVE AND INSTALL EGR COOLER ASSEMBLY (RIGHT BANK)………………………………………………………………………………….2644
METHOD FOR REMOVING EGR COOLER ASSEMBLY (RIGHT BANK)……………………………………………………………………………..2644
METHOD FOR INSTALLING EGR COOLER ASSEMBLY (RIGHT BANK)……………………………………………………………………………2665
REMOVE AND INSTALL EGR COOLER ASSEMBLY (LEFT BANK)…………………………………………………………………………………..2694
METHOD FOR REMOVING EGR COOLER ASSEMBLY (LEFT BANK)………………………………………………………………………………2694
METHOD FOR INSTALLING EGR COOLER ASSEMBLY (LEFT BANK)…………………………………………………………………………….2712
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY………………………………………………………………………………………….2738
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY……………………………………………………………………………………..2738
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY……………………………………………………………………………………2741
REMOVE AND INSTALL ALTERNATOR BELT…………………………………………………………………………………………………2744
METHOD FOR REMOVING ALTERNATOR BELT…………………………………………………………………………………………….2744
METHOD FOR INSTALLING ALTERNATOR BELT…………………………………………………………………………………………..2746
REMOVE AND INSTALL ALTERNATOR ASSEMBLY……………………………………………………………………………………………..2750
METHOD FOR REMOVING ALTERNATOR ASSEMBLY…………………………………………………………………………………………2750
METHOD FOR INSTALLING ALTERNATOR ASSEMBLY……………………………………………………………………………………….2753
REMOVE AND INSTALL RADIATOR ASSEMBLY……………………………………………………………………………………………….2759
METHOD FOR REMOVING RADIATOR ASSEMBLY…………………………………………………………………………………………..2759
METHOD FOR INSTALLING RADIATOR ASSEMBLY…………………………………………………………………………………………2764
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY…………………………………………………………………………………….2770
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY………………………………………………………………………………..2770
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY………………………………………………………………………………2773
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY…………………………………………………………………………………………….2777
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY………………………………………………………………………………………..2777
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY………………………………………………………………………………………2782
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY……………………………………………………………………………………….2788
REMOVE COOLING FAN MOTOR ASSEMBLY………………………………………………………………………………………………2788
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY…………………………………………………………………………………2814
REMOVE AND INSTALL POWER MODULE PACKAGING ASSEMBLY…………………………………………………………………………………..2839
REMOVE POWER MODULE PACKAGING ASSEMBLY………………………………………………………………………………………….2839
METHOD FOR INSTALLING POWER MODULE PACKAGING ASSEMBLY…………………………………………………………………………….2854
REMOVE AND INSTALL ENGINE PTO AND HYDRAULIC ASSEMBLY…………………………………………………………………………………2869
METHOD FOR REMOVING ENGINE PTO AND HYDRAULIC ASSEMBLY…………………………………………………………………………….2870
METHOD FOR INSTALLING ENGINE PTO AND HYDRAULIC ASSEMBLY…………………………………………………………………………..2902
REMOVE AND INSTALL ENGINE FRONT OIL SEAL……………………………………………………………………………………………2935
METHOD FOR REMOVING ENGINE FRONT OIL SEAL……………………………………………………………………………………….2935
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL……………………………………………………………………………………..2942
REMOVE AND INSTALL ENGINE REAR OIL SEAL…………………………………………………………………………………………….2950
REMOVE ENGINE REAR OIL SEAL……………………………………………………………………………………………………2950
INSTALL ENGINE REAR OIL SEAL…………………………………………………………………………………………………..2952
REMOVE AND INSTALL FUEL COOLER ASSEMBLY…………………………………………………………………………………………….2956
METHOD FOR REMOVING FUEL COOLER ASSEMBLY………………………………………………………………………………………..2956
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY………………………………………………………………………………………2958
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY…………………………………………………………………………………………….2960
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY………………………………………………………………………………………..2960
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY………………………………………………………………………………………2965
REMOVE AND INSTALL FUEL TANK ASSEMBLY………………………………………………………………………………………………2971
METHOD FOR REMOVING FUEL TANK ASSEMBLY………………………………………………………………………………………….2971
METHOD FOR INSTALLING FUEL TANK ASSEMBLY………………………………………………………………………………………..2974
REMOVE AND INSTALL KDPF ASSEMBLY…………………………………………………………………………………………………..2978
METHOD FOR REMOVING KDPF ASSEMBLY………………………………………………………………………………………………2978
METHOD FOR INSTALLING KDPF ASSEMBLY…………………………………………………………………………………………….2987
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY……………………………………………………………………………………………2998
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY……………………………………………………………………………………….2998
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY……………………………………………………………………………………..3000
REMOVE AND INSTALL KCCV ASSEMBLY (RIGHT BANK)……………………………………………………………………………………….3001
METHOD FOR REMOVING KCCV ASSEMBLY (RIGHT BANK)…………………………………………………………………………………..3001
METHOD FOR INSTALLING KCCV ASSEMBLY (RIGHT BANK)…………………………………………………………………………………3004
REMOVE AND INSTALL KCCV ASSEMBLY (LEFT BANK)………………………………………………………………………………………..3008
METHOD FOR REMOVING KCCV ASSEMBLY (LEFT BANK)……………………………………………………………………………………3008
METHOD FOR INSTALLING KCCV ASSEMBLY (LEFT BANK)………………………………………………………………………………….3012
REMOVE AND INSTALL VGT ASSEMBLY (RIGHT BANK)………………………………………………………………………………………..3017
METHOD FOR REMOVING VGT ASSEMBLY (RIGHT BANK)……………………………………………………………………………………3017
METHOD FOR INSTALLING VGT ASSEMBLY (RIGHT BANK)………………………………………………………………………………….3031
REMOVE AND INSTALL VGT ASSEMBLY (LEFT BANK)…………………………………………………………………………………………3047
METHOD FOR REMOVING VGT ASSEMBLY (LEFT BANK)…………………………………………………………………………………….3047
METHOD FOR INSTALLING VGT ASSEMBLY (LEFT BANK)…………………………………………………………………………………..3061
REMOVE AND INSTALL AIR CLEANER ASSEMBLY…………………………………………………………………………………………….3077
METHOD FOR REMOVING AIR CLEANER ASSEMBLY………………………………………………………………………………………..3077
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY………………………………………………………………………………………3080
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY……………………………………………………………………………….3084
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY…………………………………………………………………………..3084
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY…………………………………………………………………………3087
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY………………………………………………………………………………..3090
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY……………………………………………………………………………3090
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY………………………………………………………………………….3093
POWER TRAIN…………………………………………………………………………………………………………………………3096
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY………………………………………………………………………………………………3096
METHOD FOR DISASSEMBLING PTO ASSEMBLY…………………………………………………………………………………………..3096
METHOD FOR ASSEMBLING PTO ASSEMBLY……………………………………………………………………………………………..3101
REMOVE AND INSTALL PTO ASSEMBLY……………………………………………………………………………………………………3105
METHOD FOR REMOVING PTO ASSEMBLY……………………………………………………………………………………………….3105
METHOD FOR INSTALLING PTO ASSEMBLY……………………………………………………………………………………………..3106
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY……………………………………………………………………………..3107
REMOVE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…………………………………………………………………………………….3107
INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY……………………………………………………………………………………3111
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY……………………………………………………………………………………….3115
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY……………………………………………………………………………………3116
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY………………………………………………………………………………………3122
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY…………………………………………………………………………..3131
REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY………………………………………………………………………………….3132
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY…………………………………………………………………….3140
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY……………………………………………………………………………………3146
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY………………………………………………………………………………..3146
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY…………………………………………………………………………………..3152
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY……………………………………………………………………………………………3159
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY……………………………………………………………………………………….3159
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY……………………………………………………………………………………..3159
UNDERCARRIAGE AND FRAME………………………………………………………………………………………………………………3161
REMOVE AND INSTALL IDLER ASSEMBLY………………………………………………………………………………………………….3161
METHOD FOR REMOVING IDLER ASSEMBLY……………………………………………………………………………………………..3161
METHOD FOR INSTALLING IDLER ASSEMBLY……………………………………………………………………………………………3162
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY……………………………………………………………………………………………3163
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY……………………………………………………………………………………….3163
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY……………………………………………………………………………………..3164
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY………………………………………………………………………………………….3166
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY……………………………………………………………………………………..3166
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY……………………………………………………………………………………3167
SEPARATION AND CONNECTION OF TRACK ASSEMBLY…………………………………………………………………………………………3169
METHOD FOR SEPARATING TRACK ASSEMBLY……………………………………………………………………………………………3169
METHOD FOR INSTALLING TRACK ASSEMBLY……………………………………………………………………………………………3170
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY…………………………………………………………………………………………….3172
METHOD FOR DISASSEMBLING IDLER ASSEMBLY…………………………………………………………………………………………3172
METHOD FOR ASSEMBLING IDLER ASSEMBLY……………………………………………………………………………………………3174
DISASSEMBLE AND ASSEMBLE AIDLER ADJUSTMENT CYLINDER ASSEMBLY………………………………………………………………………….3177
METHOD FOR DISASSEMBLING AIDLER ADJUSTMENT CYLINDER ASSEMBLY………………………………………………………………………3177
METHOD FOR ASSEMBLING AIDLER ADJUSTMENT CYLINDER ASSEMBLY…………………………………………………………………………3178
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY………………………………………………………………………………………3180
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY…………………………………………………………………………………..3180
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY……………………………………………………………………………………..3181
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY……………………………………………………………………………………..3183
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY…………………………………………………………………………………3183
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY……………………………………………………………………………………3184
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY…………………………………………………………………………………………3187
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY…………………………………………………………………………………….3187
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY…………………………………………………………………………………..3191
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY…………………………………………………………………………………………..3195
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY………………………………………………………………………………………3195
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY…………………………………………………………………………………….3197
HYDRAULIC SYSTEM…………………………………………………………………………………………………………………….3200
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY……………………………………………………………………………………..3200
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY…………………………………………………………………………………3200
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY……………………………………………………………………………….3202
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY………………………………………………………………………………..3206
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY…………………………………………………………………………….3207
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY……………………………………………………………………………….3208
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY………………………………………………………………………………………….3209
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY……………………………………………………………………………………..3209
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY……………………………………………………………………………………3217
REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY………………………………………………………………………………………….3225
METHOD FOR REMOVING HYDRAULIC PUMP ASSEMBLY……………………………………………………………………………………..3226
METHOD FOR INSTALLING HYDRAULIC PUMP ASSEMBLY……………………………………………………………………………………3244
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY…………………………………………………………………………………………..3263
REMOVE CONTROL VALVE ASSEMBLY………………………………………………………………………………………………….3264
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY…………………………………………………………………………………….3277
REMOVE AND INSTALL SWING MOTOR ASSEMBLY…………………………………………………………………………………………….3293
REMOVE SWING MOTOR ASSEMBLY……………………………………………………………………………………………………3293
METHOD FOR INSTALLING SWING MOTOR ASSEMBLY………………………………………………………………………………………3299
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY……………………………………………………………………………3305
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY………………………………………………………………………..3305
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY…………………………………………………………………………..3305
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY…………………………………………………………………………………..3308
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY……………………………………………………………………………….3308
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY………………………………………………………………………………….3309
DISASSEMBLE AND ASSEMBLE GREASE GUN ASSEMBLY………………………………………………………………………………………..3312
METHOD FOR DISASSEMBLING GREASE GUN ASSEMBLY…………………………………………………………………………………….3312
METHOD FOR ASSEMBLING GREASE GUN ASSEMBLY……………………………………………………………………………………….3312
WORK EQUIPMENT………………………………………………………………………………………………………………………3313
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY…………………………………………………………………………………………3313
METHOD FOR REMOVING BUCKET CYLINDER ASSEMBLY…………………………………………………………………………………….3314
METHOD FOR INSTALLING BUCKET CYLINDER ASSEMBLY…………………………………………………………………………………..3316
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY……………………………………………………………………………………………3318
METHOD FOR REMOVING ARM CYLINDER ASSEMBLY……………………………………………………………………………………….3318
METHOD FOR INSTALLING ARM CYLINDER ASSEMBLY……………………………………………………………………………………..3320
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY…………………………………………………………………………………………..3323
METHOD FOR REMOVING BOOM CYLINDER ASSEMBLY………………………………………………………………………………………3323
METHOD FOR INSTALLING BOOM CYLINDER ASSEMBLY…………………………………………………………………………………….3326
REMOVE AND INSTALL BUCKET ASSEMBLY…………………………………………………………………………………………………3329
METHOD FOR REMOVING BUCKET ASSEMBLY…………………………………………………………………………………………….3329
METHOD FOR INSTALLING BUCKET ASSEMBLY…………………………………………………………………………………………..3331
REMOVE AND INSTALL ARM ASSEMBLY……………………………………………………………………………………………………3334
REMOVE ARM ASSEMBLY…………………………………………………………………………………………………………..3334
METHOD FOR INSTALLING ARM ASSEMBLY……………………………………………………………………………………………..3340
REMOVE AND INSTALL BOOM ASSEMBLY…………………………………………………………………………………………………..3345
METHOD FOR REMOVING BOOM ASSEMBLY………………………………………………………………………………………………3345
METHOD FOR INSTALLING BOOM ASSEMBLY…………………………………………………………………………………………….3348
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY…………………………………………………………………………….3352
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY…………………………………………………………………………3353
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY……………………………………………………………………………3356
CAB AND ITS ATTACHMENTS………………………………………………………………………………………………………………3361
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY………………………………………………………………………………………….3361
REMOVE OPERATOR CAB ASSEMBLY…………………………………………………………………………………………………..3362
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY……………………………………………………………………………………..3369
REMOVE AND INSTALL CAB BASE……………………………………………………………………………………………………….3376
METHOD FOR REMOVING CAB BASE…………………………………………………………………………………………………..3376
METHOD FOR INSTALLING CAB BASE…………………………………………………………………………………………………3380
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)………………………………………………………………………………..3385
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)……………………………………………………………………………3386
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)………………………………………………………………………….3387
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ASSEMBLING TYPE)…………………………………………………………………………….3394
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ASSEMBLING TYPE)………………………………………………………………………..3394
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ASSEMBLING TYPE)………………………………………………………………………3396
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY…………………………………………………………………………………….3398
REMOVE AIR CONDITIONER UNIT ASSEMBLY……………………………………………………………………………………………3398
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY………………………………………………………………………………3413
REMOVE AND INSTALL OPERATOR’S SEAT…………………………………………………………………………………………………3426
METHOD FOR REMOVING OPERATOR’S SEAT…………………………………………………………………………………………….3426
METHOD FOR INSTALLING OPERATOR’S SEAT…………………………………………………………………………………………..3429
REMOVE AND INSTALL SEAT BELT………………………………………………………………………………………………………3432
METHOD FOR REMOVING SEAT BELT………………………………………………………………………………………………….3432
METHOD FOR INSTALLING SEAT BELT………………………………………………………………………………………………..3433
REMOVE AND INSTALL FRONT WIPER ASSEMBLY…………………………………………………………………………………………….3435
METHOD FOR REMOVING FRONT WIPER ASSEMBLY………………………………………………………………………………………..3435
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY………………………………………………………………………………………3439
ELECTRICAL SYSTEM……………………………………………………………………………………………………………………3443
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY (RIGHT BANK)……………………………………………………………………………3443
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY (RIGHT BANK)……………………………………………………………………….3443
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY (RIGHT BANK)……………………………………………………………………..3445
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY (LEFT BANK)…………………………………………………………………………….3447
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY (LEFT BANK)………………………………………………………………………..3447
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY (LEFT BANK)………………………………………………………………………3448
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY…………………………………………………………………………………………3451
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY…………………………………………………………………………………….3451
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY…………………………………………………………………………………..3452
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY…………………………………………………………………………………….3454
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY………………………………………………………………………………..3454
METHOD FOR INSTALLING KomVision CONTROLLER………………………………………………………………………………………3455
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY…………………………………………………………………………………………3457
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY…………………………………………………………………………………….3457
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY…………………………………………………………………………………..3460
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR………………………………………………………………………………3463
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR………………………………………………………………………….3463
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR………………………………………………………………………..3464
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR ASSEMBLY (RIGHT BANK)………………………………………………………………..3465
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR ASSEMBLY (RIGHT BANK)……………………………………………………………3465
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR ASSEMBLY (RIGHT BANK)………………………………………………………….3466
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR ASSEMBLY (LEFT BANK)…………………………………………………………………3468
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR ASSEMBLY (LEFT BANK)…………………………………………………………….3468
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR ASSEMBLY (LEFT BANK)…………………………………………………………..3469
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR………………………………………………………………………………………….3471
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR……………………………………………………………………………………..3471
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR……………………………………………………………………………………3477
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR…………………………………………………………………………………3483
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR…………………………………………………………………………….3483
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR…………………………………………………………………………..3488
REMOVE AND INSTALL KomVision CAMERA………………………………………………………………………………………………..3493
METHOD FOR REMOVING KomVision CAMERA……………………………………………………………………………………………3493
METHOD FOR INSTALLING KomVision CAMERA………………………………………………………………………………………….3497
REMOVE AND INSTALL KOMTRAX Plus CONTROLLER ASSEMBLY………………………………………………………………………………….3501
METHOD FOR REMOVING KOMTRAX Plus CONTROLLER ASSEMBLY……………………………………………………………………………..3501
METHOD FOR INSTALLING KOMTRAX Plus CONTROLLER ASSEMBLY……………………………………………………………………………3502
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY……………………………………………………………………………………….3504
METHOD FOR REMOVING WIRELESS LAN UNIT ASSEMBLY…………………………………………………………………………………..3504
METHOD FOR NSTALLING WIRELESS LAN UNIT ASSEMBLY………………………………………………………………………………….3506
60 MAINTENANCE STANDARD………………………………………………………………………………………………………………….3509
CONTENTS……………………………………………………………………………………………………………………………3510
ABBREVIATION LIST……………………………………………………………………………………………………………………3511
ENGINE AND COOLING SYSTEM…………………………………………………………………………………………………………….3517
MAINTENANCE STANDARD OF ENGINE MOUNT……………………………………………………………………………………………….3517
MAINTENANCE STANDARD FOR PTO………………………………………………………………………………………………………3518
MAINTENANCE STANDARD OF COOLING FAN PUMP……………………………………………………………………………………………3520
MAINTENANCE STANDARD OF EPC VALVE OF COOLING FAN PUMP…………………………………………………………………………….3523
MAINTENANCE STANDARD OF COOLING FAN MOTOR…………………………………………………………………………………………..3524
POWER TRAIN…………………………………………………………………………………………………………………………3527
MAINTENANCE STANDARD OF SWING CIRCLE……………………………………………………………………………………………….3527
MAINTENANCE STANDARD OF SWING MACHINERY…………………………………………………………………………………………….3528
MAINTENANCE STANDARD OF FINAL DRIVE………………………………………………………………………………………………..3530
MAINTENANCE STANDARD OF SPROCKET…………………………………………………………………………………………………..3532
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING……………………………………………………………………..3533
UNDERCARRIAGE AND FRAME………………………………………………………………………………………………………………3534
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION………………………………………………………………………………..3534
MAINTENANCE STANDARD OF IDLER……………………………………………………………………………………………………..3537
MAINTENANCE STANDARD OF TRACK ROLLER……………………………………………………………………………………………….3539
MAINTENANCE STANDARD OF CARRIER ROLLER……………………………………………………………………………………………..3540
MAINTENANCE STANDARD OF TRACK SHOE…………………………………………………………………………………………………3542
MAINTENANCE STANDARD OF DOUBLE SHOE………………………………………………………………………………………………..3545
MAINTENANCE STANDARD OF TRIPLE SHOE………………………………………………………………………………………………..3546
HYDRAULIC SYSTEM…………………………………………………………………………………………………………………….3547
MAINTENANCE STANDARD OF MAIN PUMP………………………………………………………………………………………………….3547
MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE……………………………………………………………………………………3551
MAINTENANCE STANDARD OF SWING MOTOR………………………………………………………………………………………………..3553
MAINTENANCE STANDARD OF TRAVEL MOTOR……………………………………………………………………………………………….3556
MAINTENANCE STANDARD OF CONTROL VALVE………………………………………………………………………………………………3560
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE VALVE…………………………………………………………………………………3594
MAINTENANCE STANDARD OF PPC CUT-OFF VALVE…………………………………………………………………………………………..3595
MAINTENANCE STANDARD OF SUCTION SELECTOR VALVE………………………………………………………………………………………3599
MAINTENANCE STANDARD OF PPC CUT-OFF VALVE…………………………………………………………………………………………..3601
MAINTENANCE STANDARD OF SUCTION SELECTOR VALVE………………………………………………………………………………………3605
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE……………………………………………………………………………3607
MAINTENANCE STANDARD OF TRAVEL PPC VALVE……………………………………………………………………………………………3610
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT…………………………………………………………………………………………3613
WORK EQUIPMENT………………………………………………………………………………………………………………………3614
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE………………………………………………………………………………………3614
DIMENSION OF ARM……………………………………………………………………………………………………………..3618
DIMENSIONS OF BUCKET………………………………………………………………………………………………………….3620
MAINTENANCE STANDARD OF BOOM CYLINDER………………………………………………………………………………………………3623
MAINTENANCE STANDARD OF ARM CYLINDER……………………………………………………………………………………………….3624
MAINTENANCE STANDARD OF BUCKET CYLINDER…………………………………………………………………………………………….3625
80 APPENDIX…………………………………………………………………………………………………………………………….3627
CONTENTS……………………………………………………………………………………………………………………………3628
ABBREVIATION LIST……………………………………………………………………………………………………………………3631
AIR CONDITIONER SYSTEM……………………………………………………………………………………………………………….3637
PRECAUTIONS FOR REFRIGERANT……………………………………………………………………………………………………….3637
AIR CONDITIONER COMPONENT…………………………………………………………………………………………………………3638
AIR CONDITIONER COMPONENT…………………………………………………………………………………………………………3640
SPECIFICATIONS OF AIR CONDITIONER………………………………………………………………………………………………….3642
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE……………………………………………………………………………………3643
OUTLINE OF REFRIGERATION CYCLE…………………………………………………………………………………………………….3644
COMPONENT PARTS OF AIR CONDITIONER SYSTEM………………………………………………………………………………………………3646
AIR CONDITIONER UNIT……………………………………………………………………………………………………………..3646
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT……………………………………………………………………………………3646
FUNCTION OF AIR CONDITIONER UNIT……………………………………………………………………………………………….3648
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT……………………………………………………………………………..3649
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………………………….3650
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………….3650
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………………………….3650
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT………………………………………………………………………..3651
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………………………3651
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………………………….3651
FUNCTION OF DUAL PRESSURE SWITCH…………………………………………………………………………………………………..3652
AIR CONDITIONER CONTROLLER………………………………………………………………………………………………………..3653
STRUCTURE OF AIR CONDITIONER CONTROLLER…………………………………………………………………………………………3653
COMPRESSOR………………………………………………………………………………………………………………………3654
STRUCTURE OF COMPRESSOR……………………………………………………………………………………………………….3654
SPECIFICATIONS OF COMPRESSOR…………………………………………………………………………………………………..3654
FUNCTION OF COMPRESSOR………………………………………………………………………………………………………..3654
CONDENSER……………………………………………………………………………………………………………………….3655
STRUCTURE OF CONDENSER………………………………………………………………………………………………………..3655
SPECIFICATIONS OF CONDENSER……………………………………………………………………………………………………3655
FUNCTION OF CONDENSER…………………………………………………………………………………………………………3655
RECEIVER DRIER…………………………………………………………………………………………………………………..3656
STRUCTURE OF RECEIVER DRIER……………………………………………………………………………………………………3656
SPECIFICATIONS OF RECEIVER DRIER……………………………………………………………………………………………….3656
FUNCTION OF RECEIVER DRIER…………………………………………………………………………………………………….3656
SENSORS FOR AIR CONDITIONER SYSTEM…………………………………………………………………………………………………3657
FUNCTION OF SUNLIGHT SENSOR……………………………………………………………………………………………………3657
STRUCTURE OF AMBIENT TEMPERATURE SENSOR…………………………………………………………………………………………3657
FUNCTION OF AMBIENT TEMPERATURE SENSOR………………………………………………………………………………………….3657
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER………………………………………………………………..3658
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER……………………………………………………………………..3660
AIR CONDITIONER SYSTEM DIAGRAM………………………………………………………………………………………………………..3662
AIR CONDITIONER CONTROL PANEL……………………………………………………………………………………………………..3663
EXPLANATION OF AIR CONDITIONER EQUIPMENT……………………………………………………………………………………………3663
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER……………………………………………………………………………….3664
FUNCTION OF AIR CONDITIONER CONTROLLER………………………………………………………………………………………….3665
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS………………………………………………………………3666
TESTING AIR LEAKAGE (DUCT)……………………………………………………………………………………………………………3670
METHOD FOR TESTING AIR LEAKAGE (DUCT)………………………………………………………………………………………………3670
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION……………………………………………………………………………………3671
TEST VENT (MODE) CHANGEOVER…………………………………………………………………………………………………………..3673
METHOD FOR TESTING VENT (MODE) CHANGEOVER…………………………………………………………………………………………..3673
TESTING FRESH/RECIRC AIR CHANGEOVER……………………………………………………………………………………………………3677
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER………………………………………………………………………………………3677
TEST SUNLIGHT SENSOR…………………………………………………………………………………………………………………3678
METHOD FOR TESTING SUNLIGHT SENSOR…………………………………………………………………………………………………3678
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT…………………………………………………………………………………………….3679
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT…………………………………………………………………………….3679
TEST RELAYS…………………………………………………………………………………………………………………………3681
METHOD FOR TESTING RELAYS…………………………………………………………………………………………………………3681
AIR CONDITIONER TROUBLESHOOTING CHART 1………………………………………………………………………………………………..3682
AIR CONDITIONER TROUBLESHOOTING CHART 2………………………………………………………………………………………………..3683
KomVision SYSTEM…………………………………………………………………………………………………………………….3686
STRUCTURE AND OPERATION OF KomVision SYSTEM…………………………………………………………………………………………….3686
PRECAUTIONS FOR KomVision SYSTEM…………………………………………………………………………………………………..3686
LAYOUT DRAWING OF KomVision SYSTEM…………………………………………………………………………………………………3687
LAYOUT DRAWING OF KomVision SWITCHES AND MONITORS………………………………………………………………………………..3687
KomVision SYSTEM DIAGRAM………………………………………………………………………………………………………3688
FUNCTION OF KomVision SYSTEM…………………………………………………………………………………………………..3688
COMPONENT PARTS OF KomVision SYSTEM………………………………………………………………………………………………..3690
KomVision CONTROLLER………………………………………………………………………………………………………….3690
KomVision MONITOR…………………………………………………………………………………………………………….3695
KomVision CAMERA……………………………………………………………………………………………………………..3700
TESTING AND ADJUSTING KomVision SYSTEM…………………………………………………………………………………………………3701
SET AND OPERATE KomVision MONITOR………………………………………………………………………………………………….3701
SETTING DEFAULT OF KomVision SYSTEM…………………………………………………………………………………………….3701
TOUCH PANEL OPERATION…………………………………………………………………………………………………………3702
OPERATOR MODE AND MAINTENANCE MODE OF KomVision MONITOR…………………………………………………………………………..3702
METHOD FOR OPERATING KomVision MAINTENANCE MODE………………………………………………………………………………….3703
METHOD FOR OPERATING MAIN SETTINGS……………………………………………………………………………………………..3705
METHOD FOR CHECKING SYSTEM STATE……………………………………………………………………………………………….3712
METHOD FOR CONFIRMING ERROR LOG………………………………………………………………………………………………..3713
HOW TO PERFORM CHCKDSK………………………………………………………………………………………………………..3714
METHOD FOR INITIALIZING KomVision CONTROLLER…………………………………………………………………………………….3715
CAMERA CALIBRATION……………………………………………………………………………………………………………….3716
7 CAMERA CALIBRATION……………………………………………………………………………………………………………..3717
CALIBRATION SHEET…………………………………………………………………………………………………………….3717
METHOD FOR OPERATING 7 CAMERA CALIBRATION……………………………………………………………………………………….3728
1 CAMERA CALIBRATION……………………………………………………………………………………………………………..3742
METHOD FOR USING 1 CAMERA CALIBRATION…………………………………………………………………………………………..3742
TROUBLESHOOTING OF KomVision SYSTEM……………………………………………………………………………………………………3747
RELATED INFORMATION ON TROUBLESHOOTING…………………………………………………………………………………………………3748
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM…………………………………………………………………………………3748
PROCEDURE FOR TESTING AND TROUBLESHOOTING…………………………………………………………………………………………..3749
SYMPTOM AND TROUBLESHOOTING NUMBERS………………………………………………………………………………………………..3753
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE………………………………………………………………………………………3754
CONNECTORS LIST AND LAYOUT………………………………………………………………………………………………………..3756
FAILURE CODES TABLE………………………………………………………………………………………………………………….3772
FAILURE CODE [DBP0KM]…………………………………………………………………………………………………………….3773
FAILURE CODE [DBP0KT]…………………………………………………………………………………………………………….3774
FAILURE CODE [DBP0MC]…………………………………………………………………………………………………………….3775
FAILURE CODE [DBP0NR]…………………………………………………………………………………………………………….3776
FAILURE CODE [DBP5KP]…………………………………………………………………………………………………………….3777
FAILURE CODE [DBPLKA]…………………………………………………………………………………………………………….3780
FAILURE CODE [DBPLKB]…………………………………………………………………………………………………………….3783
FAILURE CODE [DBPRKR]…………………………………………………………………………………………………………….3785
FAILURE CODE [DPQ1LD]…………………………………………………………………………………………………………….3791
FAILURE CODE [DPQ4KB]…………………………………………………………………………………………………………….3792
FAILURE CODE [DR10KA]…………………………………………………………………………………………………………….3793
FAILURE CODE [DR20KA]…………………………………………………………………………………………………………….3795
FAILURE CODE [DR30KA]…………………………………………………………………………………………………………….3797
FAILURE CODE [DR40KA]…………………………………………………………………………………………………………….3799
FAILURE CODE [DR50KA]…………………………………………………………………………………………………………….3801
FAILURE CODE [DR60KA]…………………………………………………………………………………………………………….3803
FAILURE CODE [DR90KA]…………………………………………………………………………………………………………….3805
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…………………………………………………………………………………………..3807
E-67 KomVision MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS………………………………………………………………………..3807
E-68 KomVision MONITOR IMAGES ARE NOT DISPLAYED CLEARLY………………………………………………………………………………3811
E-69 KomVision MONITOR CANNOT BE TOUCH……………………………………………………………………………………………..3818
E-70 NIGHT LIGHTING LAMP OF KomVision MONITOR IS ABNORMAL…………………………………………………………………………….3821
E-71 PART OF THE CAMERA IMAGE IS NOT DISPLAYED ON THE KomVision MONITOR………………………………………………………………..3824
E-72 IMAGE ON KomVision MONITOR IS NOT DISPLAYED PROPERLY AFTER CALIBRATION…………………………………………………………….3826
90 CIRCUIT DIAGRAMS……………………………………………………………………………………………………………………..3827
CONTENTS……………………………………………………………………………………………………………………………3828
ABBREVIATION LIST……………………………………………………………………………………………………………………3829
HYDRAULIC CIRCUIT DIAGRAM…………………………………………………………………………………………………………….3835
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM…………………………………………………………………………………………..3835
HYDRAULIC CIRCUIT DIAGRAM…………………………………………………………………………………………………………3839
ELECTRICAL CIRCUIT DIAGRAM……………………………………………………………………………………………………………3841
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM………………………………………………………………………………………….3841
ELECTRICAL CIRCUIT DIAGRAM (1/28)………………………………………………………………………………………………….3845
ELECTRICAL CIRCUIT DIAGRAM (2/28)………………………………………………………………………………………………….3847
ELECTRICAL CIRCUIT DIAGRAM (3/28)………………………………………………………………………………………………….3849
ELECTRICAL CIRCUIT DIAGRAM (4/28)………………………………………………………………………………………………….3851
ELECTRICAL CIRCUIT DIAGRAM (5/28)………………………………………………………………………………………………….3853
ELECTRICAL CIRCUIT DIAGRAM (6/28)………………………………………………………………………………………………….3855
ELECTRICAL CIRCUIT DIAGRAM (7/28)………………………………………………………………………………………………….3857
ELECTRICAL CIRCUIT DIAGRAM (8/28)………………………………………………………………………………………………….3859
ELECTRICAL CIRCUIT DIAGRAM (9/28)………………………………………………………………………………………………….3861
ELECTRICAL CIRCUIT DIAGRAM (10/28)…………………………………………………………………………………………………3863
ELECTRICAL CIRCUIT DIAGRAM (11/28)…………………………………………………………………………………………………3865
ELECTRICAL CIRCUIT DIAGRAM (12/28)…………………………………………………………………………………………………3867
ELECTRICAL CIRCUIT DIAGRAM (13/28)…………………………………………………………………………………………………3869
ELECTRICAL CIRCUIT DIAGRAM (14/28)…………………………………………………………………………………………………3871
ELECTRICAL CIRCUIT DIAGRAM (15/28)…………………………………………………………………………………………………3873
ELECTRICAL CIRCUIT DIAGRAM (16/28)…………………………………………………………………………………………………3875
ELECTRICAL CIRCUIT DIAGRAM (17/28)…………………………………………………………………………………………………3877
ELECTRICAL CIRCUIT DIAGRAM (18/28)…………………………………………………………………………………………………3879
ELECTRICAL CIRCUIT DIAGRAM (19/28)…………………………………………………………………………………………………3881
ELECTRICAL CIRCUIT DIAGRAM (20/28)…………………………………………………………………………………………………3883
ELECTRICAL CIRCUIT DIAGRAM (21/28)…………………………………………………………………………………………………3885
ELECTRICAL CIRCUIT DIAGRAM (22/28)…………………………………………………………………………………………………3887
ELECTRICAL CIRCUIT DIAGRAM (23/28)…………………………………………………………………………………………………3889
ELECTRICAL CIRCUIT DIAGRAM (24/28)…………………………………………………………………………………………………3891
ELECTRICAL CIRCUIT DIAGRAM (25/28)…………………………………………………………………………………………………3893
ELECTRICAL CIRCUIT DIAGRAM (26/28)…………………………………………………………………………………………………3895
ELECTRICAL CIRCUIT DIAGRAM (27/28)…………………………………………………………………………………………………3897
ELECTRICAL CIRCUIT DIAGRAM (28/28)…………………………………………………………………………………………………3899
INDEX…………………………………………………………………………………………………………………………………..3901