Complete service repair manual with Electrical Wiring Diagrams for Komatsu Log Loader/Road Builder Excavator PC390LL-10, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Log Loader/Road Builder Excavator PC390LL-10 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

CEAM027101 - Log Loader_Road Builder Excavator PC390LL-10 Operation & Maintenance Manual.pdf
CEBM027501 - Log Loader_Road Builder Excavator PC390LL-10 Shop Manual.pdf
CEBM027502 - Log Loader_Road Builder Excavator PC390LL-10 Shop Manual.pdf

Total Pages: 2,673 pages
File Format: PDF
Language: English

CEAM027101 - Log Loader_Road Builder Excavator PC390LL-10 Operation & Maintenance Manual...2
  CEAM027101 PC390LL-10 S/N A50601 and UP...2
    INTRODUCTION...4
      FORWARD...5
      SAFETY INFORMATION...6
        Safety Labels...7
      INTRODUCTION...8
        Intended Use...8
        Directions of Machine...8
          Structure to Protect the Operator...8
        Breaking-In the New Machine...9
        Product Information...10
          Product Identification Number (Pin)/Machine Serial No. Plate...10
          EPA* Regulations, Engine Number Plate...10
        Service Meter Location...11
        Your Machine Serial Numbers and Distributor...11
        Engine Acronyms...11
      TABLE OF CONTENTS...12
    SAFETY...22
      SAFETY LABELS...23
        Location of Safety Labels...23
        Safety Labels...24
        Unique Safety Decals for Log Loader and Road Builder Excavators...32
      GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...37
        Precautions Before Starting Operation...37
          Ensuring Safe Operation...37
          Understanding the Machine...37
        Preparations for Safe Operation...37
          Precautions Regarding Safety-Related Equipment...37
          Inspecting Machine...37
        Clothing and Personal Protective Items...37
        Keep Machine Clean...38
        Keep Operator's Compartment Clean...38
        Fire Extinguisher and First Aid Kit...38
        Safety Equipment...38
        If Problems are Found...38
        Fire Prevention and Explosion Prevention...39
        Action if Fire Occurs...40
        Handrails and Steps...41
        Mounting and Dismounting...41
        No Persons on Attachments...41
        Leaving Operator's Seat with Lock...42
        Emergency Exit from Operator's Cab...42
        Do Not Get Caught in Work Equipment...43
        Precautions Related to Protective Structures...43
        Falling Objects, Flying Objects and Intruding Objects Prevention...43
        Unauthorized Modification...44
        Precautions Related to Attachments and Options...44
        Precautions Related to Cab Glass...44
        Precautions When Running Engine Inside Building...44
        Safety at Job Site...45
        Working on Loose Ground...45
        Distance to High Voltage Cables...45
        Ensure Good Visibility...46
        Signalman's Signal and Signs...46
        Asbestos Dust Hazard Prevention...47
      SAFETY MACHINE OPERATION...48
        Starting Engine...48
          Checks Before Starting Engine...48
          Safety Rules for Starting Engine...49
          Starting Engine in Cold Weather...49
          Starting Engine with Booster Cables...49
        Operation...50
          Checks Before Operation...50
          Safety Rules for Changing Machine Directions...50
          Safety Rules for Traveling...51
          Traveling on Slopes...52
          Operations on Slopes...53
          Prohibited Operations...54
          Operations on Snow or Frozen Surfaces...56
          Parking Machine...56
      TRANSPORTATION...57
        Loading and Unloading...57
        Shipping the Machine...58
      TOWING...58
        Safety Rules for Towing...58
      LIFTING OBJECTS WITH BUCKET...59
        Safety Rules for Lifting Objects...59
      SAFETY MAINTENANCE INFORMATION...60
        Warning Tag...60
        Keep Work Place Clean and Tidy...60
        Select Suitable Place for Inspection and Maintenance...60
        Only Authorized Personnel...60
        Appoint Leader When Working with Others...60
        Stop Engine Before Carrying Out Maintenance...61
        Precautions When Working at High Places...61
        Two Workers for Maintenance When Engine is Running...62
        Attachments...62
        Work on Machine...63
        Work Under the Machine...63
        Proper Tools...63
        Battery Disconnect Switch...64
        Removing Battery Terminals...64
        Welding...64
        Battery...64
          Battery Hazard Prevention...64
        When Using Hammer...65
        Precautions with High Temperature Coolant...65
        Precautions with High Temperature Oil...66
        Safety Rules for High-Pressure Oil...66
          Precaution for High Fuel Pressure...66
          Safety Handling High-Pressure Hoses or Piping...66
        Precaution for High Voltage...67
        Noise...67
        Safety First When Using High-Pressure Grease to Adjust Track Tension...67
        Do Not Disassemble Recoil Springs...68
        Accumulator...68
        Handling Gas Spring...68
          Precautions When Using...68
          Precautions When Discarding...69
        Compressed Air...69
        Air Conditioner Maintenance...69
        Waste Materials...69
        Select Window Washer Fluid...69
        Personnel...69
        Periodic Replacement of Safety Critical Parts...70
    OPERATION...72
      MACHINE VIEW ILLUSTRATIONS...73
        General View of Log Loader Machine...73
        General View of Road Builder Machine...74
        General View of Cab...76
      CONTROLS AND GAUGES...77
        Machine Monitor...78
      EXPLANATION OF COMPONENTS...79
        Machine Monitor...79
          Basic Operation of Machine Monitor...80
          Warning Display...85
          Meter Display...95
          Gauges and Meter...102
          Monitor Switches Portion...105
          Handling Function Switches...115
          User Menu Selector Switch...119
          User Menu...120
          Machine Settings...132
          Maintenance Screen Setting...137
        Monitor Setting...139
          Screen Adjustment...139
          Screen Adjustment (Camera)...140
          Clock Adjustment...140
          Time...142
      SWITCHES...147
        Starting Switch...148
        Fuel Control Dial...148
        Cigarette Lighter...148
        Swing Lock Switch...149
        Lamp Switch...149
        Room Lamp Switch...150
        Soft Swing Switch...151
        Emergency Pump Drive Switch...152
        Swing Brake Cancel Switch...152
        Seat Heater Switch...153
        Engine Shutdown Secondary Switch...154
      CONTROL LEVERS AND PEDALS...155
        Lock Lever...155
        Travel Levers...156
        Work Equipment Control Lever...157
      EMERGENCY ESCAPE...158
      ENGINE HOOD...159
        When Opening (Normal Case: Intermediate Lock Position)...159
        When Closing (Normal Case: Intermediate Lock Position)...161
      CAPS AND COVERS WITH LOCK...163
        Open and Close Caps with Lock...163
          Opening the Cap...163
          Locking the Cap...163
        Open and Close Covers with Lock...164
          Opening the Cover (Locked Cover)...164
          Locking the Cover...164
        Lock and Unlock Engine Hood...164
          Opening the Hood (Locked Hood)...164
          Locking the Hood...164
        Lock and Unlock Cab Door...165
          Opening the Door (Locked Door)...165
          Locking the Door...165
      DRINK BOX...166
      MAGAZINE BOX...166
      CUP HOLDER...166
      ASHTRAY...167
      AIR CONDITIONER CONTROLS...168
        Air Conditioner Control Panel...168
        Method of Operation...173
          Automatic Operation...173
          Stopping Automatic Operation...174
          Manual Operation...174
          Stop Manual Operation...176
          Operation with Cold Air to Face and Warm Air to Feet...176
          Defroster Operation...178
        Rules for Using Air Conditioner...180
        Air Conditioner Maintenance...180
      RADIO...181
        Control Panel...181
        Operation Method...183
          Frequency Adjustment...183
          Frequency Adjustment (Auto Presetting)...183
          Preset Call...183
          Preset Memory...183
          Sound Adjustment (Balance)...183
          Sound Adjustment (Treble)...184
          Sound Adjustment (Bass)...184
          Time Adjustment...184
          Stowing Radio Antenna...184
      AUXILIARY ELECTRIC POWER...185
        24 V Power Source...185
        12 V Power Source...185
      FUSE...186
      FUSIBLE LINK...188
      TOOL BOX...188
      GREASE GUN HOLDER...188
      BATTERY DISCONNECT SWITCH...189
      SYSTEM OPERATING LAMP...190
      HANDLING KOMATSU DIESEL PARTICULATE FILTER (KDPF)...191
        Operation Procedure of Manual Stationary Regeneration...196
          Komatsu Diesel Particulate Filter (KDPF) Regeneration Disable Procedure...199
          While Regeneration is Being Performed: Stopping Regeneration...200
          Handling Komatsu Closed Crankcase Ventilation (KCCV)...201
      HANDLING MACHINES EQUIPPED WITH KOMTRAX...202
        Basic Precautions...202
      MACHINE OPERATIONS AND CONTROLS...203
        Before Starting Engine...203
          Walk-Around Checks...203
          Checks Before Starting...205
          Adjustment...215
        Seat Belt Inspection...224
        Seat Belt...225
        Operations Before Starting Engine...226
      STARTING ENGINE...228
        Turbo Protect Function...231
      AFTER STARTING ENGINE...232
        Engine Warm Up...234
        Hydraulic System Warm-Up...236
        Operation After Completion of Warming-Up Operation...242
      STOPPING THE ENGINE...244
      MACHINE OPERATION...245
        Preparations for Moving the Machine...245
        Moving Machine Forward...246
        Moving Machine Backward...247
        Stopping Machine...248
      STEERING THE MACHINE...249
        Steering...249
          Steering the Machine When Stopped...249
          Changing Direction of the Machine...250
          Counter-Rotation Turn (Spin Turn)...250
      SWINGING...251
      WORK EQUIPMENT CONTROLS AND OPERATIONS...252
      WORKING MODE...254
        Working Mode Switch...254
        One-Touch Power Max. Switch...256
      PROHIBITED OPERATIONS...257
      GENERAL OPERATION INFORMATION...260
        Traveling...260
        High Speed Travel...260
        Permissible Water Depth...261
      TRAVELING ON SLOPES...262
      ESCAPE FROM MUD...264
        Track on One Side Stuck...264
        Tracks on Both Sides Stuck...264
      RECOMMENDED APPLICATIONS...265
        Backhoe Work...265
        Shovel Work...265
        Ditching Work...265
        Loading Work...266
      BUCKET REPLACEMENT AND INVERSION...267
        Replacement...267
        Inversion...269
      PARKING MACHINE...271
      MACHINE INSPECTION AFTER DAILY WORK...273
      LOCKING...273
      TRANSPORTATION...273
        Transportation Procedure...273
        Loading and Unloading with Trailer...274
          Loading...275
          Securing Machine...278
          Stowing Radio Antenna...282
          Rear View Mirrors...282
          Unloading...285
      LIFTING MACHINE...287
        Standard Specification Machines...287
      COLD WEATHER OPERATION...289
        Cold Weather Operation Information...289
          Fuel and Lubricants...289
          Coolant...289
          Battery...290
      AFTER DAILY WORK COMPLETION...291
      AFTER COLD WEATHER SEASON...291
      LONG TERM STORAGE...292
        Before Storage...292
        During Storage...292
        After Storage...293
        Starting Machine After Long-Term Storage...293
      TROUBLES AND ACTIONS...294
        Running Out of Fuel...294
        Phenomena that are Not Failures...294
        Towing the Machine...295
        Lightweight Towing Hole...296
        Severe Job Condition...296
        Discharged Battery...297
          Battery Removal and Installation...297
          Battery Charges...298
          Starting Engine with Booster Cables...299
      OTHER TROUBLE...301
        Electrical System...301
        Chassis...302
        Engine...303
        Electronic Control System...305
          Point of Contact to Telephone When Error Occurs...305
    MAINTENANCE...306
      MAINTENANCE INFORMATION...307
      OUTLINE OF SERVICE...309
        Handling Oil, Fuel, Coolant, and Performing Oil Clinic...309
          Oil...309
          Fuel...310
          Coolant and Water for Dilution...310
          Grease...311
          Carrying Out KOWA (Komatsu Oil Wear Analysis)...311
          Storing Oil and Fuel...312
          Filters...312
        Electric System Maintenance...312
      WEAR PARTS...313
        Wear Parts List...313
      RECOMMENDED FUEL, COOLANT, AND LUBRICANT...314
        Lubrication Chart...314
        Fuel, Coolant, and Lubricants to Match the Ambient Temperature...316
        KDPF (Komatsu Diesel Particulate Filter)...316
        Recommended Brands, Recommended Quality for Products Other than Komatsu Genuine Oil...317
      TORQUE SPECIFICATIONS...318
        Torque List...318
          Torque of Bolts...318
          Torque of Hose Nuts...319
          Torque of Split Flange Bolts...319
          Torque for Flared Nuts...319
          Torque for O-Ring Boss Piping Joints...321
          Torque for O-Ring Boss Plugs...321
          Torque for Hoses (Taper Seal Type and Face Seal Type)...322
      SAFETY CRITICAL PARTS...323
        Safety Critical Parts List...324
      MAINTENANCE SCHEDULE...325
        Maintenance Schedule Table...325
      MAINTENANCE PROCEDURE...327
        Initial 10 Hours Maintenance...327
        Initial 250 Hours Maintenance (Only After the First 250 Hours)...327
        Initial 500 Hours Maintenance (Only After the First 500 Hours)...327
        When Required...328
          Check, Clean and Replace Air Cleaner Element...328
          Clean Inside of Cooling System...335
          Check and Tighten Track Shoe Bolts...341
          Check and Adjust Track Tension...342
          Replace Bucket Teeth (Vertical Pin Type)...344
          Replace Bucket Teeth (Horizontal Pin Type)...347
          Replace Bucket Side Cutter, Shroud...349
          Adjust Bucket Clearance...350
          Check Window Washer Fluid Level, Add Fluid...351
          Check and Maintain Air Conditioner...352
          Wash Washable Floor...353
          Set Machine at Angle...355
          Check Gas Spring...356
          Bleeding Air From Hydraulic System...357
        Check Before Starting...359
        Every 50 Hours Maintenance...360
          Lubricating Road Builder...360
          Lubricating Log Loader...362
        Every 250 Hours Maintenance...363
          Check Level of Battery Electrolyte...363
          Check Air Conditioner Compressor Belt Tension, Adjust...365
          Lubricate Swing Circle...366
          Check Oil Level in Swing Machinery Case, Add Oil...367
        Every 500 Hours Maintenance...368
          Lubricating...368
          Change Oil in Engine Oil Pan...370
          Replace Engine Oil Filter Cartridge...370
          Replace Fuel Pre-Filter Cartridge...372
          Check Swing Pinion Grease Level, Add Grease...376
          Clean and Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, and Condenser Fins...377
          Clean Air Conditioner Fresh/Recirc Filters...379
          Replace Breather Element in Hydraulic Tank...381
          Replace Additional Breather Element in Hydraulic Tank...382
          Check Oil Level in Final Drive Case, Add Oil...383
          Check Oil Level in Swing Machinery Case, Add Oil...384
        Every 1000 Hours Maintenance...385
          Replace Hydraulic Oil Filter Element...385
          Change Oil in Swing Machinery Case...386
          Check Oil Level in Damper Case, Add Oil...387
          Replace Fuel Main Filter Cartridge...388
          Check All Tightening Points of Engine Exhaust Pipe Clamps...390
          Check Fan Belt Tension and Replace Fan Belt...390
          Check Nitrogen Gas Charge Pressure in Accumulator (For Breaker)...390
        Every 2000 Hours Maintenance...391
          Change Oil in Final Drive Case...391
          Clean Hydraulic Tank Strainer...392
          Check Charge Pressure of Nitrogen Gas in Accumulator (For Control Circuit)...393
          Check Alternator...397
          Check Engine Valve Clearance, Adjust...397
          Replace Komatsu Closed Crankcase Ventilation (KCCV) Filter Element...398
        Every 4000 Hours Maintenance...402
          Check Water Pump...402
          Check Vibration Damper...402
          Check Starting Motor...402
          Replace Accumulator (For Control Circuit)...403
          Check for Missing Fuel Spray Prevention Cap, Hardening of Rubber...404
          Check Operating Condition of Compressor...404
        Every 4500 Hours Maintenance...405
          Clean Komatsu Diesel Particulate Filter (KDPF)...405
          Replace Komatsu Closed Crankcase Ventilation (KCCV) Hose...405
        Every 5000 Hours Maintenance...406
          Change Oil in Hydraulic Tank...406
        Every 8000 Hours Maintenance...408
          Replace Fuel Spray Prevention Cap...408
          Replace High-Pressure Piping Clamp...408
    SPECIFICATIONS...410
      SPECIFICATIONS...411
        Dimensions...412
        Working Range...415
          Road Builder...415
          Log Loader...417
        Lifting Capacity...419
    OPTIONS, ATTACHMENTS...422
      GENERAL PRECAUTIONS FOR SAFETY...423
        Precautions When Selecting...423
        Read the Operation and Maintenance Manual Thoroughly...423
        Precautions When Removing or Installing...423
        Precautions When Using...423
      BUCKET WITH HOOK...424
        Hook Condition...424
        Safety Rules for Lifting Operations...424
      Straight Travel (Option)...425
      TRACK SHOES SELECTION...427
      BUCKET TEETH SELECTION...428
        Selection Guide for Horizontal or Vertical Pin Type Tooth...428
CEBM027501 - Log Loader_Road Builder Excavator PC390LL-10 Shop Manual...430
  CEBM027501 PC390LL-10 S/N A50601-...430
    CONTENTS...432
    00 - FOREWORD...433
      SAFETY...433
        Safety Notice...433
          Important Safety Notice...433
          General Precautions...433
          Preparations For Work...434
          Precautions During Work...434
      GENERAL...437
      HOW TO READ THE SHOP MANUAL...439
        Volumes...439
        Distribution and Updating...439
        Filing Method...439
        Revised Edition Mark...439
        Revisions...439
        Symbols...439
      HOISTING INSTRUCTIONS...440
        Hoisting...440
        Making Signs...440
        Precautions...440
          Precautions for Sling Work...440
          Precautions for Using Mobile Crane...441
          Precautions for Using Overhead Hoist Crane...441
        Selecting Wire Ropes...442
      HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS...443
        Points to Remember When Handling Electric Equipment...443
        Points to Remember When Handling Hydraulic Equipment...455
      PUSH PULL COUPLER...457
        Type 1...457
          Disconnection...457
          Connection...457
        Type 2...458
          Disconnection...458
          Connection...458
        Type 3...459
          Disconnection...459
          Connection...459
      EXPLANATION OF MAINTENANCE STANDARD TERMS...460
      HANDLING OF FUEL SYSTEM DEVICES...461
      HANDLING OF INTAKE SYSTEM PARTS...462
      STANDARD TIGHTENING TORQUE...463
        Bolts And Nuts...463
        Tightening Torque Of Hose Nuts...464
        Tightening Torque Of Split Flange Bolts...464
        Tightening Torque For Flared Nuts...464
        Tightening Torques for Split Flanged Bolts...465
        Tightening Torques For O-ring Boss Piping Joints...465
        Table Of Tightening Torques For O-ring Boss Plugs...465
        Tightening Torque For Hoses (Taper Seal Type And Face Seal Type)...466
          Tightening Torque For Face Seal Joints...466
          For 102, 107, and 114 Engine Series (Bolts and Nuts)...466
          For 102, 107, and 114 Engine Series (Eye Joints)...467
          For 102, 107, and 114 Engine Series (Taper Screws)...467
      ELECTRIC WIRE CODE...468
        Classification By Thickness...468
        Classification By Color And Code...468
        How To Read Electric Wire Code...469
      PRECAUTIONS FOR OPERATIONS...472
        Precautions When Carrying Out Removal Work...472
        Precautions When Carrying Out Installation Work...473
        Precautions When Completing the Operation...474
      CONVERSION TABLES...475
        Method Of Using The Conversion Table...475
      COATING MATERIALS...481
      LIST OF ABBREVIATIONS...483
        List of Abbreviations Used in the Shop Manual...483
        List of Abbreviations Used in the Circuit Diagrams...487
    01 - GENERAL...489
      SPECIFICATIONS...490
        Dimension Drawings...490
          Road Builder...490
          Log Loader...490
        Dimensions...491
        Working Ranges...492
          Road Builder...492
          Log Loader...493
        Engine...494
        Undercarriage...494
        Hydraulic System...495
          Road Builder...495
          Log Loader...496
      WEIGHT TABLE...497
      FUEL, COOLANT AND LUBRICANTS...499
        Lubrication Chart...501
    10 - STRUCTURE AND FUNCTION...503
      ENGINE AND COOLING SYSTEM...506
        Engine Related Parts...506
        Cooling System...508
      POWERTRAIN SYSTEM...510
        Powertrain...510
        Swing Circle...512
        Final Drive...513
      TRACK FRAME • RECOIL SPRING...514
      HYDRAULIC SYSTEM...516
        Hydraulic Component Layout...516
        Valve Control...518
        Hydraulic Tank...520
        Oil Filler Cap...521
        CLSS...522
          Structure of CLSS...522
          Basic principle...523
        Main Pump...526
          Operation...530
          LS Valve...532
          PC Valve...538
          LS(PC)-EPC Valve...545
        Control Valve...548
        Functions and Operation by Valve...560
          Hydraulic Circuit Diagram and Name of Valves...560
          Unload Valve...562
          Introduction of LS Pressure...563
          LS By-Pass Plug...564
          Pressure Compensation Valve...565
          Shuttle Valve In Pressure Compensation Valve...568
          Boom Regeneration Circuit...570
          Arm Regeneration Circuit...572
          Merge-Divider Valve...574
          LS Selector Valve...577
          Self-Pressure Reducing Valve...578
          Travel Junction Valve...581
          Travel PPC Shuttle Valve...584
          Boom Hydraulic Drift Prevention Valve...586
          Arm Hydraulic Drift Prevention Valve (Road Builder)...589
          Arm Drift Prevention Valve (Log Loader)...592
          Operation...593
          Suction Safety Valve for Drift Prevention Valve...595
          Arm Quick Return Valve...596
          Variable Back Pressure Valve...598
          Main Relief Valve...600
          Suction 2-Stage Safety Valve...601
        Swing Motor...603
          Swing Holding Brake...605
          Relief Valve...607
          Swing 2-Stage Relief Valve...609
          Swing Motor Reverse Prevention Valve...610
        Travel Motor - Type KMV200ADT-2...613
          Operation of Travel Motor...616
          Parking Brake...618
          Brake Valve...620
          Safety Valve...622
        PPC Valve...626
          Work Equipment and Swing PPC Valve...626
          Travel PPC Valve...631
          1st-Line Attachment PPC Valve (with EPC Valve) (If Equipped)...636
          EPC Valve (If Equipped)...638
          2nd-Line Attachment PPC Valve (If Equipped)...641
        Solenoid Valve...643
        Attachment Solenoid Valve...645
        Center Swivel Joint...647
        Accumulator...648
          PPC Accumulator...648
      WORK EQUIPMENT...649
        Work Equipment - Road Builder...649
        Work Equipment - Log Loader...650
        Work Equipment Shim...651
        Bucket Play Adjustment Shim...651
      ELECTRICAL SYSTEM...653
        Electrical Control System...653
          Machine Control System Diagram...653
          Engine Control Function...655
          Engine and Pump Combined Control Function...657
          Pump and Valve Control Function...663
          One-Touch Power Maximizing Function...665
          Machine Push-Up Function...667
          Auto-Deceleration Function...669
          Engine Automatic Warm-Up Function...671
          Overheat Prevention Function...673
          Turbocharger Protection Function...674
          Swing Control Function...675
          Swing Control Function (with Soft Swing Option)...676
          Quick Warm-Up Function...678
          Swing 2-Stage Relief Function...678
          Travel Control Function...679
          PPC Lock Function...681
          Attachment Flow Control Function...682
        System Component Part...683
          Engine Controller...683
          Pump Controller...687
          Fuel Control Dial...690
          Resister for PC-EPC valve...691
          CAN Terminating Resistor...692
          Engine Oil Pressure Switch...693
          PPC Oil Pressure Switch...694
      MACHINE MONITOR SYSTEM...695
        Machine Monitor...697
          Input and Output Signals...698
          Display...700
          Gauges...702
          Caution Monitor...704
          Pilot Monitor...707
        Switches...710
          Guidance ICON and Function Switch...712
          Operator Mode Function...715
          Service Mode Function...717
      KOMTRAX SYSTEM...718
        KOMTRAX terminal...719
        Input and Output Signals...720
      SENSORS...722
        Ambient Pressure Sensor...722
        Charge (Boost) Pressure and Temperature Sensor...723
        Coolant Temperature Sensor...724
        Ne (Crankshaft) Speed Sensor...724
        Bkup (Camshaft) Speed Sensor...725
        Common Rail Pressure Sensor...725
        Exhaust Manifold Pressure Sensor...726
        EGR Orifice Temperature Sensor...726
        EGR Valve Lift Sensor...727
        Turbo Speed Sensor...728
        KVGT Position Sensor...729
        Mass Air Flow and Temperature Sensor...730
        KDPF Differential Pressure and Outlet Pressure Sensor...730
        KDOC Inlet Temperature Sensor...731
        KDOC Outlet Temperature Sensor...731
        KDPF Outlet Temperature Sensor...732
        Crankcase Pressure Sensor...732
        Engine Oil Level Sensor...733
        Fuel Level Sensor...734
        Coolant Level Sensor...735
        Hydraulic Oil Temperature Sensor...735
        Front Pump Oil Pressure Sensor...736
        Rear Pump Oil Pressure Sensor...737
        PPC Oil Pressure Sensor...738
        Air Cleaner Clogging Sensor...739
        Front Pump Swash Plate Sensor...740
        Rear Pump Swash Plate Sensor...742
        Water-In-Fuel Sensor...744
    20- STANDARD VALUE TABLES...745
      STANDARD SERVICE VALUE TABLES...746
        Standard Value Table for Engine Related Parts...746
        Standard Value Table for Chassis Related Parts...748
          Engine Speed...748
          Travel of Control Valve Spool...748
          Travel of Control Lever...749
          Operating Effort of Control Lever and Pedal...749
          Hydraulic Pressure...750
          Swing...751
          Travel...752
          Work Equipment...753
          Performance in Combined Operation...754
          Pump Swash Plate Sensor...755
          Main Pump...755
        Posture of Machine for Measuring Performance and Measurement Procedure...757
          Control Valve: Spool Stroke...757
          Swing 1: Overrun When Stopping Swing, Time Taken to Start Swing, Time Taken to Swing...757
          Swing 2: Hydraulic Drift of Swing...757
          Travel 1: Travel Speed, Idle Running (Without Load)...758
          Travel 2: Travel Speed (Actual Run), Travel Deviation...758
          Travel 3: Travel Deviation...759
          Travel 4: Hydraulic Drift of Travel...759
          Work Equipment 1: Hydraulic Drift of Work Equipment...760
          Work Equipment 2: Boom Speed...760
          Work Equipment 3: Arm Speed...760
          Work Equipment 4: Bucket Speed/Heel Speed...761
          Work Equipment 5: Boom Time Lag...761
          Work Equipment 6: Arm Time Lag...762
          Work Equipment 7: Bucket Time Lag...762
    90- DIAGRAMS AND SCHEMATICS...763
      HYDRAULIC CIRCUIT DIAGRAM...765
        Symbols in Hydraulic Circuit Diagram...765
        Hydraulic Circuit Diagram (1/2)...768
        Hydraulic Circuit Diagram (2/2)...769
      ELECTRICAL SYSTEM...770
        Symbols in Electrical Circuit Diagrams...770
        Air Conditioner Electrical Circuit Diagram...773
        Electrical Circuit Diagram - Log Loader Unique...774
        Electrical Circuit Diagram (1/6)...775
        Electrical Circuit Diagram (2/6)...776
        Electrical Circuit Diagram (3/6)...777
        Electrical Circuit Diagram (4/6)...778
        Electrical Circuit Diagram (5/6)...779
        Electrical Circuit Diagram (6/6)...780
        Cab Diagram...781
CEBM027502 - Log Loader_Road Builder Excavator PC390LL-10 Shop Manual...782
  CEBM027502 PC390LL-10...782
    CONTENTS...783
    00 - FORWARD...784
      SAFETY...784
        Safety Notice...784
          Important Safety Notice...784
          General Precautions...784
          Preparations For Work...785
          Precautions During Work...785
      GENERAL...788
      HOW TO READ THE SHOP MANUAL...790
        Volumes...790
        Distribution and Updating...790
        Filing Method...790
        Symbols...790
      HOISTING INSTRUCTIONS...791
        Hoisting...791
        Making Signs...791
        Precautions...791
          Precautions for Sling Work...791
          Precautions for Using Mobile Crane...792
          Precautions for Using Overhead Hoist Crane...792
        Selecting Wire Ropes...793
      HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS...794
        Points to Remember When Handling Electric Equipment...794
        Points to Remember When Handling Hydraulic Equipment...806
      PUSH PULL COUPLER...808
        Type 1...808
          Disconnection...808
          Connection...808
        Type 2...809
          Disconnection...809
          Connection...809
        Type 3...810
          Disconnection...810
          Connection...810
      EXPLANATION OF MAINTENANCE STANDARD TERMS...811
      HANDLING OF FUEL SYSTEM DEVICES...812
      HANDLING OF INTAKE SYSTEM PARTS...813
      STANDARD TIGHTENING TORQUE...814
        Bolts And Nuts...814
        Tightening Torque Of Hose Nuts...815
        Tightening Torque Of Split Flange Bolts...815
        Tightening Torque For Flared Nuts...815
        Tightening Torques for Split Flanged Bolts...816
        Tightening Torques For O-ring Boss Piping Joints...816
        Table Of Tightening Torques For O-ring Boss Plugs...816
        Tightening Torque For Hoses (Taper Seal Type And Face Seal Type)...817
          Tightening Torque For Face Seal Joints...817
          For 102, 107, and 114 Engine Series (Bolts and Nuts)...817
          For 102, 107, and 114 Engine Series (Eye Joints)...818
          For 102, 107, and 114 Engine Series (Taper Screws)...818
      ELECTRIC WIRE CODE...819
        Classification By Thickness...819
        Classification By Color And Code...819
        How To Read Electric Wire Code...820
      PRECAUTIONS FOR OPERATIONS...823
        Precautions When Carrying Out Removal Work...823
        Precautions When Carrying Out Installation Work...824
        Precautions When Completing the Operation...825
      CONVERSION TABLES...826
        Method Of Using The Conversion Table...826
      COATING MATERIALS...832
      LIST OF ABBREVIATIONS...834
        List of Abbreviations Used in the Shop Manual...834
        List of Abbreviations Used in the Circuit Diagrams...838
    01 - GENERAL...840
      SPECIFICATIONS...841
        Dimension Drawings...841
          Road Builder...841
          Log Loader...841
        Dimensions...842
        Working Ranges...844
          Road Builder...844
          Log Loader...845
        Engine...846
        Undercarriage...846
        Hydraulic System...847
          Road Builder...847
          Log Loader...848
      WEIGHT TABLE...849
      FUEL, COOLANT AND LUBRICANTS...851
        Lubrication Chart...853
    10 - STRUCTURE AND FUNCTION...854
      ENGINE AND COOLING SYSTEM...857
        Engine Related Parts...857
        Cooling System...859
      POWERTRAIN SYSTEM...861
        Powertrain...861
        Swing Circle...863
        Final Drive...864
      TRACK FRAME • RECOIL SPRING...865
        MEMORANDUM...866
      HYDRAULIC SYSTEM...867
        Hydraulic Component Layout...867
        Valve Control...869
        Hydraulic Tank...871
        Oil Filler Cap...872
        CLSS...873
          Structure of CLSS...873
          Basic principle...874
        Main Pump...877
          Operation...881
          LS Valve...883
          PC Valve...889
          LS(PC)-EPC Valve...896
        Control Valve...899
        Functions and Operation by Valve...911
          Hydraulic Circuit Diagram and Name of Valves...911
          Unload Valve...913
          Introduction of LS Pressure...914
          LS By-Pass Plug...915
          Pressure Compensation Valve...916
          Shuttle Valve In Pressure Compensation Valve...919
          Boom Regeneration Circuit...921
          Arm Regeneration Circuit...923
          Merge-Divider Valve...925
          LS Selector Valve...928
          Self-Pressure Reducing Valve...929
          Travel Junction Valve...932
          Travel PPC Shuttle Valve...935
          Boom Hydraulic Drift Prevention Valve...937
          Arm Hydraulic Drift Prevention Valve (Road Builder)...940
          Arm Drift Prevention Valve (Log Loader)...943
          Operation...944
          Suction Safety Valve for Drift Prevention Valve...946
          Arm Quick Return Valve...947
          Variable Back Pressure Valve...949
          Main Relief Valve...951
          Suction 2-Stage Safety Valve...952
        Swing Motor...954
          Swing Holding Brake...956
          Relief Valve...958
          Swing 2-Stage Relief Valve...960
          Swing Motor Reverse Prevention Valve...961
        Travel Motor - Type KMV200ADT-2...964
          Operation of Travel Motor...967
          Parking Brake...969
          Brake Valve...971
          Safety Valve...973
            1. When pressure in chamber (MB) has become high (when rotating clockwise)...973
            2. When pressure in chamber (MA) has become high (when rotating counterclockwise)...973
            1. When starting travel (high-pressure setting)...974
            2. When travel is stopped (low-pressure setting)...975
            MEMORANDUM...976
        PPC Valve...977
          Work Equipment and Swing PPC Valve...977
          Travel PPC Valve...982
            MEMORANDUM...986
          1st-Line Attachment PPC Valve (with EPC Valve) (If Equipped)...987
          EPC Valve (If Equipped)...989
          2nd-Line Attachment PPC Valve (If Equipped)...992
        Solenoid Valve...994
        Attachment Solenoid Valve...996
        Center Swivel Joint...998
        Accumulator...999
          PPC Accumulator...999
      WORK EQUIPMENT...1000
        Work Equipment - Road Builder...1000
        Work Equipment - Log Loader...1001
        Work Equipment Shim...1002
        Bucket Play Adjustment Shim...1002
      ELECTRICAL SYSTEM...1004
        Electrical Control System...1004
          Machine Control System Diagram...1004
          Engine Control Function...1006
          Engine and Pump Combined Control Function...1008
          Pump and Valve Control Function...1014
          One-Touch Power Maximizing Function...1016
          Machine Push-Up Function...1018
          Auto-Deceleration Function...1020
          Engine Automatic Warm-Up Function...1022
          Overheat Prevention Function...1024
          Turbocharger Protection Function...1025
          Swing Control Function...1026
          Swing Control Function (with Soft Swing Option)...1027
            1. Swing Lock and Swing Holding Brake Functions with Soft Swing...1028
            2. Operation of Swing Holding Brake Release Switch...1028
          Quick Warm-Up Function...1029
          Swing 2-Stage Relief Function...1029
          Travel Control Function...1030
          PPC Lock Function...1032
          Attachment Flow Control Function...1033
        System Component Part...1034
          Engine Controller...1034
          Pump Controller...1038
          Fuel Control Dial...1041
          Resister for PC-EPC valve...1042
          CAN Terminating Resistor...1043
          Engine Oil Pressure Switch...1044
          PPC Oil Pressure Switch...1045
      MACHINE MONITOR SYSTEM...1046
        Machine Monitor...1048
          Input and Output Signals...1049
          Display...1051
          Gauges...1053
          Caution Monitor...1055
          Pilot Monitor...1058
            MEMORANDUM...1060
        Switches...1061
          Guidance ICON and Function Switch...1063
          Operator Mode Function...1066
          Service Mode Function...1068
      KOMTRAX SYSTEM...1069
        KOMTRAX terminal...1070
        Input and Output Signals...1071
      SENSORS...1073
        Ambient Pressure Sensor...1073
        Charge (Boost) Pressure and Temperature Sensor...1074
        Coolant Temperature Sensor...1075
        Ne (Crankshaft) Speed Sensor...1075
        Bkup (Camshaft) Speed Sensor...1076
        Common Rail Pressure Sensor...1076
        Exhaust Manifold Pressure Sensor...1077
        EGR Orifice Temperature Sensor...1077
        EGR Valve Lift Sensor...1078
        Turbo Speed Sensor...1079
        KVGT Position Sensor...1080
        Mass Air Flow and Temperature Sensor...1081
        KDPF Differential Pressure and Outlet Pressure Sensor...1081
        KDOC Inlet Temperature Sensor...1082
        KDOC Outlet Temperature Sensor...1082
        KDPF Outlet Temperature Sensor...1083
        Crankcase Pressure Sensor...1083
        Engine Oil Level Sensor...1084
        Fuel Level Sensor...1085
        Coolant Level Sensor...1086
        Hydraulic Oil Temperature Sensor...1086
        Front Pump Oil Pressure Sensor...1087
        Rear Pump Oil Pressure Sensor...1088
        PPC Oil Pressure Sensor...1089
        Air Cleaner Clogging Sensor...1090
        Front Pump Swash Plate Sensor...1091
        Rear Pump Swash Plate Sensor...1093
        Water-In-Fuel Sensor...1095
    20 - STANDARD VALUE TABLES...1096
      STANDARD SERVICE VALUE TABLES...1097
        Standard Value Table for Engine Related Parts...1097
        Standard Value Table for Chassis Related Parts...1099
          Engine Speed...1099
          Travel of Control Valve Spool...1099
          Travel of Control Lever...1100
          Operating Effort of Control Lever and Pedal...1100
          Hydraulic Pressure...1101
          Swing...1102
          Travel...1103
          Work Equipment...1104
          Performance in Combined Operation...1105
          Pump Swash Plate Sensor...1106
          Main Pump...1106
        Posture of Machine for Measuring Performance and Measurement Procedure...1108
          Control Valve: Spool Stroke...1108
          Swing 1: Overrun When Stopping Swing, Time Taken to Start Swing, Time Taken to Swing...1108
          Swing 2: Hydraulic Drift of Swing...1108
          Travel 1: Travel Speed, Idle Running (Without Load)...1109
          Travel 2: Travel Speed (Actual Run), Travel Deviation...1109
          Travel 3: Travel Deviation...1110
          Travel 4: Hydraulic Drift of Travel...1110
          Work Equipment 1: Hydraulic Drift of Work Equipment...1111
          Work Equipment 2: Boom Speed...1111
          Work Equipment 3: Arm Speed...1111
          Work Equipment 4: Bucket Speed/Heel Speed...1112
          Work Equipment 5: Boom Time Lag...1112
          Work Equipment 6: Arm Time Lag...1113
          Work Equipment 7: Bucket Time Lag...1113
    30 - TESTING AND ADJUSTING...1114
      GENERAL INFORMATION...1119
        Tools for Testing, Adjusting, and Troubleshooting...1119
        Sketch of Tools for Testing and Adjusting...1126
          MEMORANDUM...1128
      ENGINE AND COOLING SYSTEM...1129
        Checking Engine Speed...1129
          1. Preparation work...1129
          2. Testing low idle speed...1129
            A. Start the engine and set the fuel control dial to the low idle (MIN) position...1129
            B. Set all the control levers and pedals for work equipment, swing, and travel to the neutral position and test the engine speed...1129
          3. Testing high idle speed...1129
            A. Start the engine and set the fuel control dial to the full speed (MAX) position...1129
            B. Set the working mode in the Power Mode (P) and set the auto-deceleration to OFF...1129
            C. Set the swing lock switch to ON position...1129
            D. Set all control the levers and pedals for work equipment, swing, and travel to the neutral position and test the engine speed...1129
          4. Testing 2-pump relief speed...1129
            A. Start the engine and operate the arm cylinder to "arm IN" stroke end...1129
            B. Set the swing lock switch to OFF position...1129
            C. Set the fuel control dial to the full speed (MAX) position and set the working mode to the Power mode (P)...1129
            D. Operate the left work equipment control lever to relieve the arm circuit at the IN stroke end and test the engine speed...1129
          5. Testing speed (around rated speed) at 2-pump relief + one-touch power maximizing function...1129
            A. Start the engine and operate the arm cylinder to "arm IN" stroke end...1129
            B. Set the fuel control dial to the full speed (MAX) position and set the working mode to the Power mode (P)...1129
            C. While operating the left work equipment control lever to relieve the arm circuit at "arm IN" stroke end and pressing the one-touch power maximizing switch, test the engine speed...1129
          6. Testing auto-deceleration speed...1130
            A. Start the engine, set the fuel control dial to full speed position (MAX), and turn the auto deceleration function ON...1130
            B. Set all the control levers and pedals for work equipment, swing, and travel to the neutral position and measure the engine speed when the auto-deceleration operates...1130
        Measuring Boost Pressure...1131
          1. Open the engine hood and remove boost pressure pickup plug (1) from the intake air connector...1131
          2. Install nipple [1] of boost gauge kit A and connect them to gauge [2]...1132
          3. Run the engine at middle or higher speed and bleed oil from the hose...1132
          4. Set the working mode to the Power mode (P) and turn the swing lock switch ON...1132
          5. Measure the boost pressure when the hydraulic relief is made by arm IN operation + one-touch power max. with engine at full speed...1132
          6. After finishing measurement, remove the measuring tools and return the removed parts to their original position...1132
          1. Open the engine hood and fix stay (1) at the lock position (2)...1132
          2. Loosen bolt (4) fixing lock plate (3), lower lock plate (3) and release the lock...1133
          3. Pull stay (1) to your side, hold handgrip (4) and push the engine hood backward...1133
          4. After pushing the engine hood fully backward, fix stay (1) securely at lock position(5)...1133
          MEMORANDUM...1134
        Measuring Exhaust Gas Color...1135
          1. Open the engine hood and remove plug (1)...1135
          2. Testing by using handy smoke checker B1...1135
            A. Fit a sheet of filter paper to smoke checker B1...1135
            B. Insert the exhaust gas intake pipe in port (3) for the removed plug...1136
            C. Start the engine and, while the arm IN circuit is relieved and engine is run at full speed, absorb the exhaust gas to the filtering paper operating the handle of smoke checker B1...1136
            D. Remove the filter paper and compare it with the attached scale to make a judgment...1136
            E. After finishing measurement, remove the measuring tools and return the removed parts to their original position...1136
          3. Testing by using smoke meter B2...1136
            A. Connect the probe hose, receptacle of the accelerator switch and air hose to smoke meter B2...1136
            B. Connect the power cable to the AC 100 V receptacle...1136
            C. Insert probe [1] of the smoke meter B2 into port (3) of the removed plug (1)...1136
            D. Loosen the cap nut of the suction pump and set a filter paper there...1136
            E. Turn on the power switch of smoke meter B2...1136
            F. Start the engine and, while the arm IN circuit is relieved, depress the accelerator pedal of smoke meter B2 to absorb the exhaust gas to the filtering paper...1136
            G. Place the filter paper contaminated with exhaust gas on new filter papers (more than 10 sheets) in the filter paper holder and read the indicated value...1136
            H. After finishing measurement, remove the measuring tools and return the removed parts to their original position...1136
        Measuring and Adjusting Valve Clearance...1137
          Testing...1137
            1. Open the engine hood and remove step (1) and support (2)...1137
            2. Remove debris guarding as required to access areas defined in the following instructions...1137
            3. Remove EGR orifice temperature sensor (3) to protect it from damaging...1137
            4. Remove brackets (5) (three places) fastened together to the head cover...1138
            5. Disconnect hoses (6) and (7), and connectors (8) and (9)...1138
            6. In order to secure the space necessary to remove the head cover, remove bracket (9) (four bolts) and bracket (10) (one bolt) and move wiring harness (11) and connector box (12) from the current positions...1138
            7. After removing hose (13), remove breather box (14) (two bolts)...1138
            8. In order to secure the space necessary to remove the head cover, remove clamps (16) (two places) fixing tube (15) and move tube (15) from the current position...1139
            9. Remove head cover mounting bolts (eight bolts)...1139
            10. Tilt and pass the head cover through bellows pipe (17) to remove...1139
            11. Remove cap (18) of the front gear cover...1139
            12. Set the No. 1 cylinder to the compression top dead center...1139
              A. Remove cap (19) of the flywheel housing, then insert gear C1 and rotate the crankshaft in the normal direction...1139
              B. After aligning TDC stamp line (a) of the front gear cover with stamp line (b) of the supply pump gear, set No.1 piston to the compression top dead center...1139
            13. While the No. 1 cylinder is at the compression top dead center, check the valve clearances marked with ˜ in the following figure...1140
            14. Then, rotate the crankshaft one turn in the normal direction and check the valve clearance of the remaining valves marked ...1140
            15. The valve clearance is normal if it is within the following standard value range...1140
            16. After finishing test, remove the testing tools and restore the machine...1140
          Adjustment...1141
            1. While fixing adjustment screw (11), loosen lock nut (10)...1141
            2. Insert feeler gauge C2 in the clearance between rocker arm (8) and crosshead (9) and adjust the valve clearance with adjustment screw (11)...1141
            3. While fixing adjustment screw (11), tighten lock nut (10)...1141
            4. After finishing test, remove the testing tools and restore the machine...1141
            MEMORANDUM...1142
        Measuring Compression Pressure...1143
          1. Remove debris guarding as required to access areas defined in the following instructions...1143
          2. Remove the cylinder head cover and set the piston of the tested cylinder to the compression top dead center. For detail, see “Measuring and Adjusting Valve Clearance” on page 30-24...1143
          3. Remove brackets (1)...1143
          4. After removing fuel spray prevention cap (2), remove the sleeve nut and disconnect high-pressure pipe (3)...1144
          5. Loosen injector terminal nut (4) to remove the terminal from injector (9)...1144
          6. Remove the mounting bolts of rocker arm assembly (5) on the exhaust side, then remove rocker arm assembly (5)...1144
          7. Remove retaining nut (6) and remove inlet connector (7)...1144
          8. Remove holder (8)...1144
          9. Remove injector (9)...1144
          10. Install gasket D4 to the tip of adapter D3 and insert them into the injector mounting portion...1145
          11. Fix adapter D3 with mounting holders (8) for the injector...1145
          12. Install rocker arm assembly (5)...1145
          13. Adjust the valve clearances...1145
          14. Connect hoses (10) and (11), connectors (12) and (13), and sensor (14)...1145
          15. Connect gauge assembly D1 to adapter D3...1146
          16. Select the "no injection cranking mode" by operating the machine monitor...1146
          17. Rotate the crankshaft by the starting motor and measure the compression pressure...1146
          18. After finishing the test, remove the testing tools and restore the machine...1146
            A. Install the injector to the cylinder head while facing its fuel inlet hole to the air intake manifold...1146
            B. Tighten holder mounting bolt (19) by three to four threads...1146
            C. Set inlet connector (7)...1146
            D. Check inlet connector (7) for the following items. If anything wrong is found, replace it...1146
            i. When burrs or wear is found in the inlet connector top-end (a) and rear-end (b) portions...1146
            ii. When foreign matters are found in the edge filter at rear- end (c) of the inlet connector...1146
            iii. Cracks or deterioration are recognizable on the O-ring of the inlet connector upper (d) portion...1146
            iv. There is a worn part or an uneven seat contact mark on sealing face (e) at the front end of the inlet connector...1147
            E. Apply engine oil to the O-ring of inlet connector (7) and the head side...1147
            F. Fasten inlet connector (7) temporarily with retaining nut (6)...1147
            G. Tighten mounting bolts (19) for holder (8) alternately...1147
            H. Tighten retaining nut (6) of inlet connector (7)...1147
            I. Tighten the sleeve nut for high-pressure pipe (3) in the order of cylinder head side and common rail (10) side...1147
            J. Install fuel spray prevention cap (1)...1147
            K. Install rocker arm assembly (5)...1148
            L. Adjust the valve clearances...1148
            M. Tighten injector terminal nut (4)...1148
            N. Install the cylinder head cover...1148
          1. The ones which have visually recognizable longitudinal slits (b) or spots (c) in the area within 2 mm from the tip (a)...1148
          2. The ones on which fingernail is caught by a level difference that develops on the taper seal end within 2 mm from the tip (d) due to fatigue...1148
          1. Fasten inlet connector (1) by use of retaining nut (2) with the specified torque...1149
          2. When installing common rail (3), loosen three mounting bolts (4) to (6) once, then temporarily finger tighten them...1149
          3. Install high-pressure pipe assembly (7) between the supply pump and common rail, then tighten the sleeve nuts on the supply pump side and common rail side to the specified torque...1149
          4. Install injection pipes (8) to (13) between the common rail and each cylinder inlet connector, then tighten the sleeve nuts on the inlet connector side and common rail side to the specified torque...1149
          5. Tighten three common rail mounting bolts (4) to (6) to the specified torque...1149
          6. Tighten the brackets of the sandwich clamps, that fix the high-pressure pipe and injection pipe, to the specified torque...1149
          7. Tighten sandwich clamp (19) to the specified torque...1150
          1. Fasten inlet connector (1) by tightening retaining nut (2) to the specified torque...1150
          2. When installing common rail (3), loosen three mounting bolts (4) to (6) once, then temporarily finger tighten them...1150
          3. Install injection pipes (7) to (12) between the common rail and each cylinder inlet connector, then tighten the sleeve nuts on the inlet connector side and common rail side to the specified torque...1150
          4. Tighten three common rail mounting bolts (4) to (6) to the specified torque...1150
          5. Tighten the bolts for the brackets of the sandwich clamps, that fix the high-pressure pipe and injection pipe, to the specified torque...1151
          6. Fasten sandwich clamp (19) by tightening the bolt to the specified torque...1151
          1. Install high-pressure pipe assembly (7) between the supply pump and common rail, then tighten the sleeve nuts on the supply pump side and common rail side to the specified torque...1151
          2. Tighten sleeve nuts for the injection pipes (8) to (13) between the common rail and each cylinder inlet connector and sleeve nuts on the common rail side to the specified torque...1151
          3. Loosen all the sandwich clamps for the injection pipe...1152
          4. Tighten the mounting bolts for brackets (14) to (18) for the sandwich clamp to the specified torque...1152
          5. Fasten sandwich clamp (19) by tightening the bolt to the specified torque...1152
        Measuring Blow-By Pressure...1153
          1. Open the engine hood and remove crank case pressure sensor (1)...1153
          2. Disconnect hose (3) on gas outlet side of the KCCV, then plug hose (3) and KCCV tube by using plugs E2...1153
          3. After disconnecting hose (4) on the inlet side of KCCV, plug the tube of KCCV to which the hose is connected by using plug E2, install tool and adapter [1] of blow-by checker E1 to hose (4), and then connect gauge [2]...1154
          4. After installing crank case pressure sensor (1), start the engine and set the work equipment mode to power mode (P), and turn the swing lock switch to the ON position...1154
          5. While running the engine at high idle, relieve the arm IN circuit and measure the blow by pressure...1154
          6. After finishing measurement, remove the measuring tools and return the removed parts to their original position...1154
        Measuring Engine Oil Pressure...1155
          1. Remove oil pressure pickup plug (2) at the bottom of engine controller wiring harness (1)...1156
          2. After installing adapter F2, install nipple [1] in the hydraulic tester F4 and connect sensor adapter assembly F1...1156
          3. Connect service oil pressure connector (CNP49) (11) and sensor adapter assembly F1...1156
          4. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1156
          5. Measure the oil pressures when the engine runs at the rated output speed and low idle...1157
          6. After finishing test remove the testing tools and return the removed parts...1157
          1. Remove oil pressure pickup plug (2) at the bottom of engine controller wiring harness (1)...1157
          2. After Installing adapter F2, install nipple [1] and hose [2] in hydraulic tester F4, then connect them to oil pressure gauge F5...1157
          3. Start the engine and turn the auto-decelerator OFF...1157
          4. Measure the oil pressures when the engine runs at the rated output speed and low idle...1157
          5. After finishing test remove the testing tools and return the removed parts...1157
          MEMORANDUM...1158
        Measuring EGR Valve and KVGT Oil Pressure...1159
          1. Remove debris guarding as required to access areas defined in the following instructions...1159
          2. Open the engine hood and remove step (1)...1159
          3. Disconnect hoses (2) and (3)...1159
          4. Install adapter G1 and G2, the install nipple [1] and hose [2] of hydraulic tester G3 and connect them to gauge [4]...1160
          5. Start the engine and measure the oil pressure at low idle...1160
          6. After completing measurement, remove the measuring tools and return the machine to the original condition...1160
        Measuring Fuel Pressure...1161
          Testing Low-Pressure Circuit (Main Fuel Filter Inlet Side)...1163
            1. Open the side cover on the right side of the machine and remove fuel pressure pickup port plug (1) on the main fuel filter inlet side...1163
            2. Install adapter H3, install nipple [1] and hose [2] of hydraulic tester H1 and connect them to oil pressure gauge H4...1163
            3. Start the engine and measure the pressure in the low-pressure circuit with the engine at high idle...1163
            4. After completing measurement, remove the measuring tools and return the machine to the original condition...1163
          Testing Low-Pressure Circuit (Pressure Difference)...1164
            1. Remove fuel pressure pickup plug (1) at the main fuel filter inlet side and fuel pressure pickup plug (2) on the outlet side...1164
            2. Install adapter H3 to each of the inspection holes on the inlet and outlet sides, and then install nipple [1] and hose [2] in hydraulic tester H1, and connect them to oil pressure gauge H4...1164
            3. Start the engine and measure the pressure on the inlet and outlet sides of the low-pressure circuit with the engine at high idle...1164
            4. Calculate the pressure difference in the low pressure circuit...1164
            5. After completing measurement, remove the measuring tools and return the machine to the original condition...1164
          Testing Return Circuit...1165
            1. Remove pipe (1) between the air cleaner and KVGT...1165
            2. Remove brackets (2)...1165
            3. Remove joint bolt (3) from the fuel return hose of the supply pump...1165
            4. In place of joint bolt (3), install screw H5 and nipple [1] and hose [2] in hydraulic tester H1, and then connect them to oil pressure gauge [3]...1165
            5. After installing pipe (1) between the air cleaner and KVGT, start the engine and measure the pressure in the return circuit with the engine at high idle...1166
            6. After finishing test, remove the testing tools and restore the machine...1166
          Testing the Negative Pressure Circuit (At Fuel Supply Connector)...1167
            1. Remove fuel pressure pickup plug (1) of the fuel supply connector...1167
            2. Connect adapter H3 and fuel vacuum gauge H6...1167
            3. Start the engine and measure the pressure in the negative pressure circuit with the engine at high idle...1167
            4. After finishing test, remove the testing tools and restore the machine...1167
          Testing the Negative Pressure Circuit (At Supply Pump)...1168
            1. Disconnect fuel tube(1) from supply pump (2)...1168
            2. Remove fitting (3) mounted to supply pump (2)...1168
            3. Install hose assembly [1] of adapter kit H7 to fitting H8, and install them to supply pump (2)...1168
            4. Reconnect fuel tube (1)...1168
            5. Connect vacuum gauge H6 to hose assembly [1]...1168
            6. Start the engine and measure the pressure in the negative pressure circuit with the engine at high idle...1168
            7. After finishing the test, remove the testing tools and restore the machine...1168
          Testing Fuel Feed Pump Outlet Pressure (At Supply Pump)...1169
            1. The measuring position is the same as that used for the fuel negative pressure circuit pressure test (at supply pump). However, only gauge H9 is used for the testing tool...1169
            2. Operate fuel feed pump (10) by turning the starting switch to the ON position and measure the pressure at the fuel feed pump outlet...1169
            3. After finishing test remove the testing tools and return the removed parts...1169
        Measuring Fuel Delivery, Return and Leakage...1170
          Testing Supply Pump Delivery...1171
            1. Remove the fuse for the electric fuel feed pump...1171
            2. Remove pipe (1) between the air cleaner and KVGT...1171
            3. Remove brackets (2)...1172
            4. Remove fuel spray prevention cap (3) and remove the high- pressure pipe (4)...1172
            5. Install hose J6 to the connector on the discharge side of the supply pump...1172
            6. After installing pipe (1) between the air cleaner and KVGT, crank the engine for 30 seconds and measure the delivery by using measuring cylinder J7...1172
            7. After finishing test, remove the testing tools and restore the machine...1173
          Testing Supply Pump Return Rate...1173
            1. Remove pipe (1) between the air cleaner and KVGT...1173
            2. Remove brackets (2)...1173
            3. Remove joint bolt (3) from the fuel return hose of the supply pump...1173
            4. Install cap nut [1] of tester kit J1 to fuel return hose (4) to prevent outflow of fuel...1174
            5. Install joint J2 to the supply pump by using joint bolt J3...1174
            6. Install hose J8 to joint J2...1174
            7. After installing pipe (1) between the air cleaner and KVGT, start the engine and measure the fuel return rate for 30 seconds with the engine running at low idle by using measuring cylinder J7...1174
            8. After finishing test, remove the testing tools and restore the machine...1174
          Testing Leakage from Pressure Limiter...1175
            1. Remove joint bolt (1) of the pressure limiter and disconnect spill tube (2)...1175
            2. Install cap nut [1] of tester kit J1 to spill tube (2) to prevent outflow of fuel...1175
            3. Install joint J2 to the pressure limiter with joint bolt J3...1175
            4. Install hose J8 to joint J2...1175
            5. Start the engine and measure the fuel leakage rate for 60 seconds with the engine running at low idle by using measuring cylinder J7...1175
            6. After finishing test, remove the testing tools and restore the machine...1175
          Measuring Return Rate from Injector...1176
            1. Remove check valve (1) on the cylinder head and disconnect spill tube (2)...1176
            2. Install cap nut [1] of tester kit J1 to spill tube (2) to prevent outflow of fuel...1176
            3. Install joint J2 to the cylinder head with joint bolt J3...1176
            4. Install hose J8 to joint J2...1176
            5. Start the engine and measure the fuel return rate in 60 seconds by using measuring cylinder J7 with the engine at low idle...1176
            6. After finishing test, remove the testing tools and restore the machine...1176
          Testing Delivery of Fuel Feed Pump...1177
            1. Remove pipe (1) between the air cleaner and KVGT...1177
            2. Remove brackets (2)...1177
            3. Remove the connector of the supply pump and install fitting J9...1177
            4. Install adapter kit J10 to fitting J9 and connect the fuel tube again...1177
            5. Install adapter J11 and insert it into measuring cylinder J7...1177
            6. Turn the starting switch to the ON position to operate the fuel feed pump...1177
            7. When the fuel starts to flow out continuously, measure the delivery for 10 seconds by using measuring cylinder J7...1177
            8. Repeat the measurement of step 7 three times and calculate the mean...1177
            9. After finishing test, remove the testing tools and restore the machine...1177
        Bleeding Air from Fuel System...1178
          Bleeding Air...1178
            1. Fill the fuel tank up with fuel...1178
            2. Open the side cover on the right side of the machine...1178
            3. Loosen hand primer (1) and pull it out, and then operate it forward and backward...1178
            4. After bleeding air, push in and tighten hand primer (1)...1178
        Checking Fuel Circuit for Leakage...1179
          1. Spray color checker (developer) L to the fuel supply pump, common rail, fuel injectors, and joints of the high-pressure fuel piping...1179
          2. Start the engine, keep its speed at 1,000 rpm or below, and stop it when its speed is stabilized...1179
          3. Stop the engine and check the fuel piping and devices for fuel leakage...1179
          4. Start the engine and keep it running at low idle...1179
          5. Stop the engine and check the fuel piping and devices for fuel leakage...1179
          6. Start the engine and keep it running at high idle...1179
          7. Stop the engine and check the fuel piping and devices for fuel leakage...1179
          8. Run the engine at high idle, then load it...1179
          9. Stop the engine and check the fuel piping and devices for fuel leakage...1179
        Handling Cylinder Cut-Out Mode Operation...1180
          1. This mode is used to find out a cylinder which does not output power properly (or, combustion in it is abnormal)...1180
          2. When a cylinder is selected for the Cylinder Cut Out Mode operation, if the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has one or more defects. The following problems can be considered:...1180
          3. The injector of each cylinder is separately controlled electronically in the common rail fuel injection system, so the cylinder cut-out test can be performed easily by the simple operations of the switches compared with the mechanical fuel injecti...1180
        Handling No-Injection Cranking Operation...1180
        Checking and Adjusting Air Conditioner Compressor Belt Tension...1181
          Checking...1181
            1. Open the engine hood and remove belt guard (1)...1181
            2. Press the intermediate point of the belt between fan pulley and compressor pulley with a finger and measure deflection (a) of the belt...1181
            3. After finishing testing, return the machine status as it was...1181
          Adjusting...1181
            1. Loosen mounting bolt (2) and fixing bolt (3) of bracket (1)...1181
            2. Slide bracket (1) by using the bar, adjust the belt tension and then tighten fixing bolt (3)...1181
            3. Tighten mounting bolts (2) of bracket (1)...1181
            4. After completing adjustment, return the machine to original condition...1181
        Replacing Fan Belt...1182
          1. Open the engine hood and remove fan guard (1) and fan belt guard (2)...1182
          2. Insert wrench (a) to the portion A (width across flats: 12.7 mm) of tensioner assembly (4), and rotate it toward the rear of the machine to decrease the fan belt (3) tension...1182
          3. Replace fan belt (3)...1182
        Replacing Alternator Belt...1183
          1. Open the engine hood and remove fan guard (1) and fan belt guard (2)...1183
          2. Insert wrench (b) to the portion B (width across flats: 12.7 mm) of tensioner assembly (4), and rotate it toward the rear of the machine to decrease the alternator belt (3) tension...1183
          3. Replace alternator belt (3)...1183
          MEMORANDUM...1184
      POWER TRAIN...1185
        Testing Swing Circle Bearing Clearance...1185
          Testing...1185
            1. Fasten dial gauge K to swing circle outer race (1) or inner race (2), and touch the probe to the end surface of inner race (2) or outer race (1) on the opposite side...1185
            2. Set the work equipment to the maximum reach posture and set the bucket tip to the height of the under side of the revolving frame...1185
            3. Set the reading of dial gauge K to the zero point...1185
            4. Set the arm almost perpendicular to the ground and lower the boom until the front part of the tracks float about 150 - 200 mm (6 - 8 in)...1186
            5. From this state, read the dial gauge K value...1186
            6. Return the machine to the condition of step 2 and check that dial gauge K indicates zero point...1186
      UNDERCARRIAGE AND FRAME...1187
        Testing and Adjusting Track Shoe Tension...1187
          Testing...1187
            1. Run the engine at low idle and move the machine forward by the length of track on ground, and then stop slowly...1187
            2. Place square bar [1] on the track shoes between the idler and the 1st carrier roller...1187
            3. Measure maximum clearance (a) between steel bar [1] and track shoe...1187
          Adjusting...1187
            1. Increasing tension...1187
              A. Add grease through grease fitting (1) by using a grease gun...1187
              B. To check that the tension is proper, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly...1187
              C. After adjusting, check the track tension again according to the above procedure...1187
            2. Decreasing tension...1188
              A. Loosen valve (2) to discharge grease, and then tighten it...1188
              B. To check that the tension is proper, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly...1188
              C. After adjusting, check the track tension again according to the above procedure...1188
      HYDRAULIC SYSTEM...1189
        Releasing Remaining Pressure from Hydraulic Circuit...1189
          1. Releasing Remaining Pressure from Hydraulic Tank...1189
            A. Lower the work equipment to the ground in a stable posture and stop the engine...1189
            B. Gradually loosen oil filler cap (1) of the hydraulic tank to release air in the tank...1189
          2. Releasing Remaining Pressure from Hydraulic Cylinder Circuit...1189
            A. Release the residual pressure from the hydraulic tank. For details, see “Releasing Remaining Pressure from Hydraulic Circuit” on page 30-76...1189
            B. Set the starting switch to ON position and set the lock lever to the FREE position, and then operate the right and left work equipment control levers forward, backward, to the right, and to the left...1189
            C. Start the engine and run it at low idle for 10 seconds to raise the pressure in the accumulator...1189
            D. Repeat above steps B and C two to three times, and all remaining pressure is completely released from the piping...1189
          3. Releasing Remaining Pressure from Swing Motor Circuit...1189
          4. Releasing Remaining Pressure from Travel Motor Circuit...1189
          MEMORANDUM...1190
        Measuring and Adjusting of Oil Pressure in Work Equipment, Swing, and Travel Circuits...1191
          Testing...1191
          Measuring Method by Using Machine Monitor...1191
            1. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1191
            2. Increase the hydraulic oil temperature to the operating range and measure the pump delivery pressure...1192
          Measuring Method by Using Oil Pressure Gauge...1193
            1. Open the side cover on the left side of the machine and remove oil pressure pickup plugs (1) and (2) of the main pump...1193
            2. Install nipple M3 and connect oil pressure gauge [3] and hose [2] of hydraulic tester M1...1193
            3. Start the engine and increase the hydraulic oil temperature to the operating range. Read oil pressure gauge [3]...1194
          Combination of Pump, Actuator, and Valve...1195
          Measuring Unload Pressure...1195
            1. Start the engine, set the working mode to Power Mode (P), and turn the auto-decelerator OFF...1195
            2. Set all control levers and pedals to the NEUTRAL and measure the oil pressure while running the engine at full speed...1195
          Measuring Work Equipment Relief Pressure...1195
            1. Start the engine and set the working mode to Power Mode (P)...1195
            2. Run the engine at full speed and operate the cylinder to be measured to the stroke end...1195
            3. Measure the oil pressure when the cylinder is relieved...1195
          Measuring Swing Relief Pressure...1196
            1. Start the engine, set the working mode to the Power Mode (P), and turn the swing lock switch ON...1196
            2. Measure hydraulic oil pressure when the engine is running at full speed and the swing circuit is relieved...1196
          Measuring Travel Relief Pressure...1196
            1. Start the engine and lock the travel mechanism...1196
            2. Set the working mode to Power Mode (P)...1196
            3. Measure the pressure when the engine is running at full speed and the travel circuit is relieved...1196
          Work After Finishing Measurement...1196
          Adjusting...1197
          Adjusting Work Equipment and Travel Relief Pressure...1197
            1. Disconnect the pilot hose...1197
            2. While fixing pressure adjustment screw (5), loosen locknut (6)...1197
            3. Turn adjustment screw (5) to adjust the pressure...1197
            4. While fixing pressure adjustment screw (5), tighten locknut (6)...1197
            5. Connect the pilot hose...1197
            6. After finishing adjustment, check the oil pressure again according to the above measuring procedure...1197
          Adjusting Boom LOWER Relief Pressure (On the Side Where High Pressure is Set)...1198
            1. Disconnect the pilot hose...1198
            2. While fixing pressure adjustment screw (9), loosen locknut (8)...1198
            3. Turn adjustment screw (9) to adjust the pressure...1198
            4. While fixing pressure adjustment screw (9), tighten locknut (8)...1198
            5. Connect the pilot hose...1198
            6. After finishing adjustment, check the oil pressure again according to the above measuring procedure...1198
          Adjusting Boom LOWER Relief Pressure (On the Side Where Low Pressure is Set)...1199
            1. Disconnect the pilot hose...1199
            2. While fixing pressure adjustment screw (11), loosen locknut (10)...1199
            3. Turn adjustment screw (11) to adjust the pressure...1199
            4. While fixing pressure adjustment screw (11), tighten locknut (10)...1199
            5. Connect the pilot hose...1199
            6. After finishing adjustment, check the oil pressure again according to the above measuring procedure...1199
          Adjusting Swing Relief Pressure...1200
            1. Disconnect the pilot hose...1200
            2. While fixing pressure adjustment screw (14), loosen locknut (13)...1200
            3. Turn adjustment screw (14) to adjust the pressure...1200
            4. While fixing pressure adjustment screw (14), tighten locknut (13)...1200
            5. Connect the pilot hose...1200
            6. After finishing adjustment, check the oil pressure again according to the above measuring procedure...1200
        Measuring Oil Pressure in Control Circuit...1201
          Measuring with Machine Monitor...1201
            1. Remove oil pressure pickup plug (1) of the control valve...1202
            2. Install nipple N2 and connect sensor adapter assembly N1...1202
            3. Connect service oil pressure connector (CNP49) (11) and sensor adapter assembly N1...1202
            4. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1203
            5. Increase the hydraulic oil temperature to the operating range...1203
            6. Set all control levers in NEUTRAL and measure the [Service Pressure Sensor] oil pressure while running the engine at full speed...1203
            7. After finishing test, remove the testing tools and restore the machine...1203
            MEMORANDUM...1204
          Measuring with Oil Pressure Gauge...1205
            1. Remove oil pressure pickup plug (1) of the control valve...1205
            2. Install nipple N2 and connect hose [2] and oil pressure gauge [3] of hydraulic tester N4...1205
            3. Start the engine and keep it running until the hydraulic oil temperature increases to the operating range...1206
            4. Measure the hydraulic oil pressure, when the engine is running at full speed and all the control levers are set to NEUTRAL...1206
            5. After finishing test, remove the testing tools and restore the machine...1206
        Measuring and Adjusting Oil Pressure in Pump PC Control Circuit...1207
          Testing...1208
          Measuring PC Valve Output Pressure (Servo Piston Inlet Pressure) With Machine Monitor...1208
            1. Remove oil pressure pickup plugs (3) and (4) of the main pump...1208
            2. Install nipple P2 to each pressure pickup port...1208
            3. Connect sensor adapter assembly P1 to front control pressure pickup port (3)...1208
            4. Connect service oil pressure connector (CNP49) (11) and sensor adapter assembly P1...1208
            5. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1209
            6. Increase the hydraulic oil temperature to the operating range...1209
            7. Measure the pump delivery pressure and PC valve output pressure (servo piston inlet pressure) at the same time after setting the machine to the following conditions with the engine running at full speed...1209
            8. After finishing test, remove the testing tools and restore the machine...1209
            9. Connect sensor adapter assembly P1 to rear control pressure pickup port (4)...1209
            10. Connect service oil pressure connector (CNP49) (11) and sensor adapter assembly P1...1210
            11. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1210
            12. Increase the hydraulic oil temperature to the operating range...1210
            13. Measure the pump delivery pressure and PC valve output pressure (servo piston inlet pressure) at the same time after setting the machine to the following conditions with the engine running at full speed...1210
            14. After finishing test remove the testing tools and restore the machine...1210
          Measuring PC-EPC Valve Output Pressure With the Machine Monitor...1211
            1. Remove oil pressure pickup plugs (5) and (6) of the main pump...1211
            2. Install nipple P2 to each pressure pickup port...1211
            3. Connect sensor adapter assembly P1 to front PC mode selector pressure pickup port (5)...1211
            4. Connect service oil pressure connector (CNP49) (11) and sensor adapter assembly P1...1211
            5. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1211
            6. Increase the hydraulic oil temperature to the operating range...1212
            7. Measure the hydraulic oil pressure with all the control levers set to the NEUTRAL and the engine running at low speed and at full speed...1212
            8. After finishing test remove the testing tools and restore the machine...1212
            9. Connect sensor adapter assembly P1 to rear PC mode selector pressure pickup port (6)...1212
            10. Connect service oil pressure connector (P49) (11) and sensor adapter assembly P1...1212
            11. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1212
            12. Increase the hydraulic oil temperature to the operating range...1213
            13. Measure the hydraulic oil pressure with all the control levers set to the NEUTRAL and the engine running at low speed and at full speed...1213
            14. After finishing test remove the testing tools and restore the machine...1213
            MEMORANDUM...1214
          Measuring PC Valve Output Pressure (Servo Piston Inlet Pressure) With Oil Pressure Gauge...1215
            1. Remove oil pressure pickup plugs (3) and (4) of the main pump...1215
            2. Install nipple P2 to each pressure pickup port...1215
            3. Connect hose [2] and oil pressure gauge [3] of hydraulic tester P4 to front control pressure pickup port (3)...1215
            4. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1216
            5. Increase the hydraulic oil temperature to the operating range...1216
            6. Measure the pump delivery pressure and PC valve output pressure (servo piston inlet pressure) at the same time after setting the machine to the following conditions with the engine running at full speed...1216
            7. After finishing test remove the testing tools and restore the machine...1216
            8. Connect hose [2] and oil pressure gauge [3] of hydraulic tester P4 to rear control pressure pickup port (4)...1216
            9. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1217
            10. Increase the hydraulic oil temperature to the operating range...1217
            11. Measure the pump delivery pressure and PC valve output pressure (servo piston inlet pressure) at the same time after setting the machine to the following conditions with the engine running at full speed...1217
            12. After finishing test remove the testing tools and restore the machine...1217
            MEMORANDUM...1218
          Measuring PC-EPC Valve Output Pressure With Oil Pressure Gauge...1219
            1. Remove oil pressure pickup plugs (5) and (6) of the main pump...1219
            2. Install nipple P2 to each pressure pickup port...1219
            3. Connect hose [2] and oil pressure gauge [3] of hydraulic tester P4 to front PC mode selector pressure pickup port (5)...1219
            4. Start the engine and keep it running until the hydraulic oil temperature increases to the operating range...1219
            5. Measure the hydraulic oil pressure with all the control levers set to the NEUTRAL and the engine running at low speed and at full speed...1219
            6. After finishing test remove the testing tools and restore the machine...1220
            7. Connect hose [2] and oil pressure gauge [3] of hydraulic tester P4 to rear PC mode selector pressure pickup port (6)...1220
            8. Start the engine and keep it running until the hydraulic oil temperature increases to the operating range...1220
            9. Measure the hydraulic oil pressure with all the control levers set to the NEUTRAL and the engine running at low speed and at full speed...1220
            10. After finishing test remove the testing tools and restore the machine...1220
          Adjusting...1221
            1. Loosen lock nut (9)...1221
            2. Adjust the pressure by rotating adjustment screw (10) clockwise or counterclockwise...1221
            3. Tighten lock nut (9)...1221
            4. After finishing adjustment, check again that the PC valve output pressure (servo piston inlet pressure) is normal according to the above measuring procedure...1221
        Measuring and Adjusting Oil Pressure in Pump LS Control Circuit...1222
          Testing...1223
          Measuring LS Valve Output Pressure (Servo Piston Inlet Pressure) With Machine Monitor...1223
            1. Remove oil pressure pickup plugs (3) and (4) of the main pump...1223
            2. Install nipple Q2 to each pressure pickup port...1223
            3. Connect sensor adapter assembly Q1 to front control pressure pickup port (3)...1223
            4. Connect service oil pressure connector (CNP49) (11) and sensor adapter assembly Q1...1223
            5. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1224
            6. Increase the hydraulic oil temperature to the operating range and raise the track of the measured side...1224
            7. Measure the pump delivery pressure and LS valve output pressure (servo piston inlet pressure) at the same time after setting the machine to the following conditions with the engine running at full speed...1224
            8. After finishing test remove the testing tools and restore the machine...1224
            9. Connect sensor adapter assembly Q1 to rear control pressure pickup port (4)...1225
            10. Connect service oil pressure connector (CN-P49) (11) and sensor adapter assembly Q1...1225
            11. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1225
            12. Increase the hydraulic oil temperature to the operating range and raise the track of the measured side...1226
            13. Measure the pump delivery pressure and LS valve output pressure (servo piston inlet pressure) at the same time after setting the machine to the following conditions with the engine running at full speed...1226
            14. After finishing test remove the testing tools and restore the machine...1226
          Measuring LS Differential Pressure with the Machine Monitor...1227
            1. Remove oil pressure pickup plugs (1) and (2) of the main pump...1227
            2. Install nipple Q2 to each pressure pickup port...1227
            3. Connect sensor adapter assembly Q1 to front LS pressure pickup port (1)...1227
            4. Connect service oil pressure connector (CN-P49) (11) and sensor adapter assembly Q1...1227
            5. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1228
            6. Increase the hydraulic oil temperature to the operating range and raise the track of the measured side...1228
            7. While running the engine at full speed under the following condition, measure the pump delivery pressure and LS pressure (actuator load pressure) simultaneously...1228
            8. After finishing test remove the testing tools and restore the machine...1229
            9. Connect sensor adapter assembly Q1 to rear LS pressure pickup port (2)...1229
            10. Connect service oil pressure connector (P49) (11) and sensor adapter assembly Q1...1229
            11. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1229
            12. Increase the hydraulic oil temperature to the operating range and raise the track of the measured side...1230
            13. While running the engine at full speed under the following condition, measure the pump delivery pressure and LS pressure (actuator load pressure) simultaneously...1230
            14. After finishing test remove the testing tools and restore the machine...1230
          Measuring LS-EPC Valve Output Pressure with the Machine Monitor...1231
            1. Remove pressure pickup port plug (7) of the main pump...1231
            2. Install nipple Q2 to the pressure pickup port...1231
            3. Connect sensor adapter assembly Q1 to LS set selector pressure pickup port (7)...1231
            4. Connect service oil pressure connector (CN-P49) (11) and sensor adapter assembly Q1...1231
            5. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1231
            6. Increase the hydraulic oil temperature to the operating range...1232
            7. Measure the oil pressure when the engine is running at full speed and the travel speed switch and travel control lever are operated...1232
            8. After finishing test, remove the testing tools and restore the machine...1232
          Measuring LS Valve Output Pressure (Servo Piston Inlet Pressure) with Oil Pressure Gauge...1233
            1. Remove oil pressure pickup plugs (3) and (4) of the main pump...1233
            2. Install nipple Q2 to each pressure pickup port...1233
            3. Connect hose [2] and oil pressure gauge [3] of hydraulic tester Q4 to front control pressure pickup port (3)...1233
            4. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1234
            5. Increase the hydraulic oil temperature to the operating range and raise the track of the measured side...1234
            6. Measure the pump delivery pressure and LS valve output pressure (servo piston inlet pressure) at the same time after setting the machine to the following conditions with the engine running at full speed...1234
            7. After finishing test, remove the testing tools and restore the machine...1235
            8. Connect hose [2] and oil pressure gauge [3] of hydraulic tester Q4 to rear control pressure pickup port (4)...1235
            9. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1235
            10. Increase the hydraulic oil temperature to the operating range and raise the track of the measured side...1235
            11. Measure the pump delivery pressure and LS valve output pressure (servo piston inlet pressure) at the same time after setting the machine to the following conditions with the engine running at full speed...1235
            12. After finishing test remove the testing tools and restore the machine...1236
          Measuring LS Differential Pressure with Oil Pressure Gauge...1237
            1. Remove oil pressure pickup plugs (1) and (2) of the main pump...1237
            2. Install nipple Q2 to each pressure pickup port...1237
            3. Connect hose [2] and oil pressure gauge [3] or differential pressure gauge Q6 of hydraulic tester Q4 to front pump LS pressure pickup port (1)...1237
            4. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1238
            5. Increase the hydraulic oil temperature to the operating range and raise the track of the measured side...1238
            6. While running the engine at full speed under the following condition, measure the pump delivery pressure and LS pressure (actuator load pressure) simultaneously...1238
            7. After finishing test, remove the testing tools and restore the machine...1239
            8. Connect hose [2] and oil pressure gauge [3] or differential pressure gauge Q6 of hydraulic tester Q4 to rear pump LS pressure pickup port (2)...1239
            9. Start the engine and set the machine monitor to "Monitoring/Pre- defined" or "Monitoring" screen...1240
            10. Increase the hydraulic oil temperature to the operating range and raise the track of the measured side...1240
            11. While running the engine at full speed under the following condition, measure the pump delivery pressure and LS pressure (actuator load pressure) simultaneously...1240
            12. After finishing test remove the testing tools and restore the machine...1240
          Measuring LS-EPC Valve Output Pressure with Oil Pressure Gauge...1241
            1. Remove pressure pickup port plug (7) of the main pump...1241
            2. Install nipple Q2 to the pressure pickup port...1241
            3. Connect hose [2] and oil pressure gauge [3] of hydraulic tester Q4 to rear LS set selector pressure pickup port (7)...1241
            4. Start the engine and keep it running until the hydraulic oil temperature increases to the operating range...1241
            5. Measure the oil pressure when the engine is running at full speed and the travel speed switch and travel control lever are operated...1241
            6. After finishing test, remove the testing tools and restore the machine...1241
          Adjusting...1242
            1. While fixing adjustment screw (10), loosen lock nut (11)...1242
            2. Turn adjustment screw (10) to adjust the pressure...1242
            3. While fixing adjustment screw (10), tighten lock nut (11)...1242
            4. After finishing adjustment, check that the LS differential pressure is normal in the above measuring procedure...1242
        Measuring Solenoid Valve Output Pressure...1243
          Testing...1244
          Measuring with Machine Monitor...1244
            1. Start the engine and set the machine monitor to "Monitoring" screen...1244
            2. Increase the hydraulic oil temperature to the operating range...1244
            3. While running the engine at full speed, operate each control lever and each switch to turn each solenoid valve ON and OFF, and check the "Monitoring" screen...1244
          Measuring with Oil Pressure Gauge...1245
            1. Disconnect outlet hoses (1) to (8) of the solenoid valves to be measured...1245
            2. Install adapter R3 or R4 and reconnect the hoses...1245
            3. Connect nipple [1], hose [2], and oil pressure gauge [3] in hydraulic tester R1...1245
            4. Start the engine and keep it running until the hydraulic oil temperature increases to the operating range...1246
            5. While running the engine at full speed, operate each control lever and each switch to turn each solenoid valve ON and OFF, and measure the oil pressure...1246
            6. After finishing test, remove the testing tools and restore the machine...1246
          Operating Condition...1247
        Soft Swing Adjustments (If Equipped)...1249
          Overview...1249
          Testing...1249
            1. Place the machine in a location where 360° continuous swing operation is possible...1249
            2. Place the control switch in the "SOFT" position...1249
            3. Place the swing lever in the full swing position and wait for the swing speed to stabilize...1249
            4. After the swing speed is stable, flip the control switch to the "OFF" position...1249
            5. If no change in the swing speed is noted, then the system is operating normal...1249
            6. If you feel a surge in swing speed when the switch is flipped to the "OFF" position, then the system requires balancing...1249
          Adjustments...1249
            To balance the system proceed as follows:...1249
              1. Warm the unit to normal hydraulic temperature...1249
              2. Place the swing lock switch to the "ON" position...1249
              3. Snap a 0 - 600 psi gauge onto the "shuttle" gauge port (4) and record the pressure when the swing lever is in full swing for both (A) left and (B) right swing. A=________(left swing reading) B=________(right swing reading) C=(A+B)/2=________...1249
              4. Move the same gauge to "pilot pressure" gauge port (3). Adjust the smaller of two adjustable cartridges (1) to produce a pressure that matches "C"...1249
        Measuring PPC Valve Output Pressure...1250
          Testing...1250
          Measuring with Machine Monitor...1250
            1. Start the engine and set the machine monitor to "Monitoring/Pre-defined" or "Monitoring" screen...1250
            2. Increase the hydraulic oil temperature to the operating range...1251
            3. Measure the pressure when the engine is running at full speed and the control lever of the circuit to be measured is kept at the NEUTRAL position and at the full stroke...1251
          Measuring with Oil Pressure Gauge...1251
            1. Disconnect PPC circuit oil pressure hoses (1) to (10) to be measured...1251
            2. Install adapter S3 or S4 and connect the hoses again which have been disconnected...1252
            3. Connect nipple [1], hose [2], and oil pressure gauge [3] in hydraulic tester S1...1252
            4. Start the engine and keep it running until the hydraulic oil temperature increases to the operating range...1252
            5. Measure the pressure when the engine is running at full speed and the control lever of the circuit to be measured is kept at the NEUTRAL position and at the full stroke...1252
            6. After finishing test, remove the testing tools and restore the machine...1252
        Adjusting Play of Work Equipment and Swing PPC Valves...1253
          Adjusting...1253
            1. Remove boot (1)...1253
            2. Loosen locknut (2) and tighten disc (3) until it touches the heads of four pistons (4)...1253
            3. Fix the position of disc (3) and tighten locknut (2) to the specified torque...1253
            4. Install boot (1)...1253
        Testing Pump Swash Plate Sensor...1254
          Testing Output Voltage of Pump Swash Plate Sensor...1254
            1. Start the engine and raise the track on the side to be tested, by using the work equipment, and prepare for running the track idle...1254
            2. Set the working mode to the Power Mode (P) and set the travel speed to the High...1254
            3. Set the swing lock switch to ON position...1254
            4. While running the engine at full speed, set all the levers and pedals for work equipment, swing, and travel to the neutral, and then set the travel lever to stroke end in order to run a track idle, and measure the voltage during each operation...1254
            MEMORANDUM...1255
          Isolating the Parts Causing Hydraulic Drift in Work Equipment...1256
            1. Checking boom cylinder and bucket cylinder...1256
              A. Set the work equipment in the same posture as when measuring hydraulic drift, and stop the engine...1256
              B. When testing the boom cylinder, set the boom control lever to the RAISE position...1256
            2. Checking arm cylinder...1256
              A. Move the arm cylinder to about 100 mm {3.397 in} before the IN stroke end and stop the engine...1256
              B. Operate the arm control lever to the arm IN position...1256
              A. If the work equipment is set to the above posture (where the work equipment holding pressure is applied to the bottom side), the oil leaks from the bottom side to the head side. The volume on the head side is less than that on the bottom side by t...1256
              B. As the inner pressure in the head side is increased, it is balanced with the pressure in the bottom side at a certain level (which depends on the leak quantity), and the lowering speed is reduced...1256
              C. If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the bottom side is closed by the check valve at this time), the oil in the head side flows in the drain circuit. As a result, the pressure is in ba...1256
        Measuring Oil Leakage...1258
          1. Measurement of leakage from boom cylinder...1258
            A. Extend the boom cylinder to the boom RAISE stroke end and stop the engine...1258
            B. Disconnect hose (1) on the cylinder head side and block the hose end by a flange...1258
            C. Run the engine at full speed and relieve the boom circuit by extending the cylinder...1258
            D. Start measuring the oil leakage 30 seconds after relieving is started, and measure the leak for 1 minute...1258
            E. After finishing testing, return the machine status as it was...1258
          2. Measurement of oil leakage from arm cylinder...1258
            A. Fully extend the arm cylinder, lower the work equipment, and stop the engine...1258
            B. Disconnect hose (2) on the cylinder head side and block the hose end by a flange...1259
            C. Run the engine at full speed and relieve the arm circuit by extending the arm cylinder...1259
            D. Start measuring the oil leakage 30 seconds after relieving is started, and measure the leak for 1 minute...1259
            E. After finishing testing, return the machine status as it was...1259
          3. Measurement of oil leakage from bucket/heel cylinder...1259
            A. Fully extend the bucket/heel cylinder, lower the work equipment, and stop the engine...1259
            B. Disconnect hose (3) on the cylinder head side and block the hose end by a flange...1259
            C. Run the engine at full speed and relieve the bucket circuit by extending the cylinder...1259
            D. Start measuring the oil leakage 30 seconds after relieving is started, and measure the leak for 1 minute...1260
            E. After finishing testing, return the machine status as it was...1260
          4. Measurement of oil leakage from swing motor...1260
            A. Disconnect two drain hoses (4) and block the hose side end by plugs...1260
            B. Set the swing lock switch to the ON position...1260
            C. Run the engine at full speed and relieve the swing circuit by swinging...1260
            D. After finishing testing, return the machine status as it was...1260
          5. Measurement of oil leakage from travel motor...1260
            A. Remove the travel motor cover...1260
            B. Run the engine, lock the travel mechanism, and stop the engine...1260
            C. Disconnect drain hose (5) of the travel motor and block the hose end by a plug...1260
            D. Run the engine at full speed, relieve the travel circuit, and measure the oil leakage...1261
            E. After finishing testing, return the machine status as it was...1261
        Bleeding Air From Hydraulic Circuit...1262
          1. Air bleeding from main pump...1263
            A. Loosen air bleeder (1) and check that oil oozes out from it...1263
            B. After oil containing no bubbles flows out, tighten air bleeder (1)...1263
          2. Starting engine...1263
          3. Bleeding air from cylinder...1263
            A. Run the engine at low idle for approximately 5 minutes...1263
            B. While running the engine at low speed, raise and lower the boom four to five times...1263
            C. While running the engine at full speed, perform step B...1263
            D. While running the engine at low idle speed, move the piston rod to the stroke end and relieve the oil...1263
            E. Bleed air from the arm cylinder and bucket cylinder according to steps B to D...1263
          4. Bleeding air from swing motor...1263
            A. Run the engine at low idle...1263
            B. Loosen S port hose (4) slowly to make sure oil oozes out through the S port hose...1263
            C. When oil does not flow out, stop the engine once, disconnect S port hose and then fill up the motor case with oil...1263
            D. After bubble-free oil flows out, tighten the S port hose...1263
            E. Swing slowly right and left more than 2 times each...1264
          5. Bleeding air from travel motor...1264
            A. Remove travel motor cover...1264
            B. Run the engine at low speed...1264
            C. Loosen air bleeder (5) and check that oil oozes out from it...1264
            D. After oil containing no bubbles flows out, tighten air bleeder (5)...1264
            E. Raise one track by using the work equipment...1264
          6. Bleeding air from swivel joint...1264
            A. Run the engine at low idle...1264
            B. Lift the track on one side at a time, then bleed air by slowly running at idle (in L.H. travel, R.H. travel, forward and reverse)...1264
          7. Checking oil level and starting work...1265
            A. Run the engine, retract the arm cylinder and bucket/heel cylinder to the stroke end, lower the work equipment to the ground, and stop the engine...1265
            B. Check the oil level using sight gauge (3) on the side face of the hydraulic tank...1265
          MEMORANDUM...1266
      MIRROR ADJUSTMENT...1267
        Mirror (A)...1267
        Mirror (B)...1269
        Mirror (C)...1270
      ELECTRICAL SYSTEM...1271
        Special Functions of Machine Monitor...1271
          Upper Part of machine monitor (display portion)...1272
          Upper Part of Machine Monitor (Switch Portion)...1272
          Lower Part of Machine Monitor (Switch Portion)...1272
        Ordinary Functions and Special Functions of Machine Monitor...1272
          1. Ordinary functions: Operator mode...1272
          2. Special function: Service mode...1272
          Operator Mode (Outline)...1275
            Display of KOMATSU Logo...1277
            Display of Inputting Password...1277
            Display of Check of Breaker Mode...1277
            Display of Check Before Starting...1278
            Display of Warning After Check Before Starting...1278
            Display of Ending of Maintenance Interval...1278
            Display of Check of Working Mode and Travel Speed...1278
            Display of Standard Screen...1279
            Display of End Screen...1279
            Display of Engine Shutdown Secondary Switch Screen...1279
            Selection of Auto-Deceleration...1279
            Selection of Working Mode...1280
              1. While the standard screen is displayed, press the working mode selector switch, and the working mode selection screen is displayed...1280
              2. Operate the function switches or working mode selector switch to select the desired working mode and enter the selection...1280
              3. When the ordinary screen is displayed again, large working mode monitor (a) is displayed for 2 seconds, and then the setting of the working mode is changed to the selected mode...1280
            Selection of Travel Speed...1281
            Operation to Stop Alarm Buzzer...1281
            Operation of Windshield Wiper...1281
            Operation of Window Washer...1281
            Operation of Air Conditioner/Heater...1281
            Operation to Display Camera Mode (If Camera is Installed)...1282
            Operation to Display Clock and Service Meter...1282
            Check of Maintenance Information...1283
            Setting and Display of User Mode (Including KOMTRAX Messages for User)...1283
            Display of ECO Guidance...1284
            Display of Caution Monitor...1285
            MEMORANDUM...1286
              Display of KDPF Regeneration...1287
                2. When level of urgency is high...1290
              Operation Procedure of Manual Stationary Regeneration...1292
                2. Check that there is no person or combustible matter around the machine (particularly in the direction of the exhaust gas flow)...1292
                3. Set the lock lever to LOCK position (L)...1292
                4. Set the fuel control dial to low idle (MIN) position...1292
                5. Press switch F6 to display the Komatsu Diesel Particulate Filter (KDPF) regeneration screen...1292
                6. Select manual stationary regeneration, check again that there is no person or combustible matter around the machine, then press switch F6. If the machine needs to be moved again to secure safety, move it to a safe place and repeat the procedure fr...1292
                7. This screen is displayed during the manual stationary regeneration. It may take more than 40 minutes to complete the manual stationary regeneration. Do not switch any screen or operate fuel control dial until the regeneration is complete and the s...1294
                8. After the manual stationary regeneration, the screen automatically returns to the standard screen...1294
              Komatsu Diesel Particulate Filter (KDPF) Regeneration Disable Procedure...1295
              While Regeneration is being Performed: Stopping Regeneration...1296
                2. Select regeneration disable and then press switch (F6), and the regeneration stops...1296
              Display of Action Level and Failure Code...1297
              Function of Checking Display of LCD (Liquid Crystal Display)...1298
              Function of Checking Service Meter...1298
            MEMORANDUM...1299
              Function of Changing Attachment/Maintenance Password...1300
                1. While the standard screen is displayed, perform the following operation with the numeral input switches...1300
                2. After the "Usage Limitation PASSWORD screen is displayed, input the current password using the numeral input switches and validate it using the function switch...1300
                3. After the "Usage Limitation Setting" screen is displayed, select a setting using the function switch...1300
                4. Changing a password...1301
          Service Mode...1302
            1. Check of screen display and operation of switches...1302
            2. Selection of service menu...1302
            Monitoring / Pre-Defined...1304
              1. Selecting the menu...1304
              2. Check of monitoring / pre-defined information...1304
            MEMORANDUM...1305
              Monitoring / Custom...1310
                1. Selecting the menu...1310
                2. Selecting monitoring item...1310
                3. Getting machine monitor ready for monitoring...1310
                4. Performing monitoring...1311
                5. Holding monitoring information...1311
                6. Changing machine setting mode during monitoring...1311
                7. Saving monitoring item...1312
            MEMORANDUM...1313
              Monitoring Items Table...1314
              Abnormality Record (Mechanical Systems)...1320
                1. Selecting the menu...1320
                2. Selecting sub menu...1320
                3. Information displayed on abnormality record screen...1320
                4. Clearing abnormality record...1321
              Abnormality Record (Electrical Systems)...1322
                1. Selecting the menu...1322
                2. Selecting sub menu...1322
                3. Information displayed on abnormality record screen...1322
                4. Clearing abnormality record...1323
                  A. While the "Electrical Systems" abnormality record screen is displayed, press the numeral input switches as follows...1323
                  B. Check that the screen is set in the clear mode, and then clear the items one by one or together by using the function switches...1323
                  C. After the "Electrical Sys. Error Reset" screen is displayed, press the function switches...1323
                  D. If the screen to notify completion of clearing is displayed and then the "Electrical Systems" (clear mode) screen is displayed, the clearing of the abnormality record is completed...1323
              Maintenance Record...1324
                1. Selecting the menu...1324
                2. Selecting maintenance item After the "Maintenance Record" screen is displayed, select a maintenance item to be checked by using the function switches or numeral input switches...1324
                3. Items displayed on Maintenance Record screen...1325
              Maintenance Mode Setting...1326
                1. Selecting the menu...1326
                2. Selecting sub menu...1326
                3. Contents of "Maintenance Mode Change"...1327
                4. Contents of "Maintenance Notice Time Setting"...1327
                5. Setting of each maintenance item...1327
                6. Contents of setting of set value of each maintenance item...1328
                7. Function of All Default Value...1328
              Phone Number Entry...1329
                1. Selecting the menu...1329
                2. Registering and changing phone number...1329
              Default (Key-On Mode)...1330
                1. Selecting the menu...1330
                2. Selecting sub menu...1330
                3. Selecting mode...1330
              Default (Unit)...1331
                1. Selecting the menu...1331
                2. Selecting sub menu...1331
                3. Selecting unit...1331
              Default (With/Without Attachment)...1332
                1. Selecting the menu...1332
                2. Selecting sub menu...1332
                3. Selecting With/Without...1332
            MEMORANDUM...1333
              Default (Camera)...1334
                1. Selecting the menu...1334
                2. Selecting sub menu...1334
                3. Selection of camera setting...1334
              Diagnostic Tests (Cylinder Cut-out)...1336
                1. Selecting the menu...1336
                2. Selecting sub menu...1336
                3. Selecting cylinder to be cut out...1336
                4. Resetting cut-out cylinder...1337
                5. Holding displayed data...1337
                  A. The engine speed lowers...1337
                  B. The value (quantity) of final injection command increases...1337
              Diagnostic Tests (Regeneration for Service)...1338
                1. Selecting the menu...1338
                2. Selecting sub menu...1338
                3. Setting regeneration for service...1338
                  A. KDPF forced regeneration (Stationary manual regeneration) Select "Stationary manual regeneration" on the "Regeneration for Service" screen...1339
                  B. Finish of regeneration...1339
                  C. Stopping of regeneration...1339
              Diagnostic Tests (KDPF Memory Reset)...1340
                1. Selecting the menu...1340
                2. Selecting sub menu...1340
                3. Setting KDPF memory reset...1340
              Adjustment (Pump Absorption Torque (F))...1342
                1. Selecting the menu...1342
                2. Selecting sub menu...1342
                3. Selecting pump absorption torque setting...1342
              Adjustment (Pump Absorption Torque (R))...1343
                1. Selecting the menu...1343
                2. Selecting sub menu...1343
                3. Selecting pump absorption torque setting...1343
              Adjustment (Low Speed)...1344
                1. Selecting the menu...1344
                2. Selecting sub menu...1344
                3. Selecting low speed...1344
              Adjustment (Attachment Flow Adjustment)...1345
                1. Selecting the menu...1345
                2. Selecting sub menu...1345
                3. Selecting set value code for oil flow distribution...1345
              Adjustment (Cal F Pump Swash Plate Sensor)...1346
                1. Preparation for calibration...1346
                2. Selecting the menu...1347
                3. Selecting sub menu...1347
                4. Calibration of front pump swash plate sensor for the maximum angle...1347
                  A. After the "Cal F pump swash plate sensor max" is displayed, calibrate the front pump swash plate sensor for the maximum angle by running track idle off the ground and operating the function switches...1347
                  B. Raise the right track off ground by using the work equipment and move the right travel lever to the stroke end to run the right track idle off the ground...1347
                  C. When the speed of the track running idle is stabilized, hold down [F1] of the machine monitor to start calibration...1348
                  D. Calibration is finished successfully, "OK" is displayed for the State of Adjustment to show that calibration for the maximum angle is completed...1348
                5. Calibration of front pump swash plate sensor for the minimum angle...1348
                  A. After the "Cal F pump swash plate sensor min" is displayed, set all the levers in neutral and Perform calibration on the Min. side of the front pump swash plate sensor with the function switches...1348
                  B. Wait under the following conditions:...1349
                  C. Hold down [F1] of the machine monitor to start calibration...1349
                  D. Calibration is finished successfully, "OK" is displayed for the State of adjustment to show that calibration for the minimum angle is completed...1349
              Adjustment (Cal R Pump Swash Plate Sensor)...1352
                1. Preparation for calibration...1352
                2. Selecting the menu...1352
                3. Selecting sub menu...1352
                4. Perform the subsequent calibration procedure according to "Adjustment (Cal F pump swash plate sensor)"...1352
            MEMORANDUM...1353
              Adjustment (Pump Calibration: Matching Speed Check)...1354
                1. Preparation for calibration...1354
                2. Selecting the menu...1354
                3. Selecting sub menu...1354
                4. Selection of the matching speed check menu...1355
                5. Check of matching speed (relief of arm IN circuit)...1355
                  A. When the "Matching speed check" screen is displayed, relieve the arm IN circuit and check the matching speed using the function switch...1355
                  B. In the following conditions, operate the arm or bucket lever to check the relief matching...1355
                  C. Relieve the arm IN circuit and, after the engine speed stabilized, hold down [F1] on the machine monitor to start the check...1356
                  D. As the correction is normally completed, the result is displayed...1356
                6. Check of matching speed (relief of bucket CURL circuit relieved)...1356
                  A. When the "Matching Speed Check" screen is displayed, relieve the bucket CURL circuit and check the matching speed using the function switch...1356
                  B. Wait under the following conditions...1357
                  C. Hold down [F1] of the machine monitor to start the check...1357
                  D. As the correction is normally completed, the result is displayed...1357
            MEMORANDUM...1361
              Adjustment (Pump Calibration: Matching Speed Calibration)...1362
                1. Preparation for calibration...1362
                2. Selecting the menu...1362
                3. Selecting sub menu...1362
                4. Selection of the matching speed check menu...1362
                5. Perform the subsequent calibration procedure referencing the section of "Check of matching speed"...1362
                6. Return to default...1362
              No Injection...1364
                1. Selecting the menu...1364
                2. Confirmation screen...1364
                3. Starting no injection cranking...1364
                4. Finishing no injection cranking...1365
                5. Prohibiting no injection cranking...1365
              KOMTRAX Settings (Terminal Status)...1366
                1. Selecting the menu...1366
                2. Selecting sub menu...1366
                3. Contents displayed on the terminal status screen...1366
              KOMTRAX Settings (GPS and Communication Status)...1367
                1. Selecting the menu...1367
                2. Selecting sub menu...1367
                3. Contents displayed on GPS & Communication Status screen...1367
              KOMTRAX Settings (Modem Information)...1368
                1. Selecting the menu...1368
                2. Selecting sub menu...1368
                3. Modem status displayed...1368
              Service Message...1369
                1. Selecting menu...1369
                2. Displaying message (read-only)...1369
                3. Displaying message (message with return mail function)...1369
        Angle Adjustment of Rear View Camera...1370
          1. Remove cover (1) by inserting flat-head screwdriver [1] in the hole in cover (2) and pressing the internal pawl...1370
          2. Remove two bolts (3)...1371
          3. Remove cover (1)...1371
          4. Loosen camera mounting bolts (4) (3 places) and adjust camera installation angle (A) so that corner (B) of mounting bracket (5) matches with horizontal line (C) of the camera...1371
          5. After adjusting, tighten bolts (4)...1372
          6. Install covers (1) and (2)...1372
        Handling Voltage Circuit of Engine Controller...1372
          1. Disconnect connector between the engine controller and engine. (Be sure to turn the starting switch to the OFF position when performing the connecting work.)...1372
          2. If a T to adapter is inserted in or connected to the connector between the engine controller and engine harness for troubleshooting, do not start the engine...1372
        Handling Battery Disconnect Switch...1373
          1. Pull out switch key (1) whenever you have turned the battery disconnect switch OFF...1373
          2. Check the operating condition of each controller with system operating lamp (2) to prevent abnormal stop by cutting out the battery power supply circuit while the controllers are in operation...1373
            A. When cutting out the battery power supply circuit, turn the starting switch to the OFF position and check that the system operating lamp has gone out, and then turn the battery disconnect switch to the OFF position...1373
            B. If the battery disconnect switch is turned to the OFF position (to cut out the battery power supply circuit) while the system operating lamp is lighting up, the data loss error may occur in the controllers. Do not operate the battery disconnect sw...1373
            C. The system operating lamp goes out within 2 minutes after the starting switch is turned to the OFF position...1373
            D. Even if the starting switch is in the OFF position, the system operating lamp may light up since the KOMTRAX terminal may be communicating...1373
            E. Even if the system operating lamp is off, it may seem to be lighting slightly because of a very small current inside the controller. This phenomenon does not indicate abnormality...1373
            F. To cut out the battery circuit for maintenance while the system operating lamp is lighting up, turn the starting switch to the ON position and then return to the OFF position, and the lamp goes out within 2 minutes...1373
        Testing Diodes...1374
          1. When using a digital multi meter...1374
            A. Set the multi meter to the diode range and read the indicated value...1374
            B. Apply the red (+) lead of the multi meter to the anode (P) of the diode and apply the black (—) lead to the cathode (N), and check the indicated value...1374
            C. Judge the quality of the diode by the indicated value...1374
          2. When using an analog multi meter...1374
            A. Set the multi meter in the resistance range...1374
            B. Apply the leads of the multi meter as explained below and check the movement of the pointer...1374
            i. Apply the red (+) lead of the multi meter to the anode (P) of the diode and apply the black (—) lead to the cathode (N)...1374
            ii. Apply the red (+) lead of the multi meter to the cathode (N) of the diode and apply the black (—) lead to the anode (P)...1374
            C. Judge the quality of the diode by the movement of the pointer...1374
          MEMORANDUM...1375
      PM CLINIC...1376
        PM Clinic Service...1376
          Check Items Related to Engine...1378
          Check Items Related to Oil Pressure...1379
        Check Sheet...1380
    40 - TROUBLESHOOTING...1386
      GENERAL INFORMATION ON TROUBLESHOOTING...1393
        Points to Remember When Troubleshooting...1393
          1. When performing troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after a failure occurs:...1393
          2. Points to ask the user or operator...1393
            A. Have any other problems occurred apart from the problem that has been reported?...1393
            B. Was there anything strange about the machine before the failure occurred?...1393
            C. Did the failure occur suddenly, or were there problems with the machine condition before this?...1393
            D. Under what conditions did the failure occur?...1393
            E. Had any repairs been performed before the failure? When were these repairs performed?...1393
            F. Has the same kind of failure occurred before?...1393
          3. Check before troubleshooting...1393
            A. Are abnormal symptoms detected in the machine?...1394
            B. Make checks before starting day's work...1394
            C. Make checks of other items...1394
            D. Other maintenance items can be checked externally, so check any item that is considered to be necessary...1394
          4. Confirming the failure...1394
            A. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc...1394
          5. Troubleshooting...1394
            A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the troubleshooting flowchart to locate the position of the failure exactly...1394
            B. The basic procedure for troubleshooting is as follows...1394
            i. Start from the simple points...1394
            ii. Start from the most likely points...1394
            iii. Investigate other related parts or information...1394
          6. Measures to remove root cause of failure...1394
            A. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again...1394
            B. To prevent this, always investigate why the problem occurred. Then, remove the root cause...1394
        Sequence of Events in Troubleshooting...1395
          MEMORANDUM...1396
        Checks Before Troubleshooting...1397
        Testing Procedure Before Troubleshooting...1399
          Walk-Around Check...1399
          Checking in Accordance with Checking Procedure...1401
            1. Clean around the electrolyte level lines with a cloth dampened with water and check that the electrolyte level is between UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.)...1401
            2. If the electrolyte level is below the center between the U.L. and L.L. lines, remove cap and add refined water (example: commercially available battery fluid) to the U.L. line immediately...1401
            3. After adding the purified water, securely tighten cap...1401
            1. Remove cap on the top of the battery. (described previously)...1402
            2. Look into electrolyte level check opening (3) to check the electrolyte level. If the electrolyte level is below sleeve (4), be sure to add refined water (example: commercially available battery fluid) up to the sleeve bottom (U.L. line)...1402
            3. After adding the refined water, tighten cap...1402
            1. Open up the engine hood...1406
            2. Connect the positive (+) line of the tester to alternator terminal (B) and connect the negative (-) line to the chassis ground...1406
            3. Start and warm up the engine and measure the voltage while running the engine at a medium or a higher speed...1406
            1. Open the battery cover...1406
            2. Check whether the battery relay operation sound is heard when the starting switch is turned to the ON/OFF positions...1406
        Preparation Work for Troubleshooting of Electrical System...1407
          Preparation Work...1407
            1. Machine monitor...1407
              A. Remove the screws (three pcs.) mounting cover (1)...1407
              B. Remove a mounting bolt and duct (6)...1407
              C. Insert a flat-head screwdriver in slit (3) and pull it up around projection (4) to remove cover (5)...1407
              D. Insert or connect troubleshooting T-adapters in or to connectors CM01, CM02, and CM04 on machine monitor (7)...1408
            2. Engine controller...1408
              A. Remove the undercover...1408
              B. Insert or connect troubleshooting T-adapters in or to connectors ECMJ1, ECMJ2, and CE03 on engine controller (8)...1408
            3. Pump controller...1408
              A. Slide the operator's seat and seat stand to the forward end...1408
              B. Remove the five mounting bolts and cool & hot box (9)...1408
              C. Remove the two mounting bolts, one fastener, and magazine box (10)...1408
              D. Remove the three mounting bolts and cover (11)...1408
              E. Remove the seven mounting bolts and cover (14)...1408
              F. Connect test adapters to connectors CP01 and CP02 of pump controller (15)...1408
            4. KOMTRAX communication module...1409
              A. Slide the operator's seat and seat stand to the forward end...1409
              B. Remove the five mounting bolts and cool & hot box (9)...1409
              C. Remove the two mounting bolts, one fastener, and magazine box (10)...1409
              D. Remove the three mounting bolts and cover (11)...1409
              E. Remove the seven mounting bolts and cover (14)...1409
              F. Connect troubleshooting T-adapters to connectors CK01 and CK02 of KOMTRAX communication module (15)...1409
            5. Ambient pressure sensor (AMBAIR PRESSURE) Engine Ne speed sensor (Crank sensor) Engine Bkup speed sensor (Cam sensor) Engine oil pressure switch (OIL PRESSURE SWITCH)...1410
            6. Boost pressure temperature sensor (BOOST PRES & IMT)...1410
            7. Supply pump IMV solenoid (Fuel regulator)...1410
            8. Common rail pressure sensor (Fuel rail press)...1411
            9. Engine coolant temperature sensor (Coolant temp)...1411
        Classification and Procedure for Troubleshooting...1412
          Classification of Troubleshooting...1412
          Procedure for Troubleshooting...1412
            1. Troubleshooting procedure to be taken when action level and failure code are displayed on machine monitor:...1412
            2. Troubleshooting procedure to be taken when action level and failure code are not displayed on normal screen of machine monitor:...1412
              A. If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the recorded code...1412
              B. If no failure code is recorded in the abnormality record, a failure that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system...1412
            3. Actions to take after failure is repaired...1412
            1. On the normal operation screen, while pressing number key [4] in the panel switch section, press [1], [2], and [3] in this order...1413
            2. On the service menu screen, press switch [F3] (s) in the panel switch section twice, and then select "03 Abnormality Record"...1413
            3. Press switch [F6] in the panel switch section to confirm, and then enter the "Abnormality record" screen...1413
            4. Press switch [F6] in the panel switch section to confirm, and then enter the "Mechanical system failure record" screen...1413
            5. Press switch [F3] (s) in the panel switch section to check failure codes one by one and take record of all information of all failure codes...1413
            6. Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen...1413
            7. Similarly to 2 and 3, enter the "Electrical system abnormality record" screen...1413
            8. Press switch [F3] (s) in the panel switch section to check failure codes one by one and take record of all information of all failure codes...1413
            9. While pressing number key [4] in the panel switch section, press [1], [2], and [3] in this order to enter the "Clearing mode". (Same as 1)...1413
            10. Press switch [F2] (CLEAR) in the panel switch section...1414
            11. Press switch [F6] in the panel switch section to clear all failure codes temporarily...1414
            12. Press switch [F5] (return) in the panel switch section to return to the "Electrical system abnormality record" screen. Check if there is any failure code still displayed and take record...1414
            13. Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen...1414
            14. Take record of information of all columns...1414
            15. Press switch [F2] (CLEAR) in the panel switch section to clear all codes temporarily. Check if "Abnormal" is still displayed and take record. (Same as 10 in [*1] and [*2])...1414
            16. Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen...1414
            MEMORANDUM...1415
        Symptom of Probable Failure and Troubleshooting No...1416
        Information Mentioned in Troubleshooting Table...1420
          1. Connector number indication method and handling of T-adapter For troubleshooting, insert or connect T-adapter as follows unless otherwise specified...1421
          2. Description sequence of pin number and handling of tester lead For troubleshooting, connect the positive (+) and negative (-) leads as shown below unless otherwise specified...1421
      Diagnostic Procedure for Wiring Harness Open Circuit of Pressure Sensor System...1422
        1. Measure and record resistance of the pressure sensor unit...1422
          A. Disconnect pressure sensor connector (1) and connect socket (2) to the connector on the sensor side...1422
          B. Measure resistances R1 and R2 between pins...1422
        2. Measure and record resistance with the wiring harness between the pressure sensor and engine controller connected...1422
          A. Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor connectors first. (*)...1422
          B. Connect the pressure sensor to be measured, disconnect connector (3) on the engine controller side, and connect T- adapter (4) to the connector on the wiring harness side...1423
          C. Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'...1423
        3. Determining open circuit...1423
        Connector List and Layout...1425
        Cab Connector List and Layout...1431
          Layout of connectors (1/6)...1432
          Layout of connectors (2/6)...1433
          Layout of connectors (3/6)...1434
          Layout of connectors (4/6)...1435
          Layout of cab connectors (5/6)...1436
          Layout of connectors (6/6)...1437
        Connection Table for Connector Pin Numbers...1438
        T-Branch Box and T-Branch Adapter Table...1473
        Fuse List and Location...1477
          Connection Table of Fuse Boxes...1477
          Locations of Fusible Links...1478
          Location of Fuse Boxes and Fuse Numbers...1479
        Precautions for Cleaning and Replacing KDPF (KCSF, KDOC)...1480
          1. Related information...1480
          2. When cleaning or replacing KCSF...1480
            A. In periodic cleaning for every 4,500 hours...1480
            i. Check the level of soot load. If the soot load level is displayed, turn on and continue active regeneration for service until the load becomes zero...1480
            ii. Stop the engine and wait until the temperature of piping around engine drops, then remove KDPF and remove KCSF, too...1480
            iii. Clean KCSF using the ash cleaning system, which is used at the specified maintenance shops and the like. (When reusing a removed KCSF after cleaning it)...1481
            iv. Install the cleaned KCSF to the machine. (When reusing a removed KCSF after cleaning it)...1481
            v. Install another KCSF to the machine. (When replacing a KCSF with new one)...1481
            vi. Turn starting switch to ON position and perform KDPF cleaning reset from the KDPF reset screen...1481
            vii. Start the engine and warm it up at low idle...1481
            viii. Perform active regeneration for service...1481
            B. If cracks or damages are detected...1481
            i. Stop the engine and wait until the temperature of piping around engine drops, then remove KDPF and remove KCSF, too...1481
            ii. Install another KCSF (new or used KCSF) to the machine...1481
            iii. Turn starting switch to ON position and perform KDPF cleaning reset from the KDPF reset screen...1481
            iv. Perform KDPF Change reset from the KDPF reset screen...1481
            v. Start the engine and warm it up at low idle...1481
            vi. Perform active regeneration for service...1481
            C. KDPF soot load high error 2 (CA1922) is output...1481
            i. Stop the machine and confirm from the machine monitor that the failure code (CA1922) is output...1481
            ii. On machine monitor, check history of output of "CA2639: Stationary regeneration request" and "CA1921: KDPF soot load high error 1", and "CA1922: KDPF soot load high error 2"...1481
          3. When cleaning or replacing KDOC...1482
            A. If cracks or damages are detected...1482
            i. If cracks or damages are detected on KDOC, replace KDOC...1482
            ii. Perform KDOC reset from the KDPF reset screen...1482
            B. When regeneration ineffective (CA1691) is output...1482
            i. Stop the machine and confirm from the machine monitor that the failure code (CA1691) is output. (CA2637 is sometimes output at the same time.)...1482
            ii. Check the engine exhaust gas color...1482
            iii. While CA1691 is output, perform the active regeneration for service for 40 minutes. (KDOC drying operation: Fuel is not injected during regeneration.)...1482
            iv. Stop the engine and wait until the temperature of piping around engine drops, then remove KDOC and check it for cracks and damages...1482
      FAILURE CODE (DISPLAY OF CODE)...1483
        Failure Codes Table...1483
        879AKA - A/C Inner Sensor Open Circuit...1490
        879AKB - A/C Inner Sensor Short Circuit...1490
        879BKA - A/C Outer Sensor Open Circuit...1490
        879BKB - A/C Outer Sensor Short Circuit...1490
        879CKA - Ventilating Sensor Open Circuit...1490
        879CKB - Ventilating Sensor Short Circuit...1490
        879DKZ - Sunlight Sensor Open or Short Circuit...1490
        879EMC - Ventilation Damper Abnormality...1491
        879FMC - Air Mix Damper Abnormality...1491
        879GKX - Refrigerant Abnormality...1491
        989L00 - Engine Controller Lock Caution 1...1492
        989M00 - Engine Controller Lock Caution 2...1492
        989N00 - Engine Controller Lock Caution 3...1493
        A1U0R7 - Manual Stationary Regeneration Request (96 Hour Timer Request)...1494
          1. Move the machine to a safe location and check that the engine area is free of debris...1495
          2. Turn the fuel dial to its minimum position. Apply the safety lock lever...1495
          3. Follow the instructions on the monitor and press the appropriate button to activate regeneration...1495
          4. Do not interrupt the regeneration operation by turning the fuel dial up or disengaging the safety lock lever...1495
          5. Duration of the 96 hour manual stationary regeneration is approximately 20 minutes...1495
        A1U0N3 - KDPF Dry Request (HC Release) 1...1496
          1. Turn starting switch to ON position...1497
        A1U0N4 - KDPF Dry Request (HC Release) 2...1498
        AA10NX - Air Cleaner Clogging...1500
        AB00KE - Charge Voltage Low...1502
          1. Turn starting switch to OFF position...1502
          2. Disconnect diode D01 and connect T-adapter to male side...1502
        B@BAZG - Engine Oil Pressure Low...1504
          MEMORANDUM...1505
        B@BAZK - Eng Oil Level Low...1506
        B@BCNS - Engine Coolant Overheat...1508
          MEMORANDUM...1509
        B@BCZK - Radiator Coolant Level Low...1510
        B@HANS - Hyd Oil Overheat...1512
        CA115 - Eng Ne and Bkup Speed Sens Error...1513
        CA122 - Chg Air Press Sensor High Error...1514
        CA123 - Chg Air Press Sensor Low Error...1516
        CA131 - Throttle Sensor High Error...1518
        CA132 - Throttle Sensor Low Error...1520
        CA144 - Coolant Temp Sens High Error...1522
        CA145 - Coolant Temp Sens Low Error...1524
        CA153 - Chg Air Temp Sensor High Error...1526
        CA154 - Chg Air Temp Sensor Low Error...1528
        CA187 - Sensor 2 Supply Volt Low Error...1530
          1. Turn starting switch to OFF position...1530
          2. Disconnect following connectors one by one and turn starting switch to ON position each time...1530
          3. After each troubleshooting, turn starting swith to OFF position...1530
        CA221 - Ambient Press Sensor High Error...1532
        CA222 - Ambient Press Sensor Low Error...1534
          1. Perform checkup referencing descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1534
          2. Turn starting switch to ON position...1534
          3. Turn starting switch to OFF position...1534
          4. Disconnect connectors AMB AIR PRESSURE, and connect T-adapters to female side of either of them...1534
          5. Turn starting switch to ON position...1534
          6. Turn starting switch to OFF position...1534
          7. Disconnect connectors AMB AIR PRESSURE and ECM J1, and connect T-adapters to each female side...1534
        CA227 - Sensor 2 Supply Volt High Error...1536
        CA234 - Eng Overspeed...1537
        CA238 - Ne Speed Sensor Supply Volt Error...1538
        CA239 - Ne Speed Sens Supply Volt High Error...1540
          1. Turn starting switch to OFF position...1540
          2. Disconnect connector CRANK SENSOR...1540
          3. Turn starting switch to ON position...1540
          4. Turn starting switch to OFF position...1540
          5. Disconnect wiring harness connector ECM J1...1540
          6. Turn starting switch to ON position...1540
        CA271 - IMV/PCV1 Short Error...1542
          1. Starting switch: OFF...1542
          2. Disconnect connector INLET METERING VALVE...1542
          3. Turn starting switch to ON position...1542
        CA272 - IMV/PCV1 Open Error...1544
          1. Starting switch: OFF...1544
          2. Disconnect connector INLET METERING VALVE...1544
          3. Insert T-adapter to connector ECM J1...1544
          4. Turn starting switch to ON position (with connector INLET METERING VALVE connected) and start measurement after at least one minute...1544
        CA281 - Pump Press Balance Error...1546
        CA295 - Ambient Press Sens In Range Error...1547
        CA322 - Inj #1 (L#1) Open/Short Error...1548
        CA323 - Inj #5 (L#5) Open/Short Error...1550
        CA324 - Inj #3 (L#3) Open/Short Error...1552
        CA325 - Inj #6 (L#6) Open/Short Error...1554
        CA331 - Inj #2 (L#2) Open/Short Error...1556
        CA332 - Inj #4 (L#4) Open/Short Error...1558
        CA343 - ECM Critical Internal Failure...1560
        CA351 - Injectors Drive Circuit Error...1561
        CA352 - Sensor 1 Supply Volt Low Error...1562
          1. Turn starting switch to OFF position...1562
          2. Disconnect following connectors one by one and turn starting switch to ON position each time...1562
          3. After each troubleshooting, return to step 1...1562
        CA356 - Mass Air Flow Sensor High Error...1564
          1. Be ready with starting switch to OFF position...1564
          2. Disconnect connector MAF and connect T-adapter to female side of connector...1564
          3. Turn starting switch to ON position...1564
        CA357 - Mass Air Flow Sensor Low Error...1566
        CA386 - Sensor 1 Supply Volt High Error...1569
        CA428 - Water in Fuel Sensor High Error...1570
        CA429 - Water in Fuel Sensor Low Error...1572
        CA435 - Eng Oil Press Sw Error...1574
        CA441 - Battery Voltage Low Error...1576
          1. See descriptions of wirings harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them...1576
          2. Turn starting switch to ON position...1576
        CA442 - Battery Voltage High Error...1578
        CA449 - Rail Press Very High Error...1579
          1. Turn starting switch to ON position...1580
          2. Monitoring code: 36400 is displayed with monitoring function of machine monitor...1580
        CA451 - Rail Press Sensor High Error...1582
          1. Turn starting switch to OFF position...1582
          2. Disconnect connector FUEL RAIL PRESS and connect T-adapter to female side of connector...1582
          3. Turn starting switch to ON position...1582
          1 Turn starting switch to OFF position...1583
          2. Disconnect connectors FUEL RAIL PRESS and ECM J2...1583
          3. Connect T-adapter to female side of ECM J2...1583
        CA452 - Rail Press Sensor Low Error...1584
          1. Turn starting switch to OFF position...1584
          2. Disconnect connector FUEL RAIL PRESS and connect T-adapter to female side of connector...1584
          3. Turn starting switch to ON position...1584
        CA488 - Chg Air Temp High Torque Derate...1586
          MEMORANDUM...1587
        CA515 - Rail Press Sens Sup Volt High Error...1588
          1. See descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1588
          2. Turn starting switch to ON position...1588
        CA516 - Rail Press Sens Sup Volt Low Error...1590
          1. Turn starting switch to OFF position...1590
          2. Disconnect connector FUEL RAIL PRESS...1590
          3. Turn starting switch to ON position...1590
        CA553 - Rail Press High Error 1...1592
        CA555 - Crankcase Press High Error 1...1593
        CA556 - Crankcase Press High Error 2...1594
        CA559 - Rail Press Low Error 1...1595
          1. Remove pressure pickup plug (outlet side) of fuel main filter...1597
          2. Operate feed pump of fuel pre-filter...1597
          3. Check fuel and air from pressure pickup plug for leakage level...1597
          1...1597
            A. Clogging of fuel tank breather...1597
            B. Sticking of check valve (3) installed to cooling plate (2) of engine controller (1)...1597
            C. Leakage or clogging of low-pressure fuel piping...1597
            D. Clogging of fuel pre-filter...1597
            E. Clogging of fuel main filter...1597
            F. Replace fuel filter when problem is not removed even if no clogging is found...1597
        CA595 - Turbo Speed High Error 2...1599
        CA687 - Turbo Speed Low Error...1600
          1. Turn starting switch to OFF position...1600
          2. Disconnect connector VGT_REV and connect T-adapters to female side...1600
        CA689 - Eng Ne Speed Sensor Error...1602
          1. See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check it...1602
          2. Turn starting switch to ON position...1602
          1. Remove engine assembly. For details, see "Removal and installation of engine assembly" in Disassembly and assembly...1604
          2. Remove the followings. For details, see "Removal and installation of engine rear seal" in Disassembly and assembly...1604
            1) Damper...1604
            2) Flywheel...1604
            3) Flywheel housing...1604
            4) Rear seal housing...1604
          3. Remove oil pan...1604
          4. Remove mounting bolt (2) of main cap (1)...1604
          5. Insert bolt (2) into the bolt hole of main cap (1), and shake and remove main cap (1)...1604
          6. Check mounting bolt (4) of Ne speed (crankshaft) sensing ring (3) for looseness...1604
          1. Install main cap (1) with the embossed letters "BACK" facing to the rear side of cylinder block...1605
          2. Install main cap (1) with mounting bolt (2)...1605
          3. Install oil pan. Tighten mounting bolts [1] to [32] sequentially...1605
          4. Reinstall engine rear seal and engine assembly. For details, see "Removal and installation of engine rear seal" and "Removal and installation of engine assembly" in Disassembly and assembly...1605
        CA691 - Intake Air Temp Sens High Error...1606
          1. Perform checkup referencing descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1606
          2. Turn starting switch to ON position...1606
        CA692 - Intake Air Temp Sens Low Error...1608
          1. Perform checkup referencing descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1608
          2. Turn starting switch to ON position...1608
          1. Turn starting switch to OFF position...1608
          2. Disconnect connector ECM J1 and connect T-adapters to female side...1608
        CA697 - ECM Int Temp Sensor High Error...1610
        CA698 - ECM Int Temp Sensor Low Error...1611
        CA731 - Eng Bkup Speed Sens Phase Error...1612
          1. Set No. 1 piston to compression top dead center (align stamping mark)...1612
          2. Remove Ne speed sensor (crankshaft sensor)...1612
          3. If portion (A) (portion without tooth) of speed sensing ring is visible through sensor mounting hole, installation is correctly done...1612
          1. Set No.1 piston at compression top dead center (match stamped mark)...1612
          2. Remove Bkup speed sensor...1612
          3. If two ribs (B) of camshaft gear (CAMG) are visible through sensor mounting hole, it is mounted normally...1612
        CA778 - Eng Bkup Speed Sensor Error...1614
          1. Turn starting switch to OFF position...1614
          2. Disconnect connector CAM SENSOR and connect T-adapters to female side of connector...1614
          3. Turn starting switch to ON position...1614
          1. Remove the followings. For details, see "Removal and installation of engine front seal" in Disassembly and assembly...1616
            A. Remove fan and fan belt...1616
            B. Remove front cover (2)...1616
            C. Remove damper (2)...1616
            D. Remove carrier assembly (3)...1616
            E. Remove dust seal (4) and front seal (5) from carrier assembly (3)...1616
          2. Remove front cover (6)...1616
          3. Remove housing (7)...1616
          4. Check mounting bolt (10) of gear (9) of camshaft (11) for looseness...1616
          1. Install gasket (8) to housing (7) and install front cover (6)...1617
          2. Install front seal (5) and dust seal (4) to carrier (3). For details, see "Removal and installation of engine front seal" in Disassembly and assembly...1617
            A. Install front seal (5) and dust seal (4) to carrier (3)...1617
            B. Install carrier assembly to front cover (6)...1617
            C. Install dowel pin (DP), and install damper (2)...1617
            D. Install pulley (1)...1617
            E. Install fan belt, and install the fan...1617
            F. Install the cooling system assembly...1617
        CA1117 - Persistent Data Lost Error...1618
          MEMORANDUM...1619
        CA1664 - KDOC Malfunction...1620
        CA1691 - Regeneration Ineffective...1622
          1. Turn starting switch to ON position...1623
          2. Monitor and record signal voltages from KDOC inlet temperature sensor and KDPF outlet temperature sensor with KDPF in initial state and during manual stationary regeneration. Check them to see if KDOC outlet temperature sensor is normal (see Relat...1623
          3. Perform manual stationary regeneration (see Related information)...1623
          MEMORANDUM...1625
        CA1695 - Sensor 5 Supply Volt High Error...1626
          1. Perform checkup referencing the descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1626
          2. Turn starting switch to ON position...1626
        CA1696 - Sensor 5 Supply Volt Low Error...1628
          1. Perform check up referencing the descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1628
          2. Turn starting switch to ON position...1628
        CA1843 - Crankcase Press Sens High Error...1630
          1. Perform checkup referencing descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1630
          2. Turn starting switch to ON position...1630
          1. Turn starting switch to OFF position...1630
          2. Disconnect connector P57...1630
          3. Turn starting switch to ON position...1630
          1. Turn starting switch to OFF position...1630
          2. Disconnect connectors ECM J1 and P57, and connect T-adapters to each female side...1630
          1. Turn starting switch to OFF position...1630
          2. Disconnect connectors ECM J1 and P57, and connect T-adapters to either female side...1630
          1. Turn starting switch to OFF position...1630
          2. Disconnect connector PCCV (P57) and connect T-adapters to female side...1630
          3. Turn starting switch to ON position...1630
          1. Turn starting switch to OFF position...1631
          2. Insert T-adapter in connector ECM J1...1631
          3. Turn starting switch to ON position...1631
        CA1844 - Crankcase Press Sens Low Error...1632
          1. Perform checkup referencing descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1632
          2. Turn starting switch to ON position...1632
          1. Turn starting switch to OFF position...1632
          2. Disconnect connector P57 and connect T-adapters to female side...1632
          3. Turn starting switch to ON position...1632
          1. Turn starting switch to OFF position...1632
          2. Disconnect connectors ECM J1 and P57, and connect T-adapters to each female side...1632
          1. Turn starting switch to OFF position...1633
          2. Disconnect connectors ECM J1 and P57, and connect T-adapters to either female side...1633
          1. Turn starting switch to OFF position...1633
          2. Disconnect connectors ECM J1 and P57, and connect T-adapters to either female side...1633
          1. Turn starting switch to OFF position...1633
          2. Insert T-adapters into connector P57...1633
          3. Turn starting switch to ON position...1633
          1. Turn starting switch to OFF position...1633
          2. Insert T-adapters to connector ECM J1...1633
          3. Turn starting switch to ON position...1633
        CA1879 - KDPF Differential P Sensor High Error...1634
          1. Perform check up referencing descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1634
          2. Turn starting switch to ON position...1634
          1. Turn starting switch to OFF position...1634
          2. Disconnect connector PDPF and connect T-adapters to female side...1634
          3. Turn starting switch to ON position...1634
          1. Turn starting switch to OFF position...1634
          2. Disconnect connector PDPF...1634
          3. Turn starting switch to ON position...1634
          1. Starting switch: OFF...1635
          2. Disconnect connectors CE03 and E25, and connect T-adapters to each female side...1635
          1. Turn starting switch to OFF position...1635
          2. Disconnect connectors CE03 and PDPF, and connect T-adapters to female side of connector CE03...1635
          1. Turn starting switch to ON position...1635
        CA1881 - KDPF Differential P Sensor Low Error...1636
          1. Perform checkup referencing descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1636
          2. Turn starting switch to ON position...1636
          1. Turn starting switch to OFF position...1636
          2. Disconnect connector PDPF and connect T-adapters to female side...1636
          3. Turn starting switch to ON position...1636
          1. Turn starting switch to OFF position...1637
          2. Disconnect connectors CE03 and PDPF, and connect T-adapters to each female side...1637
          1. Turn starting switch to OFF position...1637
          2. Disconnect connectors CE03 and E25, and connect T-adapters to either female side...1637
          1. Turn starting switch to OFF position...1637
          2. Disconnect connectors CE03 and PDPF, and connect T-adapters to female side of connector CE03...1637
          1. Turn starting switch to OFF position...1637
          2. Insert T-adapters into connector PDPF...1637
          3. Turn starting switch to ON position...1637
          1. Turn starting switch to ON position...1637
        CA1883 - KDPF Differential P Sens In Range Error...1638
          1. Start engine (make sure it is stopped now)...1638
          2. After warm-up operation, set fuel dial to FULL position and relieve work equipment pump circuit for 30 seconds...1638
          1. Remove KDPF differential pressure sensor tube...1638
          2. Clean KDPF differential pressure sensor tube to eliminate plugging...1638
          3. Check KDPF differential pressure sensor tube for cracking and damage...1638
          4. Connect both ends of tube securely and install KDPF differential pressure sensor tube...1638
          1. Turn starting switch to ON position...1638
          2. Monitor differential pressure sensed by KDPF differential pressure sensor on monitoring screen of machine monitor...1638
          1. Perform checkup referencing descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1638
          2. When repair is completed, perform <Clearing failure codes> in "Related information"...1638
          1. Turn starting switch to OFF position...1639
          2. Disconnect connector PDPF and connect T-adapters to female side...1639
          3. Turn starting switch to ON position...1639
          1. Turn starting switch to OFF position...1639
          2. Disconnect connector PDPF...1639
          3. Turn starting switch to ON position...1639
          1. Turn starting switch to OFF position...1639
          2. Disconnect connector PDPF and connect short connector to female side...1639
          3. Turn starting switch to ON position...1639
          1. Turn starting switch to OFF position...1639
          2. Disconnect connectors CE03 and PDPF, and connect T-adapters to each female side...1639
          1. Turn starting switch to OFF position...1639
          2. Disconnect connectors CE03 and PDPF, and connect T-adapters to either female side...1639
          1. Turn starting switch to OFF position...1639
          2. Disconnect connectors CE03 and PDPF, and connect T-adapters to female side of connector CE03...1639
          1. Turn starting switch to ON position and wait for approximately one minutes (recheck of error with turned to ON)...1640
          2. If this failure code is displayed, perform [Clearing failure codes] in "Related information"...1640
          MEMORANDUM...1641
        CA1921 - KDPF Soot Load High Error 1...1642
          1. Engine is running within light load range where engine cannot keep exhaust temperature high enough to burn soot in KDPF...1642
          2. Engine has trouble that causes excessive emission of black smoke...1642
          1. Start engine...1643
          2. Check that machine is in safe condition...1643
          3. Perform manual stationary regeneration (manual stationary regeneration is available from user mode of machine monitor)...1643
          1. Perform this troubleshooting when failure code [CA1921] or [CA2639] is displayed after manual stationary regeneration...1643
          2. Accelerate engine abruptly two times from low idle to high idle, then maintain the engine speed at high idle for five seconds...1643
        CA1922 - KDPF Soot Load High Error 2...1644
        CA1942 - Crankcase Press Sens In Range Error...1648
        CA1993 - KDPF Differential Pressure Low Error...1649
        CA2185 - Throt Sensor Sup Volt High Error...1650
        CA2186 - Throt Sensor Sup Volt Low Error...1652
        CA2249 - Rail Press Very Low Error...1654
          MEMORANDUM...1655
        CA2265 - Fuel Feed Pump Open Error...1656
          1. Turn starting switch to OFF position...1656
          2. Disconnect connector FUEL LIFT PUMP...1656
          1. Turn starting switch to OFF position...1656
          2. Disconnect connector ECM J1 and connect T-adapter to female side of connector...1656
          1. Turn starting switch to OFF position...1656
          2. Disconnect connectors ECM J1 and FUEL LIFT PUMP and connect T- adapters to female side of each connector...1656
          1. Turn starting switch to OFF position...1656
          2. Disconnect connectors ECM J1 and FUEL LIFT PUMP, and connect T- adapter to female side of ECM J1...1656
          1. Turn starting switch to OFF position...1657
          2. Disconnect connector FUEL LIFT PUMP...1657
          3. Insert T-adapter in connector ECM J1 or connect to female side of connector FUEL LIFT PUMP...1657
          4. Turn starting switch to ON position (with connector FUEL LIFT PUMP as connected) and start measurement after one minute...1657
        CA2266 - Fuel Feed Pump Short Error...1658
          1. Turn starting switch to OFF position...1658
          2. Disconnect connector FUEL LIFT PUMP...1658
          3. Turn starting switch to ON position...1658
          1. Turn starting switch to OFF position...1658
          2. Disconnect connector ECM J1 and connect T-adapter to female side of connector...1658
          1. Turn starting switch to OFF position...1658
          2. Disconnect connectors ECM J1 and FUEL LIFT PUMP and connect T- adapters to female side of each connector...1658
          1. Turn starting switch to OFF position...1658
          2. Disconnect connectors ECM J1 and FUEL LIFT PUMP, and connect T- adapter to female side of ECM J1...1658
        CA2271 - EGR Valve Pos Sens High Error...1660
          1. Turn starting switch to ON position...1660
          MEMORANDUM...1663
        CA2272 - EGR Valve Pos Sens Low Error...1664
          1. Turn starting switch to ON position...1664
        CA2288 - Turbo Speed High Error 1...1667
        CA2311 - IMV Solenoid Error...1668
        CA2349 - EGR Valve Solenoid Open Error...1669
          1. Perform checkup referencing the descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1669
          2. Turn starting switch to ON position...1669
        CA2353 - EGR Valve Solenoid Short Error...1671
          1. Perform checkup referencing the descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1671
          2. Turn starting switch to ON position...1671
        CA2357 - EGR Valve Servo Error...1673
        CA2373 - Exhaust Manifold Press Sens High error...1674
          1. Perform checkup referencing the descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1674
          2. Turn starting switch to ON position...1674
        CA2374 - Exhaust Manifold Press Sens Low Error...1676
        CA2375 - EGR Orifice Temp Sens High Error...1678
          1. Turn starting switch to ON position...1678
          1. Turn starting switch to OFF position...1679
          2. Disconnect connector EXHAUST GAS TEMPERATURE and connect T-adapters to female side...1679
          3. Turn starting switch to ON position...1679
        CA2376 - EGR Orifice Temp Sens Low Error...1680
          1. Turn starting switch to ON position...1680
        CA2381 - KVGT Pos Sens High Error...1682
        CA2382 - KVGT Pos Sens Low Error...1684
          MEMORANDUM...1687
        CA2383 - KVGT Solenoid Open Error...1688
        CA2386 - KVGT Solenoid Short Error...1690
          1. Turn starting switch to OFF position...1691
          2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-adapter to female side of ECM J2...1691
        CA2387 - KVGT Valve Servo Error...1692
        CA2554 - Exh Manifold Press Sens In Range Error...1693
        CA2555 - Grid Htr Relay Open Circuit Error...1694
        CA2556 - Grid Htr Relay Volt High Error...1696
        CA2637 - KDOC Blocked...1698
          1. KDOC surface becomes dirty and catalyst efficiency is lowered due to bad operating conditions (cleaning of KDOC)...1698
          2. Deterioration of KDOC by high temperature, efficiency drop by sticking foreign matter, efficiency drop by breakage, deterioration (replacement of KDOC with new one or used one)...1698
          1. Perform manual stationary regeneration two times from "Regeneration for service" menu(see "Related information") (to dry the KCSF)...1699
          2. Turn starting switch to OFF position...1699
          3. Perform Regeneration for service (to make sure repair is completed)...1699
        CA2639 - Manual Stationary Regeneration Request...1700
        CA2961 - EGR Orifice Temp High Error 1...1702
        CA2973 - Chg Air Press Sensor In Range Error...1703
        CA3133 - KDPF Outlet Press Sens High Error...1704
        CA3134 - KDPF Outlet Press Sens Low Error...1706
        CA3135 - KDPF Outlet Press Sens In Range Error...1708
          1. Perform check up referencing descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting"...1708
          2. When repair is completed, perform <Clearing failure codes> in "Related information"...1708
        CA3251 - KDOC Inlet Temp High Error...1712
          MEMORANDUM...1715
        CA3253 - KDOC Temp Error - Non Regeneration...1716
        CA3254 - KDOC Outlet Temp High Error 1...1718
        CA3255 - KDPF Temp Error - Non Regeneration...1721
        CA3256 - KDPF Outlet Temp High Error 1...1722
        CA3311 - KDOC Outlet Temp High Error 2...1723
        CA3312 - KDPF Outlet Temp High Error 2...1724
          MEMORANDUM...1727
        CA3313 - KDOC Inlet Temp Sensor Low Error...1728
        CA3314 - KDOC Inlet Temp Sens High Error...1732
        CA3315 - KDOC Inlet Temp Sens In Range Error...1736
          1. Starting switch: OFF...1738
          2. Disconnect connectors CE03 and E26, and connect T-adapter to either female side...1738
        CA3316 - KDOC Outlet Temp Sens Low Error...1740
        CA3317 - KDOC Outlet Temp Sens High Error...1744
        CA3318 - KDOC Outlet Temp Sens In Range Error...1748
          1. Turn the starting switch to OFF position once, then start engine...1748
          2. After warm up operation, run engine under heavy load for 10 minutes or longer in total. (Above operation may be replaced with approximately 30-minute long actual operation under heavy load with fuel control dial set to maximum.)...1748
          1. See descriptions of wirings harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them...1748
          2. When repair is completed, perform <Clearing failure codes> in "Related information"...1748
        CA3319 - KDPF Outlet Temp Sens High Error...1752
        CA3321 - KDPF Outlet Temp Sens Low Error...1756
        CA3322 - KDPF Outlet Temp Sens In Range Error...1760
          1. Turn the starting switch to OFF position once, then start engine...1760
          2. After warm up operation, run engine under heavy load for 10 minutes or longer in total. (Above operation may be replaced with approximately 30-minute long actual operation under heavy load with fuel control dial set to maximum.)...1760
          1. See descriptions of wirings harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them...1760
          2. When repair is completed, perform <Clearing failure codes> in "Related information"...1760
        CA3419 - Mass Air Flow (MAF) Sensor Sup Volt High Error...1764
        CA3421 - Mass Air Flow (MAF) Sensor Sup Volt Low Error...1766
        CA3741 - Rail Press Valve Trip Error...1768
          MEMORANDUM...1769
        D110KB - Battery Relay Output Voltage...1770
          1. Turn starting switch to OFF position...1770
          2. Turn battery disconnect switch to OFF position (to prevent short circuit during work)...1770
          3. Disconnect terminals R01 and R02, and connectors D01, H15 and CP02...1770
        D19JKZ - Personal Code Relay Abnormality...1772
          1. Turn starting switch to OFF position...1772
          2. Remove fuse No. 3 of fuse box F01. (3rd fuse from right top)...1772
          3. Disconnect connector CM01 and S14, and connect T-adapter to female side of CM01...1772
        D811MC - KOMTRAX Error...1775
        D862KA - GPS Antenna Open Circuit...1775
        D8AQKR - CAN2 Discon (KOMTRAX)...1776
        DA20MC - Pump Controller...1777
        DA22KK - Pump Solenoid Power Low Error...1778
        DA25KP - 5 V Sensor 1 Power Abnormality...1781
          1. Turn starting switch to OFF position...1781
          2. Disconnect following sensors one by one, and turn starting switch to ON position for each troubleshooting...1781
          3. After each troubleshooting, turn starting swith to OFF position...1781
        DA29KQ - Model Selection Abnormality...1784
          1. Turn starting switch to OFF position...1784
          2. Disconnect connectors CP01 and and S30, and insert T-adapter into connector S30...1784
        DA2QKR - CAN2 Discon ( Pump Con)...1786
        DA2RKR - CAN1 Discon ( Pump Con)...1789
        DAF0MB - Monitor Memory Error...1790
        DAF0MC - Monitor Error...1791
        DAF8KB - Camera Power Supply Short Circuit...1792
        DAF9KQ - Model Selection Abnormality...1794
        DAFGMC - GPS Module Error...1795
        DAFQKR - CAN2 Discon...1796
        DAZ9KQ - A/C Model Selection Abnormality...1797
        DAZQKR - CAN2 Discon (AC)...1798
          1. Turn starting switch to OFF position and set battery disconnect switch to OFF position...1799
          2. Disconnect related connectors, and connect T-adapters to female side of connector to be measured...1799
          1. Turn starting switch to OFF position and set battery disconnect switch to OFF position...1800
          2. Disconnect all related connector and connect T-adapters to each female side to be measured...1800
          1. Turn starting switch to OFF position and set battery disconnect switch to OFF position...1800
          2. Disconnect connector to be measured and insert T-adapters into connector...1800
          3. Connect battery ground cable...1800
          4. Turn starting switch to ON position...1800
          1. Turn starting switch to OFF position and set battery disconnect switch to OFF position...1800
          2. Disconnect CAN communication connectors of engine controller (connector CE03), pump controller (connector CP01), air conditioner unit (connector AC01), *ID controller (connector CC01), and KOMTRAX terminal (connector CK01) in order one by one...1800
          3. Turn battery disconnect switch to ON position, turn starting switch to ON position and perform troubleshooting...1800
          4. Return to Step 1 and check the next controller...1800
        DB2QKR - CAN2 Discon (Engine Con)...1802
          1. Turn starting switch to OFF position and set battery disconnect switch to OFF position...1803
          2. Disconnect related connectors and insert T-adapters into connector to be measured...1803
          1. Turn starting switch to OFF position and set battery disconnect switch to OFF position...1803
          2. Disconnect connector to be measured and insert T-adapters into connector...1803
          3. Turn battery disconnect switch to ON position, and turn starting switch to ON position...1803
          MEMORANDUM...1807
        DB2RKR - CAN1 Discon (Engine Con)...1808
          MEMORANDUM...1813
        DGH2KB - Hyd Oil Sensor Short Circuit...1814
        DHA4KA - Air Cleaner Clog Sensor Open Circuit...1816
        DHPAMA - F Pump Press Sensor Abnormality...1817
        DHPBMA - R Pump Press Sensor Abnormality...1820
          MEMORANDUM...1823
        DHS3MA - Arm In PPC Press Sensor Abnormality...1824
          MEMORANDUM...1827
        DHS4MA - Bucket Curl PPC Press Sensor Abnormality...1828
          MEMORANDUM...1831
        DHS8MA - Boom Raise PPC Press Sensor Abnormality...1832
          MEMORANDUM...1835
        DHS9MA - Boom Lower PPC Press Sensor Abnormality...1836
          MEMORANDUM...1839
        DHSAMA - Swing RH PPC Press Sensor Abnormality...1840
          MEMORANDUM...1843
        DHSBMA - Swing LH PPC Press Sensor Abnormality...1844
          MEMORANDUM...1847
        DHSCMA - Arm Out PPC Press Sensor Abnormality...1848
          MEMORANDUM...1851
        DHSDMA - Bucket Dump PPC Press Sensor Abnormality...1852
          MEMORANDUM...1855
        DHSFMA - Travel Fwd LH PPC Press Sensor Abnormality...1856
          MEMORANDUM...1859
        DHSGMA - Travel Fwd RH PPC Press Sensor Abnormality...1860
          MEMORANDUM...1863
        DHSHMA - Travel Rev LH PPC Press Sensor Abnormality...1864
          MEMORANDUM...1867
        DHSJMA - Travel Rev RH PPC Press Sensor Abnormality...1868
          MEMORANDUM...1871
        DKR0MA - F Pump Swash Plate Sensor Abnormality...1872
          1. Turn starting switch to OFF position...1872
          2. Replace connector P27 with connector P28...1872
          3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor...1872
          4. If E mark is not displayed again in this failure code column, F pump swash plate sensor is defective...1872
          MEMORANDUM...1875
        DKR1MA - R Pump Swash Plate Sensor Abnormality...1876
          MEMORANDUM...1879
        DV20KB - Travel Alarm Short Circuit...1880
        DW43KA - Travel Speed Sol Open Circuit...1882
        DW43KB - Travel Speed Sol Short Circuit...1884
        DW45KA - Swing Brake Sol Open Circuit...1886
          1. Turn starting switch to OFF position...1886
          2. Remove diode arrays D01 and D03, and connect T-adapters to each male side...1886
          MEMORANDUM...1889
        DW45KB - Swing Brake Sol Short Circuit...1890
          MEMORANDUM...1893
        DW91KA - Travel Junction Sol Open Circuit...1894
        DW91KB - Travel Junction Sol Short Circuit...1896
        DWA2KA - Attachment Sol Open Circuit...1898
        DWA2KB - Attachment Sol Short Circuit...1900
        DWK0KA - 2-Stage Relief Sol Open Circuit...1902
        DWK0KB - 2-Stage Relief Sol Short Circuit...1904
        DWK2KA - Variable Back Press Sol Open Circuit...1906
        DWK2KB - Variable Back Press Sol Short Circuit...1908
        DWK8KA - Swing Press C/O Sol Open Circuit...1910
        DWK8KB - Swing Press C/O Sol Short Circuit...1912
        DXA8KA - PC-EPC (F) Sol Open Circuit...1914
        DXA8KB - PC-EPC (F) Sol Short Circuit...1916
        DXA9KA - PC-EPC (R) Sol Open Circuit...1918
          MEMORANDUM...1921
        DXA9KB - PC-EPC (R) Sol Short Circuit...1922
        DXE0KA - LS-EPC Sol Open Circuit...1924
        DXE0KB - LS-EPC Sol Short Circuit...1926
        DXE4KA - Attachment Flow EPC Open Circuit...1928
        DXE4KB - Attachment Flow EPC Short Circuit...1930
        DXE5KA - Merge-divide Main Sol Open Circuit...1932
        DXE5KB - Merge-divide Main Sol Short Circuit...1934
        DXE6KA - Merge-divide LS Sol Open Circuit...1936
        DXE6KB - Merge-divide LS Sol Short Circuit...1938
        DY20KA - Wiper Working Abnormality...1940
          MEMORANDUM...1943
        DY20MA - Wiper Parking Abnormality...1944
        DY2CKB - Washer Drive Short Circuit...1946
        DY2DKB - Wiper Drive (Fwd) Short Circuit...1948
        DY2EKB - Wiper Drive (Rev) Short Circuit...1950
      ELECTRICAL SYSTEM (E-MODE)...1952
        E-1 Engine Does Not Start (Engine Does Not Rotate)...1952
          MEMORANDUM...1959
        E-2 Manual Pre-Heating System Does Not Work...1960
          MEMORANDUM...1963
        E-3 Automatic Pre-Heating System Does Not Work...1964
        E-4 Pre-Heating Monitor Does Not Light Up When Pre-Heater is Operated...1966
        E-5 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing...1968
        E-6 When Starting Switch is Turned to ON Position (Before Starting Engine), Engine Oil Level Monitor Lights Up in Yellow...1971
        E-7 When Starting Switch is Turned to ON Position (Before Starting Engine), Radiator Coolant Level Monitor Lights Up in Yellow...1971
        E-8 Coolant Temperature Monitor Lights Up in White While Engine is Running...1972
        E-9 Hydraulic Oil Temperature Monitor Lights Up in White While Engine is Running...1972
        E-10 Charge Level Monitor Lights Up While Engine is Running...1973
        E-11 Fuel Level Monitor Lights Up in Red While Engine is Running...1973
        E-12 Air Cleaner Clogging Monitor Lights Up in Yellow While Engine is Running...1973
        E-13 Engine Coolant Temperature Monitor Lights Up in Red While Engine is Running...1974
        E-14 Hydraulic Oil Temperature Monitor Lights Up in Red While Engine is Running...1974
        E-15 Engine Oil Pressure Monitor Lights Up in Red While Engine is Running...1975
        E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum...1976
        E-17 Display of Fuel Gauge Differs from Actual Fuel Level...1978
        E-18 Coolant Temperature Gauge Indicate Either Min or Max and Does Not Move...1979
          MEMORANDUM...1981
        E-20 Hydraulic Oil Temperature Gauge Indicate Either Min or Max and Does Not Move...1982
        E-21 Hydraulic Oil Temperature Gauge Differs from Actual oil Temperature...1984
        E-22 Machine Monitor Does Not Display Partially...1985
        E-23 Function Switch Does Not Work...1985
        E-24 Automatic Pre-Heating System Does Not Work (In Cold Weather)...1986
        E-25 Auto-Deceleration Monitor Does Not Light Up or Does Not Go Out When Auto-Deceleration Switch is Operated...1987
        E-26 Auto-Deceleration is Not Actuated or Canceled When Lever is Operated...1988
        E-27 Working Mode Selector Screen Selection Screen is Not Displayed When Working Mode Switch is Operated...1989
        E-28 Engine or Hydraulic Pump Setting Does Not Change When Working Mode is Changed...1989
        E-29 Travel Speed Monitor Does Not Change When Travel Speed Switch is Operated...1989
        E-32 Travel Speed Does Not Change When Travel Speed is Shifted...1990
        E-31 Alarm Buzzer Does Not Stop Sounding...1991
        E-32 When Starting Switch is Turned OFF, Service Meter is Not Displayed...1991
        E-33 Machine Monitor Service Mode Cannot be Selected...1992
          MEMORANDUM...1993
        E-34 Any of Work Equipment, Swing and Travel Does Not Work...1994
        E-35 Any of Work Equipment, Swing and Travel Can Not be Locked...1996
        E-36 Machine Can Not Swing While Swing Brake Cancel Switch is Canceled...1998
        E-37 Swing Brake Does Not Operate While Swing Brake Cancel Switch is set to NORMAL position...2000
        E-38 One-Touch Power Maximizing Function Does Not Work Or Pilot Monitor is Not Displayed...2002
        E-39 One-Touch Power Maximizing Function Cannot be Released...2005
        E-40 Travel Alarm Does Not Sound When Machine Travels...2006
        E-41 Travel Alarm Does Not Stop Sounding When Machine Stops...2008
          MEMORANDUM...2009
        E-42 Horn Does Not Sound...2010
        E-43 Horn Does Not Stop Sounding...2012
        E-44 Wiper Monitor Does Not Light Up or Go Out When Wiper Switch is Operated...2013
        E-45 Wiper Does Not Operate When Wiper Switch is Operated...2014
        E-46 Window Washer Does Not Operate When Window Washer Switch is Operated...2016
        E-47 Boom LOWER Indication is Not Displayed Properly With Monitoring Function...2016
        E-48 Arm DUMP Indication is Not Displayed Properly With Monitoring Function...2016
        E-49 Arm IN Indication is Not Displayed Properly With Monitoring Function...2016
        E-50 Boom RAISE Indication is Not Displayed Properly With Monitoring Function...2017
        E-51 Bucket CURL Indication is Not Displayed Properly With Monitoring Function...2017
        E-52 Bucket DUMP Indication is Not Displayed Properly With Monitoring Function...2017
        E-53 Swing Indication is Not Displayed Properly With Monitoring Function...2017
        E-54 Travel Indication is Not Displayed Properly With Monitoring Function...2018
        E-55 Attachment is Not Displayed Properly With Monitoring Function...2019
        E-56 Attachment Hydraulic Circuit Cannot be Changed...2022
        E-57 KOMTRAX System Does Not Work Properly...2024
        E-58 Machine Push-up Function is Not Canceled...2026
      HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...2030
        Information Mentioned in Troubleshooting Table (H Mode)...2030
          MEMORANDUM...2031
        Failure Mode and Cause Table...2032
        H-1 All of Work Equipment, Swing and Travel Operation Lacks Speed or Power...2041
          MEMORANDUM...2045
        H-2 Engine Speed Lowers Significantly or Engine Stalls...2046
        H-3 Any of Work Equipment, Swing and Travel Does Not Work...2049
        H-4 Unusual Sound is Heard from Around Hydraulic Pump...2049
        H-5 Fine Control Performance or Response is Poor...2050
        H-6 Boom Operation Lacks Speed or Power...2052
        H-7 Arm Operation Lacks Speed or Power...2057
          MEMORANDUM...2061
        H-8 Bucket Operation Lacks Speed or Power...2062
        H-9 Work Equipment Does Not Move in Single Operation...2066
        H-10 Hydraulic Drift of Boom is Large...2067
        H-11 Hydraulic Drift of Arm is Large...2068
        H-12 Hydraulic Drift of Bucket is Large...2070
          MEMORANDUM...2071
        H-13 Time Lag of Work Equipment is Large...2072
        H-14 When Part of Work Equipment is Relieved Singly, Other Parts of Work Equipment Move...2074
        H-15 One-Touch Power Maximizing Function Does Not Work...2075
        H-16 Machine Push Up Function Does Not Work...2076
        H-17 In Combined Operation of Work Equipment, Equipment Having Heavier Load Moves Slower...2077
        H-18 In Combined Operations of Swing and Boom RAISE, Boom Rising Speed is Low...2078
        H-19 In Combined Operations of Swing and Travel, Travel Speed Drops Largely...2078
        H-20 Machine Does Not Travel Straight...2079
        H-21 Travel Speed is Too Low...2082
        H-22 Machine is hard to Steer or Travel Power is Low...2084
        H-23 Travel Speed Does Not Change, or Travel Speed is Too Low or High...2088
          MEMORANDUM...2089
        H-24 One of Tracks Dose Not Run...2090
        H-25 Upper Structure Does Not Swing to the Right or Left...2092
        H-26 Upper Structure Swing Only to the Right or Left...2093
        H-27 Swing Acceleration is Poor or Swing Speed is Low (Either Right and Left)...2094
        H-28 Swing Acceleration is Poor or Swing Speed is Low in Only One Direction...2096
        H-29 Upper Structure Overruns Excessively When it Stops Swinging (Both Right and Left)...2097
        H-30 Upper Structure Overruns Excessively When it Stops Swinging (Either Right or Left)...2098
        H-31 Shock is Large When Upper Structure Stops Swinging...2099
        H-32 Large Unusual Noise is Heard When Upper Structure Stops Swinging...2100
        H-33 When Swing Holding Brake is Applied, Hydraulic Drift of Swing is Large...2101
        H-34 When Swing Holding Brake is Released, Hydraulic Drift Of Swing is Large...2102
        H-35 When additional attachment is installed, attachment circuit is not switched...2103
        H-36 Oil Flow in Attachment Circuit Cannot be Controlled...2104
          MEMORANDUM...2105
      ENGINE (S-MODE)...2106
        Information Mentioned in Troubleshooting Table (S-Mode)...2106
          1. Engine controller...2107
          2. Cooling plate...2107
          3. Check valve...2107
          4. Fuel feed pump...2107
        S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank...2108
        S-2 When Engine Cranks, Exhaust Smoke Does Not Come Out...2109
        S-3 Fuel is Being Injected But Engine Does Not Start (Incomplete Combustion: Engine Cranks but Does Not Start)...2110
        S-4 Startability is Poor...2112
        S-5 Engine Does Not Pick Up Smoothly...2114
        S-6 Engine Stops During Operation...2116
        S-7 Engine Runs Rough or is Unstable...2118
          MEMORANDUM...2119
        S-8 Engine Lacks Power...2120
        S-9 Exhaust Smoke is Black (KDPF Clogs Up Early)...2122
        S-10 Engine Oil Consumption is Excessive...2124
        S-11 Oil Becomes Contaminated Early...2125
        S-12 Fuel Consumption is Excessive...2126
        S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down)...2127
        S-14 Oil Pressure Drops...2128
        S-15 Fuel is Contaminated in Engine Oil...2130
        S-16 Coolant Mixes in Engine Oil (Oil Becomes Cloudy White)...2131
        S-17 Coolant Temperature Rises Too High (Overheating)...2132
        S-18 Unusual Noise is Heard...2133
        S-19 Vibration is Excessive...2134
        S-20 Air Cannot be Bled from Fuel Circuit...2135
        S-21 Automatic Regeneration is Operated Frequently...2136
        S-22 Active Regeneration is Operated for Long...2137
        S-23 White Smoke Comes Out in the Process of Active Regeneration...2138
          MEMORANDUM...2139
    50 - DISASSEMBLY AND ASSEMBLY...2140
      HOW TO READ THIS SECTION...2145
        Removal and Installation of Assemblies...2145
          Special Tools...2145
            A. Marks used in the column of necessity are explained below...2145
          Removal...2145
          Installation...2145
        Disassembly and Assembly of Assemblies...2146
          Special Tools...2146
            A. Necessity...2146
          Disassembly...2146
          Assembly...2147
        Coating Materials List...2148
          MEMORANDUM...2152
      SPECIAL TOOLS LIST...2153
        Sketches of Special Tools...2157
      CONNECTOR REPAIR PROCEDURES...2160
        Stripping Insulation...2160
        Wire Inspection...2160
        Contact Terminal Removal (HD30 Type)...2161
          1. Obtain the correct removal tool according to the wire size used in the connector...2161
          2. With the rear insert part of the connector facing you, snap the removal tool over the wire of the contact terminal you will be removing...2161
          3. In a straight line, carefully slide the removal tool along the wire and into the grommet until a contact resistance is felt...2161
          4. Once tool is fully inserted into the connector, carefully pull the removal tool and contact terminal-wire out of the connector...2161
          5. If contact terminal-wire will not come out, remove tool and reinsert removal tool again...2161
        Crimping Contact Terminal (HD30 Type)...2162
          1. After insulation has been stripped from the wire and contact terminal is ready for crimping, raise selector knob on Crimp Tool #HDT48-00 and rotate until arrow is aligned with wire size to be crimped...2162
          2. Loosen locknut, turn adjusting screw in until it stops...2162
          3. Insert contact terminal with barrel up. Turn adjusting screw counterclockwise until contact terminal surface is flush with indenter cover. Tighten locknut...2162
          4. Insert wire into contact terminal. Be sure contact terminal is centered between indicators...2162
          5. Close crimp tool handle until crimp cycle is completed...2162
          6. Release the tool handle and remove the crimped contact terminal...2162
          7. Using the inspection hole in the contact terminal inspect the crimped contact terminal to ensure that all strands are in the crimped barrel...2162
        Insertion of Contact Terminal (HD30 Type)...2163
          1. Grasp contact terminal approximately 25.2 mm (1 in) behind the crimped barrel...2163
          2. Hold connector with rear grommet facing you...2163
          3. Insert completed contact terminal straight into connector grommet until a positive stop is felt...2163
          4. Once contact terminal is in connector, a slight tug will confirm that the contact terminal is properly locked in place...2163
          5. For unused wire cavities, insert sealing plugs for full environmental sealing...2163
        Contact Terminal Removal (DT Type)...2164
          1. Remove the wedge lock using needle nose pliers or a hooked shaped wire...2164
          2. Pull the wedge lock straight out and save for reinstallation...2164
          3. To remove the contact terminal gently pull the wire backwards while at the same time releasing the locking finger by pushing it away from the terminal with a small screwdriver...2164
          4. Hold the rear seal grommet in place and pull the contact terminal out of the connector...2164
        Crimping Contact Terminal (DT Type)...2165
          1. After insulation has been stripped from the wire and contact terminal is ready for crimping, raise selector knob on Crimp Tool #HDT48-00 and rotate until arrow is aligned with wire size to be crimped...2165
          2. Loosen locknut, turn adjusting screw in until it stops...2165
          3. Insert contact terminal with barrel up. Turn adjusting screw counterclockwise until contact terminal surface is flush with indenter cover. Tighten locknut...2165
          4. Insert wire into contact terminal. Be sure contact terminal is centered between indicators...2165
          5. Close crimp tool handle until crimp cycle is completed...2165
          6. Release the tool handle and remove the crimped contact terminal...2165
          7. Using the inspection hole in the contact terminal inspect the crimped contact terminal to ensure that all strands are in the crimped barrel...2165
        Insertion of Contact Terminal (DT Type)...2166
          1. Grasp the crimped contact terminal approximately 25.2 mm (1 in) behind the crimped barrel...2166
          2. Hold the connector with the rear grommet facing you and insert the completed wire into the connector...2166
          3. Push the contact terminal straight into the connector until a “click” is felt. A slight tug will confirm that the contact terminal is properly locked in place...2166
          4. Once all contact terminals are in place, insert the wedge lock with the arrow pointing toward exterior locking mechanism. The wedge lock will snap into place. Rectangular wedges are not oriented and may fit either way...2166
      ENGINE AND COOLING SYSTEM...2167
        Supply Pump Assembly...2167
          Removal...2167
            1. Close the fuel stop valve at the bottom of the fuel tank...2167
            2. Open the engine hood...2167
            3. Remove fan guard (1)...2167
            4. Disconnect air conditioner hose clamp (2)...2167
            5. Remove U-bolt (3) to remove air intake tube (4) from the KVGT. [*1]...2167
            6. Remove step (5)...2168
            7. Remove frames (6)...2168
            8. Disconnect air conditioner hose clamp (7)...2168
            9. Disconnect solenoid clutch connector AC03 (8) of the air conditioner compressor...2168
            10. Remove air conditioner compressor (9) according to the following procedure...2168
              A. Loosen two mounting bolts (10)...2168
              B. Move air conditioner compressor assembly (9) and bracket (11) together in the loosening direction of belt (12)...2168
              C. Remove loosened air conditioner compressor belt (12). [*2]...2168
              D. Remove four mounting bolts (13), disconnect air conditioner compressor assembly (9) from bracket (11), and move it to a place where it is not an obstacle to the work. [*3]...2168
            11. Remove KCCV ventilator assembly (14). For details, see “KCCV Assembly” on page 50-175...2168
            12. Remove frame (15)...2168
            13. Remove air cleaner top cover (16) according to the following procedure...2168
              A. Lift up air cleaner top cover (16) to disconnect it from the air inlet of air cleaner (17)...2169
              B. Lift up and remove air cleaner top cover (16) slantways so that it does not interfere with frame (A)...2169
              C. After removing the air cleaner top cover, cover the air inlet of air cleaner (17) with a vinyl sheet etc...2169
            14. Remove cover (18)...2169
            15. Open the side cover on the right side of the machine, remove bolts (19), and disconnect receiver (20) and bracket together...2169
            16. Remove U-bolt (21) fixing tube (23). [*4]...2170
            17. Remove hose (22).[*5]...2170
            18. Remove U-bolt (24) fixing tube (23). [*4]...2170
            19. Remove hose (25). [*5]...2170
            20. Remove tube (23)...2170
            21. Disconnect intake air heater E01 (26) and wiring harness clamp (27). [*6]...2170
            22. Disconnect supply pump connector (28)...2170
            23. Remove brackets (29) and (30)...2170
            24. Remove bracket (11)...2170
            25. Remove base bracket (31)...2170
            26. Remove cover (32)...2170
            27. Remove frame (33)...2171
            28. Remove cover (34)...2171
            29. Disconnect fuel return hose (35) and fuel supply hose (36)...2171
            30. Disconnect fuel hose (37) according to the following procedure...2171
              A. Loosen elbow (38) under fuel hose (37) and direct it down...2171
              B. While pressing locks (L) at the top and bottom, disconnect fuel hose (37)...2171
            31. Remove two fuel spray prevention caps (39)...2171
            32. Remove sandwich clamp (40)...2171
            33. Remove high-pressure tube (41)...2171
            34. Disconnect overflow tube (42)...2171
            35. Remove cap (43) of the front gear cover...2172
            36. Remove nut (45) and washer (46) from supply pump shaft (44)...2172
            37. After removing the washer, tighten nut (45) again lightly...2172
            38. Rotate the crankshaft in the normal direction and bring stamp (a) of supply pump gear (47) to the top to set the No. 1 cylinder to the compression top dead center (TDC)...2172
            39. Install tool A2 with bolts [1] (M8 x 1.25)...2173
            40. Tighten evenly bolts [1] of tool A2 to disconnect the supply pump shaft from the supply pump gear...2173
            41. Remove bolts (49) and (50) to remove bracket (51)...2173
            42. Remove four mounting nuts (52) to remove supply pump assembly (53)...2173
          Installation...2173
            1. Rotate the crankshaft in the normal direction and bring stamp (a) of the supply pump gear to the top to set the No. 1 cylinder to the compression top dead center (TDC)...2173
            2. Before installing the supply pump, check that dowel pin (54) of the supply pump shaft is not damaged...2174
            3. Install new O-ring (55) to the flange of the supply pump assembly...2174
            4. Install new O-ring (56) to the lubrication port of the supply pump...2174
            5. Clean the outside contact face of the supply pump shaft and the inside contact face of the supply pump gear with contact cleaner...2174
            6. Before installing the supply pump assembly, check that the outside contact face of the supply pump shaft and the inside contact face of the supply pump gear are free from foreign material and dry...2174
            7. While matching dowel pin (54) of supply pump shaft (44) with keyway (b) of supply pump gear (47), push in supply pump assembly (53)...2174
            8. Fit washer (46) to supply pump shaft (44) and tighten nut (45) lightly...2174
            9. Tighten nuts (52) lightly to a degree that they are not loose to install supply pump assembly (53)...2175
            10. Tighten supply pump assembly mounting nuts (52) to the specified torque...2175
            11. Tighten bolts (49) and (50) of bracket (51) lightly...2175
            12. Tighten mounting bolt (50) on the cylinder head side...2175
            13. Tighten mounting bolt (49) on the supply pump flange side...2175
            14. Tighten nut (45)...2175
            15. Install cap (43) of the front gear cover...2175
            16. Install fuel hose (37)...2176
            17. Install fuel return hose (35) and fuel supply hose (36)...2176
            18. Install the high-pressure pipe according to the following procedure...2176
              A. Loosen mounting bolts (98), (99), and (100) of common rail (97), and then finger-tighten them...2177
              B. Tighten high-pressure pipe (41) between the supply pump and common rail to the specified torque...2177
              C. Tighten common rail mounting bolts (98), (99) and (100) which were loosened...2177
              D. Loosen sandwich clamp (40) of high pressure pipe...2177
              E. Tighten the bracket of sandwich clamp (40)...2177
              F. Tighten sandwich clamp (40)...2177
              G. Install two fuel spray prevention caps (39)...2177
              H. Tighten overflow tube (42)...2177
            1. Check that inlet connector (91) is fastened by tightening retaining nut (90) to the specified torque.(6 places)...2180
            2. Set common rail (97) and mounting bolts (98), (99) and (100), then finger-tighten the mounting bolts...2180
            3. Tighten high-pressure pipe (87) between the supply pump and common rail...2180
            4. Tighten high-pressure pipes (81) to (86) between the inlet connector and common rail...2180
            5. Tighten common rail mounting bolts (98), (99) and (100)...2180
            6. Tighten the bracket of the sandwich clamp which is fixing high- pressure pipe (87) and injection pipes (81) to (86)...2180
            7. Tighten sandwich clamp (89)...2181
            8. Install 14 fuel spray prevention caps (88)...2181
        Fuel Injector Assembly...2182
          Removal...2182
            1. Close the fuel stop valve at the bottom of the fuel tank...2182
            2. Open the engine hood...2182
            3. Remove fan guard (1)...2182
            4. Disconnect air conditioner hose clamp (2)...2182
            5. Remove U-bolt (3) to remove air intake tube (4) from the KVGT. [*1]...2182
            6. Remove step (5)...2183
            7. Remove frames (6)...2183
            8. Disconnect air conditioner hose clamp (7)...2183
            9. Disconnect solenoid clutch connector AC03 (8) of the air conditioner compressor...2183
            10. Remove air conditioner compressor (9) according to the following procedure...2183
              A. Loosen two mounting bolts (10)...2183
              B. Move air conditioner compressor assembly (9) and bracket (11) together in the loosening direction of belt (12)...2183
              C. Remove loosened air conditioner compressor belt (12). [*2]...2183
              D. Remove four mounting bolts (13), disconnect air conditioner compressor assembly (9) from bracket (11), and move it to a place where it is not an obstacle to the work.[*3]...2183
            11. Remove KCCV ventilator assembly (14). For details, see removal of the “KCCV Assembly” on page 50-175...2183
            12. Remove frame (15)...2183
            13. Remove air cleaner top cover (16) according to the following procedure...2183
              A. Lift up air cleaner top cover (16) to disconnect it from the air inlet of air cleaner (17)...2184
              B. Lift up and remove air cleaner top cover (16) slantways so that it does not interfere with frame (A)...2184
              C. After removing the air cleaner top cover, cover the air inlet of air cleaner (17) with a vinyl sheet etc...2184
            14. Remove cover (18)...2184
            15. Open the side cover on the right side of the machine, remove bolts (19), and disconnect receiver (20) and bracket together...2184
            16. Remove U-bolt (21) fixing tube (23). [*4]...2185
            17. Remove hose (22). [*5]...2185
            18. Remove U-bolt (24) fixing tube (23). [*4]...2185
            19. Remove hose (25). [*5]...2185
            20. Remove tube (23)...2185
            21. Disconnect intake air heater E01 (26) and wiring harness clamp (27). [*6]...2185
            22. Disconnect supply pump connector (28)...2185
            23. Remove brackets (29) and (30)...2185
            24. Disconnect EGR orifice temperature sensor connector (33) of EGR valve piping (32)...2185
            25. Disconnect wiring harness connectors (34), (35), and (36)...2185
            26. Disconnect wiring harness bracket (37)...2185
            27. Disconnect hoses (38) and (39)...2185
            28. Remove four mounting bolts (40) to remove EGR valve piping (32)...2186
            29. Loosen hose clamp (41) of EGR valve piping (32) and remove it from tube (42)...2186
            30. Disconnect tube (44) under EGR valve (43)...2186
            31. Disconnect tube (45)...2186
            32. Remove EGR valve (43)...2186
            33. Disconnect ambient pressure sensor (46)...2186
            34. Disconnect wiring harness clamp (47) and bracket (48)...2186
            35. Remove sandwich clamp (49) of the injection pipe...2186
            36. Disconnect two wiring harness connectors (50)...2186
            37. Disconnect common rail pressure sensor (51)...2186
            38. Disconnect charge (boost) pressure and temperature sensor connector (52)...2187
            39. Disconnect engine wiring harness (53) and move it to a place where it is not an obstacle to the work...2187
            40. Remove cover (54)...2187
            41. Remove air intake manifold (55)...2187
            42. By using tool A12 (long socket), remove V-clamps (56) and (57)...2187
            43. Disconnect tube (58) from KDPF piping bracket (59)...2187
            44. Remove U-bolt (56) to remove tube (58)...2187
            45. Disconnect tube clamp (62)...2187
            46. Remove KCCV outlet tube (63)...2187
            47. Remove KCCV inlet hose (64)...2187
            48. Disconnect hose clamp (65)...2187
            49. Disconnect blowby hose (66)...2187
            50. Disconnect harness connector (50) and move engine wiring harness (53) to a place where it is not an obstacle to the work...2187
            51. Remove head cover (67)...2187
            52. Loosen and remove cap (68) of the front gear cover...2188
            53. Rotate the crankshaft in the normal direction and bring stamp (a) of supply pump gear (69) to the top to set the No. 1 cylinder to the compression top dead center (TDC)...2188
            54. Loosen the capture nut at the injector head and disconnect injector wiring harness (71)...2188
            55. Remove plate (72) from rocker housing (73)...2189
            56. Loosen lock nuts (77) and then loosen adjustment screws (78) two to three turns each so that the valve spring tension will not be applied to rocker arm mounting bolts (75)...2189
            57. Remove mounting bolts (74) to remove rocker housing (73)...2189
            58. Remove 12 mounting bolts (75) to remove rocker arm assembly (76)...2189
            59. Remove 12 push rods (79)...2189
            60. Remove cross heads (80)...2189
            61. Remove 14 fuel spray prevention caps (88) of high-pressure pipe (87) and injection pipes (81) to (86)...2189
            62. Remove sandwich clamp (89) of high-pressure pipe (87) and injection pipes (81) to (86)...2189
            63. Remove high-pressure pipe (87) and injection pipes (81) to (86)...2189
            64. Remove retaining nut (90) and remove inlet connector (91)...2190
            65. Remove holder mounting bolt (92)...2190
            66. By using tool A4, remove holder (93) and injector assembly (94) together...2190
          Installation...2191
            1. Check inlet connector (91) visually. If it has any of the following faults, replace it...2191
              A. There is a burr or a worn part at front end (a) or rear end (b) of the inlet connector...2191
              B. There is foreign material in the edge filter at rear end (c) of the inlet connector...2191
              C. Cracks or deterioration is recognizable in O-ring of the inlet connector upper (d) portion...2191
              D. There is a worn part or an uneven seat contact mark on seat face (e) at the front end of the inlet connector...2191
            2. Fit gasket (95) and O-ring (96) to fuel injector (94)...2191
            3. Install holder (93) to injector (94)...2191
            4. Insert injector (94) into the cylinder head with the fuel inlet toward the air intake manifold...2191
            5. Finger-tighten mounting bolts (92) of holder (93) three to four turns...2191
            6. Tighten inlet connector (91) lightly with retaining nut (90)...2192
            7. Tighten mounting bolts (92) of holder (93) alternately...2192
            8. Tighten inlet connector (91) with retaining nut (90) to the specified torque...2192
            9. Install the high-pressure pipe and injection pipe according to the following procedure...2192
              A. Check that inlet connector (91) is fastened by tightening retaining nut (90) to the specified torque.(6 places)...2193
              B. Loosen mounting bolts (98), (99), and (100) of common rail (97), and then finger-tighten them...2193
              C. Tighten high-pressure pipe (87) between the supply pump and common rail...2193
              D. Tighten high-pressure pipes (81) to (86) between the inlet connector and common rail...2193
              E. Tighten common rail mounting bolts (98), (99) and (100)...2193
              F. Tighten the bracket of the sandwich clamp which is fixing high-pressure pipe (87) and injection pipes (81) to (86)...2193
              G. Tighten sandwich clamp (89)...2194
              H. Install 14 fuel spray prevention caps (88)...2194
            10. Install push rod (79)...2194
            11. Install crosshead (80)...2194
            12. Install and tighten rocker arm assembly (76) with mounting bolts (75)...2194
            13. Adjust the valve clearance...2195
            14. After adjusting the valve clearance, install cap (68)...2195
            15. Install the gasket to rocker housing (73)...2195
            16. Install rocker housing (73) to the cylinder head...2195
            17. Tighten the mounting bolts in the numeric order ([1] g [7]) shown in the figure...2196
            18. Install plate (72) to rocker housing (73)...2196
            19. Install injector wiring harness (71)...2196
            20. Fit the gasket to head cover (67) and install them to the rocker housing...2197
            21. Install blowby hose (66)...2197
            22. Install hose clamp (65)...2197
            23. Install KCCV inlet hose (64)...2197
            24. Install KCCV outlet tube (63)...2197
            25. Install tube clamp (62)...2197
            26. Before installing V-clamps (56) and (57), check them for abnormality...2197
            27. Tighten tube (58) and spacer (61) with U-bolt (60)...2198
            28. By using tool A12 (long socket), tighten V-clamp (57) lightly...2198
            29. Fit the gasket between the inlet flange of KDPF assembly (109) and the flange of tube (58) and check the clearance...2198
            30. By using tool A12 (long socket), tighten V-clamp (56) lightly...2198
            31. By using tool A12 (long socket), tighten V-clamp (56) to the specified torque...2198
            32. By using tool A12 (long socket), tighten V-clamp (57) to the specified torque...2198
            33. If nuts (111) and (112) of U-bolt (110) were loosened, tighten evenly at the four places...2198
            34. If mounting bolts (114) of KDPF mounting bracket (113) were loosened, tighten them...2198
            35. Finger-tighten brackets (59) and (122) for KDPF piping...2199
            36. Install tube (58) to KVGT piping bracket (59)...2199
            37. Tighten brackets (59) and (122) for KDPF piping to the specified torque...2199
            38. Install gasket (115) to air intake manifold cover (116)...2199
            39. If intake air heater (117) and air intake connector (118) were removed from the air intake manifold, install them according to the following procedure...2199
              A. Install guides [1] longer than 150 mm {5.905 in} to two upper bolt holes (A)...2199
              B. Install gasket (119), plate (120), gasket (119), intake air heater (117), gasket (119), and air intake connector (118) in order...2199
              C. Install two lower bolts (121) and finger tighten them...2199
              D. Remove guides [2], install remaining two bolts (121), and finger tighten them...2199
              E. Tighten four bolts (121) to the specified torque...2199
              F. Install the wiring terminal to portion (E) of intake air heater (117)...2200
            40. Install the air intake manifold (55)...2200
            41. Install cover (54)...2200
            42. Install sandwich clamp (49) of the injection pipe to the air intake manifold...2200
            43. While installing the following connectors, wiring harness clamp, and bracket, install engine wiring harness (53)...2200
            44. Fit a new gasket to the air intake manifold and install EGR valve (43)...2200
            45. Install tube (45)...2200
            46. Install tube (44) under EGR valve (43)...2200
            47. Install the hose portion of EGR valve piping (32) to tube (42)...2201
            48. Fit the gasket and install EGR valve piping (32)...2201
            49. Tighten hose clamp (41) to the specified torque...2201
            50. Install wiring harness bracket (37)...2201
            51. Install hoses (38) and (39) coming from the KVGT...2201
            52. Install wiring harness connectors (34), (35), and (36)...2201
            53. Install EGR orifice temperature sensor connector (33)...2201
            MEMORANDUM...2203
        Cylinder Head Assembly...2204
          Removal...2204
            1. Close the fuel stop valve at the bottom of the fuel tank...2204
            2. Open the engine hood...2204
            3. Remove fan guard (1)...2204
            4. Disconnect air conditioner hose clamp (2)...2204
            5. Remove U-bolt (3) to remove air intake tube (4) from the KVGT. [*1]...2204
            6. Remove step (5)...2205
            7. Remove frames (6)...2205
            8. Disconnect air conditioner hose clamp (7)...2205
            9. Disconnect solenoid clutch connector AC03 (8) of the air conditioner compressor...2205
            10. Remove air conditioner compressor (9) according to the following procedure...2205
              A. Loosen two mounting bolts (10)...2205
              B. Move air conditioner compressor assembly (9) and bracket (11) together in the loosening direction of belt (12)...2205
              C. Remove loosened air conditioner compressor belt (12). [*2]...2205
              D. Remove four mounting bolts (13), disconnect air conditioner compressor assembly (9) from bracket (11), and move it to a place where it is not an obstacle to the work. [*3]...2205
            11. Remove KCCV ventilator assembly (14). For details, see removal of the “KCCV Assembly” on page 50-175...2205
            12. Remove frame (15)...2205
            13. Remove air cleaner top cover (16) according to the following procedure...2205
              A. Lift up air cleaner top cover (16) to disconnect it from the air inlet of air cleaner (17)...2206
              B. Lift up and remove air cleaner top cover (16) slantways so that it will not interfere with frame (A)...2206
              C. After removing the air cleaner top cover, cover the air inlet of air cleaner (17) with a vinyl sheet etc...2206
            14. Remove cover (18)...2206
            15. Open the side cover on the right side of the machine, remove bolts (19), and disconnect receiver (20) and bracket together...2206
            16. Remove U-bolt (21) fixing tube (23). [*4]...2207
            17. Remove hose (22).[*5]...2207
            18. Remove U-bolt (24) fixing tube (23). [*4]...2207
            19. Remove hose (25). [*5]...2207
            20. Remove tube (23)...2207
            21. Disconnect intake air heater E01 (26) and wiring harness clamp (27). [*6]...2207
            22. Disconnect supply pump connector (28)...2207
            23. Remove brackets (29) and (30)...2207
            24. Remove bracket (11)...2207
            25. Remove base bracket (31)...2207
            26. Disconnect EGR orifice temperature sensor connector (33) of EGR valve piping (32)...2207
            27. Disconnect wiring harness connectors (34), (35), and (36)...2207
            28. Disconnect wiring harness bracket (37)...2207
            29. Disconnect hoses (38) and (39)...2207
            30. Remove four mounting bolts (40) to remove EGR valve piping (32)...2208
            31. Loosen hose clamp (41) of EGR valve piping (32) and remove it from tube (42)...2208
            32. Disconnect tube (44) under EGR valve (43)...2208
            33. Disconnect tube (45)...2208
            34. Remove EGR valve (43)...2208
            35. Disconnect ambient pressure sensor (46)...2208
            36. Disconnect wiring harness clamp (47) and bracket (48)...2208
            37. Remove sandwich clamp (49) of the injection pipe...2208
            38. Disconnect two wiring harness connectors (50)...2208
            39. Disconnect common rail pressure sensor (51)...2209
            40. Disconnect charge (boost) pressure and temperature sensor connector (52)...2209
            41. Disconnect engine wiring harness (53) and move it to a place where it is not an obstacle to the work...2209
            42. Remove cover (54)...2209
            43. Remove air intake manifold (55)...2209
            44. Remove engine hood assembly (125). For details, see removal of the “Engine Hood Assembly” on page 50-149...2209
            45. Remove KDPF assembly (126). For details, see removal of the “KDPF Assembly” on page 50-153...2209
            46. Disconnect tube clamp (62)...2209
            47. Remove KCCV outlet tube (63)...2209
            48. Remove KCCV inlet hose (64)...2209
            49. Remove frame (127)...2209
            50. Disconnect radiator hose clamps (128) and (129)...2209
            51. Disconnect radiator hoses (130) and (131)...2209
            52. Disconnect exhaust manifold pressure sensor connector (132)...2209
            53. Disconnect wiring harness clamp (133)...2209
            54. Remove hoses (135) and (136) from KVGT (134)...2210
            55. Remove hose (135) from connector block (181)...2210
            56. Disconnect tube (136) from tube (137)...2210
            57. Disconnect tube clamp (138) to remove tube (136)...2210
            58. Disconnect aftercooler tube (139) from KVGT (134)...2210
            59. Remove tube (140)...2210
            60. Remove two tube clamp nuts (141)...2210
            61. Loosen hose clamp (142) and remove tube (137)...2210
            62. Remove tube (143) and bracket (144)...2210
            63. Remove tube mounting bolt (145) and remove tube (42) from EGR cooler (150)...2210
            64. Disconnect tube (146)...2211
            65. Loosen hose clamp (147) and disconnect tube (148)...2211
            66. Remove four nuts (149), then sling and remove KVGT (134)...2211
            67. Disconnect hoses (151) and (152) from EGR cooler (150)...2211
            68. Remove bracket (154), connector block (181), and hoses (151) and (152) together from exhaust manifold (153)...2211
            69. Remove mounting bolt (155), then disconnect EGR cooler (150) and exhaust manifold (153)...2211
            70. Remove tube (156) under the EGR cooler...2211
            71. Remove EGR cooler (150) from EGR mounting bracket (180)...2211
            72. Remove exhaust manifold (153)...2211
            73. Remove plate (157)...2211
            74. Remove fan guard (158)...2212
            75. Disconnect radiator hose (159)...2212
            76. Disconnect wiring harness clamps (160) and (161)...2212
            77. Disconnect hose clamp (65)...2212
            78. Disconnect blowby hose (66)...2212
            79. Disconnect harness connector (50) and move engine wiring harness (53) to a place where it is not an obstacle to the work...2212
            80. Disconnect tube clamps (162) and (163)...2212
            81. Remove head cover (67)...2212
            82. Loosen and remove cap (68) of the front gear cover...2212
            83. Rotate the crankshaft in the normal direction and bring stamp (a) of supply pump gear (69) to the top to set the No. 1 cylinder to the compression top dead center (TDC)...2213
            84. Loosen the capture nut at the injector head and disconnect injector wiring harness (71)...2213
            85. Loosen lock nuts (77) and then loosen adjustment screws (78) two to three turns each so that the valve spring tension will not be applied to rocker arm mounting bolts (75)...2213
            86. Remove mounting bolts (74) to remove rocker housing (73)...2213
            87. Remove 12 mounting bolts (75) to remove rocker arm assembly (76)...2214
            88. Remove 12 push rods (79)...2214
            89. Remove cross heads (80)...2214
            90. Remove 14 fuel spray prevention caps (88) of high-pressure pipe (87) and injection pipes (81) to (86)...2214
            91. Remove sandwich clamp (89) of high-pressure pipe (87) and injection pipes (81) to (86)...2214
            92. Remove high-pressure pipe (87) and injection pipes (81) to (86)...2214
            93. Remove retaining nut (90) and remove inlet connector (91)...2214
            94. Remove holder mounting bolt (92)...2215
            95. By using tool A4, remove holder (93) and injector assembly (94) together...2215
            96. Remove tube (164)...2215
            97. Remove tube (165)...2215
            98. Remove mounting bolts (98), (99), and (100) to remove common rail (97)...2215
            99. Remove tube (166)...2215
            100. Remove hose (167)...2215
            101. Remove mounting bolts (169) to disconnect fuel filter bracket (168)...2215
            102. Remove bolts (170) and (171) to remove bracket (172) form the supply pump...2216
            103. Remove 26 mounting bolts (173) to remove cylinder head assembly (174)...2216
            104. Remove cylinder head gasket (175)...2216
            MEMORANDUM...2217
          Installation...2218
            1. Install cylinder head gasket (175) to the cylinder block...2218
            2. Sling cylinder head assembly (174) and install it to the cylinder block...2218
            3. Before installing the cylinder head bolts, check the following conditions. If any bolt is applicable, do not use it but replace it with a new one...2218
            4. Tighten the cylinder head mounting bolts in the following procedure...2218
              A. Install each cylinder head mounting bolt and tighten it at least two to three turns with the hand at first...2218
              B. Tighten in the order of [1] to [26] shown in the figure...2219
            5. Install supply pump bracket (172) to the cylinder head according to the following procedure...2219
              A. Tighten bolts (170) and (171) of bracket (172) lightly...2219
              B. Tighten mounting bolt (170) on the cylinder head side...2219
              C. Tighten mounting bolt (171) on the supply pump flange side...2219
            6. Install fuel filter bracket (168) with mounting bolt (169)...2219
            7. Install hose (167)...2219
            8. Install tube (166)...2219
            9. Install the injector assembly according to the following procedure...2220
              A. Check inlet connector (91) visually. If it has any of the following faults, replace it...2220
              i. There is a burr or a worn part at front end (a) or rear end (b) of the inlet connector...2220
              ii. There is foreign material in the edge filter at rear end (c) of the inlet connector...2220
              iii. The O-ring at top (d) of the inlet connector is cracked or deteriorated...2220
              iv. There is a worn part or an uneven seat contact mark on seat face (e) at the front end of the inlet connector...2220
              B. Fit gasket (95) and O-ring (96) to fuel injector (94)...2220
              C. Install holder (93) to injector (94)...2220
              D. Insert injector (94) into the cylinder head with the fuel inlet toward the air intake manifold...2220
              E. Finger tighten mounting bolts (92) of holder (93) three to four turns...2220
              F. Tighten inlet connector (91) lightly with retaining nut (90)...2221
              G. Tighten mounting bolts (92) of holder (93) alternately...2221
              H. Tighten inlet connector (91) with retaining nut (90) to the specified torque...2221
            10. If pressure limiter (176) is removed from common rail (97), perform the following procedure...2221
              A. Before removing pressure limiter (176), remove mud, etc. from around it thoroughly and clean it...2221
              B. Check that there is no damage on the high pressure fuel sealing surfaces on pressure limiter (176) and common rail (97)...2221
              C. Check that there is no damage on adapter (178) of pressure limiter (176)...2222
              D. If pressure limiter (176) has fuel leakage more than the specified value, do not reuse it but replace it with a new one...2222
              E. Do not reuse the seal washer but replace with a new one...2222
              F. Install pressure limiter (176) and new seal washer...2222
              G. Tighten pressure limiter (176) to the specified torque...2222
              H. After tightening to the specified torque, tighten again...2222
              I. After starting the engine, check that fuel does not leak...2222
            11. Install the high-pressure pipe and injection pipe according to the following procedure...2222
              A. Check that inlet connector (91) is fastened by tightening retaining nut (90) to the specified torque. (6 places)...2223
              B. Set common rail (97) and mounting bolts (98), (99) and (100), then finger-tighten the mounting bolts...2223
              C. Tighten high-pressure pipe (87) between the supply pump and common rail...2223
              D. Tighten high-pressure pipes (81) to (86) between the inlet connector and common rail...2223
              E. 5) Tighten common rail mounting bolts (98), (99) and (100)...2223
              F. Tighten the bracket of the sandwich clamp which is fixing high-pressure pipe (87) and injection pipes (81) to (86)...2223
              G. Tighten sandwich clamp (89)...2224
              H. Install 14 fuel spray prevention caps (88)...2224
              I. Install tube (165)...2224
              J. Install tube (164)...2224
            12. Install push rod (79)...2224
            13. Install crosshead (80)...2224
            14. Install rocker arm assembly (76) and tighten it with mounting bolts (75)...2225
            15. Adjust the valve clearance...2225
            16. After adjusting the valve clearance, install cap (68)...2225
            17. Install the gasket to rocker housing (73)...2226
            18. Install rocker housing (73) to the cylinder head...2226
            19. Tighten mounting bolts (74) in the numeric order ([1] g [7]) shown in the figure...2226
            20. Install injector wiring harness (71)...2226
            21. Fit the gasket to head cover (67) and install them to the rocker housing...2227
            22. Install blowby hose (66)...2227
            23. Install hose clamp (65)...2227
            24. Install wiring harness clamps (160) and (161)...2227
            25. Install fan guard (158)...2228
            26. Install radiator hose (159)...2228
            27. Install plate (157)...2228
            28. Fit a new gasket and install exhaust manifold (153) according to the following procedure...2228
              A. 1) Tighten all the bolts in the order of [1] to [12] shown in the figure...2228
              B. 2) Retighten only bolts [1] to [4] shown in the figure in that order...2228
            29. Install EGR cooler (150) to exhaust manifold (153) and EGR mounting bracket (180) and finger tighten it...2228
            30. Tighten mounting bolts (155) of EGR cooler (150) and exhaust manifold (153)...2228
            31. Tighten EGR cooler (150) and EGR mounting bracket (180) to the specified torque...2228
            32. Install tube (156)...2228
            33. Install a new gasket to the exhaust manifold...2229
            34. Sling and install KVGT (134), while inserting tube (148) into the hose...2229
            35. Tighten mounting nuts (149) of KVGT (134) and hose clamp (147)...2229
            36. Tighten tube (146)...2229
            37. If connector block (181) and bracket (154) were disconnected, connect them...2229
            38. Install bracket (154) installed with connector block (181) and hoses (151) and (152) to exhaust manifold (153)...2229
            39. Install hoses (151) and (152) to EGR cooler (150)...2229
            40. Tighten mounting bolt (145) of tube (42) lightly...2229
            41. Fit gasket and install tube (42) to EGR cooler (150)...2229
            42. Tighten mounting bolts (145) of tube (42) to the specified torque...2229
            43. Install bracket (144)...2229
            44. Install tube (143)...2229
            45. Install tube (137)...2230
            46. Install tube (140)...2230
            47. Install tube (136) to tube (137)...2230
            48. Install tube clamp (138)...2230
            49. Install tube (139)...2230
            50. Install hose (135) to connector block (181)...2231
            51. Install hoses (135) and (136) to KVGT (134). Put gaskets between hoses (135) and (136) and KVGT (134)...2231
            52. Install exhaust manifold pressure sensor connector (132)...2231
            53. Install wiring harness clamp (133)...2231
            54. Install radiator hoses (130) and (131)...2231
            55. Install radiator hose clamps (128) and (129)...2231
            56. Install frame (127)...2231
            57. Install KCCV inlet hose (64)...2231
            58. Install KCCV outlet tube (63)...2231
            59. Install tube clamp (62)...2231
            60. Install KDPF assembly (126). For details, see removal and installation of “KDPF Assembly” on page 50-153...2231
            61. Install engine hood assembly (125). For details, see removal and installation of “Engine Hood Assembly” on page 50-149...2231
            62. Fit gasket (115) to air intake manifold cover (116)...2232
            63. If intake air heater (117) and air intake connector (118) were removed from the air intake manifold, install them according to the following procedure...2232
              A. Install guides [1] longer than 150 mm {5.906 in} to two upper bolt holes (A)...2232
              B. Install gasket (119), plate (120), gasket (119), intake air heater (117), gasket (119), and air intake connector (118) in order...2232
              C. Install two lower bolts (121) and finger tighten them...2232
              D. Remove guides [2], install remaining two bolts (121), and finger tighten them...2232
              E. Tighten four bolts (121) to the specified torque...2232
              F. Install the wiring terminal to portion (E) of intake air heater (117)...2232
            64. Install the air intake manifold (55)...2232
            65. Install cover (54)...2232
            66. Install sandwich clamp (49) of the injection pipe to the air intake manifold...2233
            67. While installing the following connectors, wiring harness clamp, and bracket, install engine wiring harness (53)...2233
            68. Fit a new gasket to the air intake manifold and install EGR valve (43)...2233
            69. Install tube (45)...2233
            70. Install tube (44) under EGR valve (43)...2233
            71. Install the hose portion of EGR valve piping (32) to tube (42)...2234
            72. Fit the gasket and install EGR valve piping (32)...2234
            73. Tighten hose clamp (41) to the specified torque...2234
            74. Install wiring harness bracket (37)...2234
            75. Install hoses (38) and (39) coming from the KVGT...2234
            76. Install wiring harness connectors (34), (35), and (36)...2234
            77. Install EGR orifice temperature sensor connector (33)...2234
        Radiator Assembly...2236
          Removal...2236
            1. Remove under cover (1A) and (1B)...2236
            2. Drain the coolant through drain valve (2). Drain hose: inside diameter f7 mm (0.28 in)...2236
            3. Disconnect radiator hose (3). [*1]...2236
            4. Remove four cover mounting bolts (4), then remove cover (5)...2236
            5. Open engine hood (6)...2237
            6. Disconnect hose clamp (8) and disconnect reservoir tank hose (7) from the radiator...2237
            7. Disconnect hose clamps (9), (10), and (11)...2237
            8. Disconnect radiator hoses (12), (13), (14), and (15). [*2]...2237
            9. Open the side cover on the right side of the machine and remove cover (16) and frame (17)...2237
            10. Pull out reservoir tank hose (7) from cover (18)...2237
            11. Remove cover (18)...2237
            12. Remove mounting bolts (19) so that hydraulic oil cooler inlet tube (20) can be moved easily...2237
            13. Disconnect hydraulic oil cooler inlet tube (20)...2238
            14. Remove seven mounting bolts (21) to remove bracket (22)...2238
            15. Remove three mounting bolts (23) to remove bracket (24)...2238
            16. Remove four wing nuts (25) to remove nets (26) and (27)...2238
            17. Remove four mounting bolts (28) to remove cover (29)...2238
            18. Sling and remove radiator assembly (30).[*3]...2238
          Installation...2239
        Hydraulic Oil Cooler Assembly...2240
          Removal...2240
            1. Remove under covers (1A), (1B), and (2)...2240
            2. Remove drain plug (4) to drain oil from the hydraulic tank...2240
            3. Open the side cover on the right side of the machine, remove mounting bolts (5) so that hydraulic oil cooler inlet tube (6) can easily be moved...2241
            4. Remove mounting bolts (7) so that hydraulic oil cooler outlet tube (8) can be moved easily...2241
            5. Remove three mounting bolts (24), then remove cover (25) under the hydraulic oil cooler...2241
            6. Remove plug (9) of hydraulic oil cooler outlet tube (8) to drain the remaining oil...2242
            7. Disconnect hydraulic oil cooler outlet tube (8)...2242
            8. Open engine hood (10)...2242
            9. Open hose clamp (11) and disconnect reservoir tank hose (12) from the radiator...2242
            10. Remove cover (13) and frame (14)...2242
            11. Pull out reservoir tank hose (12) from cover (15)...2242
            12. Remove cover (15)...2242
            13. Disconnect hydraulic oil cooler inlet tube (6)...2243
            14. Remove seven mounting bolts (16) to remove bracket (17)...2243
            15. Remove four wing nuts (18) to remove nets (19) and (20)...2243
            16. Remove two mounting bolts (21) and cushion (22)...2243
            17. Remove three mounting bolts (23) and disconnect the frame and hydraulic oil cooler...2243
            18. Remove four mounting bolts (24), then remove cover (25)...2243
            19. Sling and remove hydraulic oil cooler assembly (26). [*1]...2243
          Installation...2244
            MEMORANDUM...2245
        Aftercooler Assembly...2246
          Removal...2246
            1. Open the engine hood and side cover on the right side of the machine and remove cover (1) and frame (2)...2246
            2. Disconnect hoses (3) and (4) from aftercooler assembly (5)...2246
            3. Set slings to aftercooler assembly (5) and remove four mounting bolts (6)...2246
            4. Sling and remove aftercooler assembly (5)...2246
          Installation...2247
        Engine and Main Pump Assembly...2248
          Removal...2248
            1. Close the fuel stop valve at the bottom of the fuel tank...2248
            2. Open the engine hood...2248
            3. Remove fan guard (1)...2248
            4. Disconnect air conditioner hose clamp (2)...2248
            5. Remove U-bolt (3) to remove air intake tube (4) from the KVGT. [*1]...2248
            6. Remove step (5)...2249
            7. Remove frames (6)...2249
            8. Disconnect air conditioner hose clamp (7)...2249
            9. Disconnect solenoid clutch connector AC03 (8) of the air conditioner compressor...2249
            10. Remove air conditioner compressor (9) according to the following procedure...2249
              A. Loosen two mounting bolts (10)...2249
              B. Move air conditioner compressor assembly (9) and bracket (11) together in the loosening direction of belt (12)...2249
              C. Remove loosened air conditioner compressor belt (12). [*2]...2249
              D. Remove four mounting bolts (13), disconnect air conditioner compressor assembly (9) from bracket (11), and move it to a place where it is not an obstacle to the work. [*3]...2249
            11. Remove KCCV ventilator assembly (14). For details, see removal and installation of “KCCV Assembly” on page 50-175...2249
            12. Remove frame (15)...2249
            13. Remove air cleaner top cover (16) according to the following procedure...2249
              A. Lift up air cleaner top cover (16) to disconnect it from the air inlet of air cleaner (17)...2250
              B. Lift up and remove air cleaner top cover (16) slant ways so that it will not interfere with frame (A)...2250
              C. After removing the air cleaner top cover, cover the air inlet of air cleaner (17) with a vinyl sheet etc...2250
            14. Remove cover (18)...2250
            15. Open the side cover on the right side of the machine, remove bolts (19), and disconnect receiver (20) and bracket together...2250
            16. Remove U-bolt (21) fixing tube (23). [*4]...2251
            17. Remove hose (22). [*5]...2251
            18. Remove U-bolt (24) fixing tube (23). [*4]...2251
            19. Remove hose (25). [*5]...2251
            20. Remove tube (23)...2251
            21. Disconnect intake air heater E01 (26) and wiring harness clamp (27). [*6]...2251
            22. Remove undercovers (28), (29), and (30)...2251
            23. Remove drain plug (31) and drain the hydraulic oil...2252
            24. Remove the engine hood assembly, referring to removal and installation of “Engine Hood Assembly” on page 50-149...2252
            25. Remove cover (32)...2252
            26. Open the side cover on the left side of the machine and remove KDPF water drain tube (33). [*7]...2252
            27. Remove covers (34), (35), and (36)...2253
            28. Remove frame (37)...2253
            29. Remove covers (38) and (39)...2253
            30. Disconnect connectors E25 (40) and E26 (41) according to the following procedure...2253
              A. Slide the lever (red) of the connector to unlock...2254
              B. While pressing the knob on the upper portion of the connector, pull out the connector...2254
            31. Disconnect eight wiring harness clamps (42) around the KDPF assembly...2254
            32. Disconnect connectors (43) to (45)...2254
            33. Disconnect hoses (46) to (48)...2254
            34. 34.Disconnect connectors (50) and (51)...2255
            35. Disconnect hoses (52) to (57)...2255
            36. Disconnect connector (58)...2255
            37. Disconnect six wiring harness clamps (49) around the main pump...2255
            38. Disconnect hose clamp (59)...2255
            39. Remove four mounting bolts (60) and disconnect pump suction tube (61)...2255
            40. Disconnect engine ground cable (62)...2255
            41. Disconnect hose clamps (63) to (68)...2255
            42. Remove radiator hoses (69) to (72)...2255
            43. Remove fan guard (73)...2255
            44. Remove brackets (74)...2256
            45. Disconnect aftercooler tube (76) from the KVGT. [*8]...2256
            46. Remove two U-bolts (75) fixing aftercooler tube (76)...2256
            47. Disconnect wiring harnesses of terminal E (77) and terminal R (78) from alternator (80). [*9]...2256
            48. Disconnect wiring harness clamp (79)...2256
            49. Disconnect fan (81)...2256
            50. Disconnect fuel return hose (82) and fuel supply hose (83). [*10]...2257
            51. Remove cover (84)...2257
            52. Disconnect fuel filter hoses (85) and (86)...2257
            53. Disconnect hose clamp (87) of lower radiator hose (88)...2257
            54. Remove radiator hose (88)...2257
            55. Disconnect hose clamp (89)...2258
            56. Remove bracket (90)...2258
            57. Remove hose (91)...2258
            58. Disconnect hose (92)...2258
            59. Disconnect engine body ground cable (93)...2258
            60. Disconnect wiring harness clamps (94) and (95)...2258
            61. Disconnect wiring harness of terminal B (97) from starting motor (96)...2258
            62. Disconnect engine oil level switch connector P44 (98)...2258
            63. Disconnect wiring harness clamps (99) to (101)...2258
            64. Disconnect wiring harness connector CE03 (103) from engine controller (102).[*12]...2259
            65. Disconnect wiring harness clamp (105)...2259
            66. Disconnect connector E24 (106) according to the following procedure. [*13]...2259
              A. Slide lever (red) (107) toward you to unlock...2259
              B. Grab and pull out connector (106) while pressing locking tab (108)...2259
            67. Disconnect hose clamp (109)...2259
            68. Disconnect engine oil filter (110) and bracket together, and bind and fix them to the engine assembly with ropes etc...2259
            69. Remove four engine mounting bolts (111). [*14]...2259
            70. Sling and remove engine and main pump assembly (112)...2260
            71. Remove main pump assembly (115) from the removed engine and main pump assembly according to the following procedure...2260
              A. Remove drain plug (116) and drain the damper oil...2260
              B. Remove the tube clamp and damper case oil filler pipe (119). [*15]...2261
              C. Remove blocks (117) and (118) to sling main pump assembly (115)...2261
              D. Remove bolt (120) at the center of gravity of main pump assembly (115)...2261
              E. Install eyebolt [1]...2261
              F. Sling main pump assembly (115) with wire [2] and remove mounting bolt (121)...2261
              G. Sling and remove main pump assembly (115)...2261
          Installation...2262
            1. Fit connector (106) and slide its outside portion deep until it is locked...2264
            2. Push in lever (red) (107) deep to lock connector (106)...2264
        Engine Front Oil Seal...2266
          Removal...2266
            1. Remove the radiator assembly, referring to removal of the “Radiator Assembly” on page 50-97...2266
            2. Remove the hydraulic oil cooler assembly, referring to removal of the “Hydraulic Oil Cooler Assembly” on page 50-101...2266
            3. Remove the aftercooler assembly, referring to removal of the “Aftercooler Assembly” on page 50-107...2266
            4. Disconnect two air conditioner hose clamps (1)...2266
            5. Remove eight bolts (2), remove air conditioner condenser (3) from the stay, and move it to a place where it is not an obstacle to the work...2266
            6. Remove fan (6)...2266
            7. Remove fan guard (7)...2267
            8. Disconnect hose clamp (8)...2267
            9. Remove fan guard (9)...2267
            10. Loosen two mounting bolts (10)...2267
            11. Move air conditioner compressor assembly (11) and bracket together in the loosening direction of air conditioner belt (13)...2267
            12. Remove air conditioner belt (13).[*1]...2267
            13. Remove fan belt (14)...2267
            14. Remove tensioner assembly (15) and bracket (16)...2268
            15. Remove alternator belt (17)...2268
            16. Remove five bolts (19) and pulley (20)...2269
            17. Remove five bolts (21) and vibration damper (22)...2269
            18. Remove the front oil seal according to the following procedure...2269
              A. Remove dust seal (23) from front oil seal carrier assembly (24)...2269
              B. Remove front oil seal carrier (24) from the front cover (25)...2269
              C. Remove front oil seal (26)...2269
          Installation...2270
            1. Wipe off material sticking to the crankshaft flange with clean cloth...2270
            2. Set tool A8 to front oil seal (26) from the pilot [1] side...2270
            3. Install front oil seal (26) from inside of front oil seal carrier (24)...2270
            4. Place pilot [1] to the crankshaft and push it and front oil seal carrier (24) together onto the crankshaft with hand...2270
            5. Remove pilot [1]...2270
            6. Apply liquid gasket to the following areas and install front oil seal carrier (24)...2270
            7. Tighten mounting nuts (28) of front oil seal carrier (24) in the numeric order ([1] g [5]) shown in the figure...2270
            8. Install dust seal (23)...2270
            9. Install vibration damper (22)...2271
            10. Install pulley (20)...2271
            11. Install alternator belt (17)...2271
            12. Install tensioner assembly (15) and bracket assembly (16)...2272
            13. Install fan belt (14)...2272
            MEMORANDUM...2273
        Engine Rear Oil Seal...2274
          Removal...2274
            1. Remove the engine and main pump assembly and separate them from each other. For details, see Removal of “Engine and Main Pump Assembly” on page 50-109...2274
            2. Remove damper assembly (1). [*1]...2274
            3. Remove the flywheel assembly according to the following procedure...2274
              A. 1) By using blocks [7], fix the engine assembly...2274
              B. Sling flywheel assembly (3)...2274
              C. Remove mounting bolt (2)...2274
              D. By using guide bolts [1], sling and remove flywheel assembly (3). [*2]...2274
            4. Remove the flywheel housing according to the following procedure...2275
              A. Place blocks under the engine oil pan to float flywheel housing (4)...2275
              B. Remove engine mounting brackets (5) and (6) from flywheel housing (4)...2275
              C. Set slings to flywheel housing (4)...2275
              D. Remove mounting bolts (7)...2275
              E. Sling and remove flywheel housing (4)...2275
            5. Remove the engine rear oil seal according to the following procedure...2275
              A. Remove rear cover (8)...2275
              i. Drain the engine oil from the engine oil pan...2275
              ii. Remove engine oil pan (9)...2275
              iii. Remove dust seal (10)...2275
              B. Remove engine rear oil seal (11) from rear cover (8)...2275
          Installation...2276
            1. Clean, degrease, and dry the gasket contact surface of the rear cover and cylinder block...2276
            2. Clean, degrease, and dry the engine rear oil seal contact surface of the crankshaft...2276
            3. Apply neutral detergent to the periphery of engine rear oil seal (11)...2276
            4. Install engine rear oil seal (11) to rear cover (8)...2276
            5. By using alignment tool [3], push engine rear oil seal (11) into proper depth of rear cover (8)...2276
            6. Remove alignment tool [3]...2276
            7. Apply liquid gasket according to the following procedure...2277
              A. Apply liquid gasket to bold-line portion (a) of the underside of rear cover (8)...2277
              B. Apply liquid gasket thickly to two hatched areas (b) in the following figure...2277
            8. Install guide pin [4] to the cylinder block...2277
            9. While positioning with guide pin [4], install gasket (12)...2277
            10. Place pilot [2] to the crankshaft and push it together with rear cover (8) with the hand...2277
            11. Remove pilot [2]...2277
            12. Install alignment tool [3] again and check that engine rear oil seal (11) is pushed in to proper depth...2277
            13. Remove guide pin [4] mentioned above...2277
            14. Loosely tighten four oil pan mounting bolts (indicated by the arrows)...2278
            15. Tighten the eight mounting bolts of rear cover (8) in the order shown in the figure to the right...2278
            16. Tighten four oil pan mounting bolts (indicated with arrows) to the specified torque...2278
            17. Remove alignment tool [3]...2278
            18. Install dust seal (10)...2278
            19. Install flywheel housing (4)...2278
            20. After installing the flywheel housing, measure the radial runout and facial runout with dial gauge [5]...2279
              A. Install dial gauge [5] to the end face of the crankshaft...2279
              B. Place the probe of dial gauge [5] at a right angle to the spigot joint portion of the flywheel housing...2279
              C. Set the pointer of dial gauge [5] to “0”, rotate the crankshaft by one turn, and measure the difference of the maximum reading of the pointer of dial gauge [5]...2279
              A. Similarly to the measurement of the radial runout, place the probe of dial gauge [5] at a right angle to the end face of the flywheel housing...2279
              B. Set the pointer of dial gauge [5] to “0”, rotate the crankshaft by one turn, and measure the difference of the maximum reading of the pointer of dial gauge [5]...2279
            1. Install dial gauge [5] to the flywheel housing...2281
            2. Place the probe of dial gauge [5] at a right angle to spigot joint portion (d) or periphery of the flywheel...2281
            3. Set the pointer of dial gauge [5] to “0”...2281
            4. Rotate the crankshaft by one turn and measure the difference of the maximum reading of the pointer of dial gauge [5]...2281
            1. Similarly to the measurement of the radial runout, place the probe of dial gauge [5] at a right angle to end face (e) of the periphery of the flywheel...2281
            2. Set the pointer of dial gauge [5] to “0”...2281
            3. Rotate the crankshaft by one turn and measure the difference of the maximum reading of the pointer of dial gauge [5]...2281
        Fuel Tank Assembly...2284
          Removal...2284
            1. Remove undercover (1)...2284
            2. Open the right side cover and open fuel tank drain valve (3) to drain the fuel...2284
            3. Remove handrails (4A), (4B), (4C), (4D), (4E)...2284
            4. Open the battery case cover and remove two bolts (12)...2285
            5. Close the battery case cover and remove two mounting bolts (13) to remove cover (14)...2285
            6. Disconnect wiring harness clamp (15) and connector P21 (16) of the fuel level sensor...2285
            7. Disconnect fuel tank lower hoses (17), (18), and (19)...2285
            8. Remove six mounting bolts (20)...2285
            9. Sling and remove fuel tank assembly (21)...2286
          Installation...2287
        Engine Hood Assembly...2288
          Removal...2288
            1. Open engine hood (1) and remove debris guard (2). Support it by using a sling...2288
            2. Remove gas springs (3) and (4)...2288
            3. Remove stay (5)...2288
            4. Close engine hood (1) and remove four mounting bolts (6) at the rear of the engine hood...2288
            5. Lift off engine hood (1)...2289
          Installation...2290
            1. Tighten engine hood (1) with four mounting bolts (6)...2290
            2. Lower engine hood (1) slowly to bring catch (7) near to pin (8) on the chassis and check the engagement...2290
            3. Adjust fore-and-aft location of engine hood (1) so that spring box (9) of catch (7) is nearly perpendicular...2290
            4. If adjustment is necessary, loosen the four engine hood mounting bolts and move the engine hood to adjust...2291
            5. After adjustment is completed, tighten engine hood mounting bolts (6) to the specified torque...2291
            1. Loosen mounting bolts (10) of catch (7)...2291
            2. While pulling the lever of catch (7) to the level, hitch catch-hook (11) to the tooth of pin (8) on the frame side...2291
            3. While pulling up catch (7) to the end with the lever on level, make a mark of the bottom of the catch bracket...2291
            4. While matching with the mark, tighten mounting bolts (10)...2291
            5. Check that catch (7) is locked smoothly...2291
        KDPF Assembly...2292
          Removal...2292
            1. Open engine hood assembly (1)...2292
            2. Remove KCCV ventilator assembly (2). For details, see removal of “KCCV Assembly” on page 50-175...2292
            3. Remove step (3)...2292
            4. Remove frame (4)...2292
            5. Open the side cover on the left side of the machine and remove KDPF water drain tube (5)...2292
            6. Remove I-joint (12) from the KDPF assembly. [*1]...2293
            7. Remove covers (6), (7), and (8)...2293
            8. Remove frame (9)...2293
            9. Remove covers (10) and (11)...2293
            10. Disconnect connectors E25 (13) and E26 (14) according to the following procedure...2294
              A. Slide the lever (red) of the connector to unlock...2294
              B. While pressing the knob on the upper portion of the connector, pull out the connector...2294
            11. Disconnect eight wiring harness clamps (15) around the KDPF assembly...2294
            12. By using tool A12 (long socket), remove V-clamp (16) and disconnect KDPF assembly (21) and tube (17)...2295
            13. Disconnect tube (17) from KVGT piping bracket (30)...2295
            14. Remove tube (17) according to the following procedure, if necessary...2295
              A. By using tool A12 (long socket), remove V-clamp (18)...2295
              B. Remove U-bolt (19) to remove tube (17)...2295
            15. Remove four bolts (22) from bracket (23)...2295
            16. Sling and remove KDPF assembly (21) from bracket (23)...2295
            17. Remove base bracket (24) according to the following procedure, if necessary...2295
              A. If wiring harness is connected to the base bracket (24), disconnect it...2295
              B. Remove two bolts (25) on the side of base bracket (24)...2295
              C. Remove eight bolts (26), then sling and remove base bracket (24)...2295
            18. .Remove nuts (24) and (25) and washers, and then remove U-bolt (26)...2296
            19. Sling and remove KDPF assembly (21) from bracket (23)...2296
            20. By using tool A12 (long socket), remove V-clamp (28) from KDPF assembly (21), and then remove exhaust pipe (29) and gasket...2296
            MEMORANDUM...2297
          Installation...2298
            1. Before installing the removed V-clamp, check it for abnormality...2298
            2. Install KDPF assembly (21) to bracket (23) according to the following procedure...2298
              A. Sling KDPF assembly (21) to mount it on bracket (23), and tighten washers (24) and nuts (25) at four places for the two U-bolts (26) so lightly that the position of the assembly can be adjusted...2298
              B. Clean exhaust pipe (29) and the flange of the KDPF assembly with parts cleaner...2298
              C. Install a new gasket between exhaust pipe (29) and the flange of the KDPF assembly...2298
              D. Install V-clamp (28), adjust the angle between exhaust pipe (29) and the T-bolt of V-clamp to 45 deg., and then tighten the clamp lightly with tool A12 (long socket)...2298
            3. If base bracket (24) was removed, install it according to the following procedure...2298
              A. Install base bracket (24) with eight bolts (26)...2298
              B. Install two bolts (25) on the side of base bracket (24)...2298
            4. Mount KDPF assembly (21),which is tightened lightly to bracket (23), on base bracket (24)...2299
            5. Tighten bracket (23) with four bolts (22)...2299
            6. Set exhaust pipe (29) at a right angle (90°) to the engine crankshaft...2299
            7. Position the inlet flange of KDPF assembly (21)...2299
            8. Tighten tube (17) and spacer (20) with U-bolt (19)...2300
            9. By using tool A12 (long socket), tighten V-clamp (18) lightly...2300
            10. Fit the gasket between the inlet flange of KDPF assembly (21) and the flange of tube (17) and check the clearance...2300
            11. By using tool A12 (long socket), tighten V-clamp (16) lightly...2300
            12. By using tool A12 (long socket), tighten V-clamp (18) to the specified torque...2300
            13. By using tool A12 (long socket), tighten V-clamp (16) to the specified torque...2300
            14. If nuts (24) and (25) of U-bolt (26) were loosened, tighten evenly at the four places...2300
            15. If mounting bolts (22) of bracket (23) were loosened, tighten them...2300
            16. Finger-tighten brackets (30) and (31) for KDPF piping...2301
            17. Install tube (17) to KDPF piping bracket (30)...2301
            18. Tighten brackets (30) and (31) for KDPF piping to the specified torque...2301
            19. Close engine hood (1) to check for interference between exhaust pipe (29) and engine hood hole. If necessary, loosen V-clamp (28) by using tool A12 (long socket) to adjust the angle to T-bolt to 45 degrees and retighten...2301
          Disassembly...2302
            1. Secure the KDPF assembly at 4 places to support its inlet body and filter assembly by using block [1]...2302
            2. Put a match mark on the assembly for correct alignment of inlet and outlet angles at reassembly...2303
            3. Disconnect connectors of KDOC inlet temperature sensor (1), KDOC outlet temperature sensor (2), and KDPF outlet temperature sensor (3) from sensor table (13)...2303
              A. Slide the lever (white) of the connector to unlock...2304
              B. While pressing the knob on the upper portion of the connector, pull out the connector...2304
            4. Remove KDOC outlet temperature sensor (2), and KDPF outlet temperature sensor (3)...2304
            5. Remove differential pressure sensor pipes (5) and (6)...2305
              A. Loosen the nuts on the filter...2305
              B. When disconnecting connectors of the differential pressure sensor pipes (5) and (6), pull them out while pushing lock (L) at the fitting...2305
              C. Remove differential pressure sensor pipes (5) and (6)...2305
            6. Remove V-clamps (7) and (8) by using tool A11 (long socket) and remove inlet body (9) and outlet body (10)...2305
            7. Remove gaskets (17) and (18) to get KDPF filter assembly (11)...2305
            8. When replacing KDPF filter (16), remove sensor table (13) and hanger (15) according to the following procedure...2306
              A. Remove band (12) by using tool A12 (long socket) to remove sensor table (13)...2306
              B. Remove band (14) using tool A12 (long socket) to remove hanger (15)...2306
              C. Remove the plug from KDPF filter assembly (11), if so attached...2306
            9. When replacing differential pressure sensor (19), remove it according to the following procedure...2306
              A. Loosen mounting bolt (20), and remove differential pressure sensor (19) from sensor table (13)...2306
              B. Disconnect the fitting of differential pressure sensor pipes (5) and (6) to remove differential pressure sensor (19)...2306
            10. When replacing KDOC inlet temperature sensor (1), remove it according to the following procedure...2307
              A. Disconnect wiring harness clamp (4) for KDOC inlet temperature sensor (1) from sensor table (13)...2307
              B. Remove KDOC inlet temperature sensor (1)...2307
          Assembly...2308
            1. Install KDPF assembly inlet body (9), KDPF filter assembly (11) and outlet body (10) in sequence...2308
              A. Place new gasket (17) on end of KDPF filter assembly (11)...2308
              B. Assemble inlet body (9) to KDPF filter assembly (11) matching the fitting location for differential pressure sensor pipe according to the mark put before removing...2308
              C. Lightly tighten V-clamp (7) according to the marking put before removal and the angle shown to the right...2308
              D. Install new gasket (18) on end of KDPF filter assembly (11)...2309
              E. Assemble outlet body (10) to KDPF filter assembly (11) matching the fitting location for differential pressure sensor pipe according to the mark put before removal...2309
              F. Tighten V-clamp (8) lightly according to the mark put before removal and the angle shown on the right...2309
            2. Tighten V-clamps (7) and (8) according to the following procedure...2309
              A. By using tool A13 (long socket), tighten the nuts of V-clamps (7) and (8)...2309
              B. Tap the entire periphery of the V-clamp with a rubber hammer in the following order: agb, cgd...2310
              C. Tighten the nuts of V-clamps (7) and (8) again...2310
            3. When a new KDPF filter is installed, install sensor table (13) and hanger (15) according to the following procedure...2310
              A. Fasten hanger (15) lightly with new band (14) using tool A12 (long socket)...2310
              B. By using tool A12 (long socket), lightly tighten sensor table (13) a new band (12)...2310
            4. Install differential pressure sensor pipes (5) and (6) according to the following procedure...2311
              A. Install differential pressure sensor pipes (5) and (6) so that they extend horizontally, and then lightly tighten the nuts...2311
              B. Install connectors of differential pressure sensor pipes (5) and (6) to differential pressure sensor (19)...2311
              C. Install differential pressure sensor pipes (5) and (6)...2311
            5. Install KDOC outlet temperature sensor (2), and KDPF outlet temperature sensor (3)...2311
            6. Install connectors of KDOC inlet temperature sensor (1), KDOC outlet temperature sensor (2), and KDPF outlet temperature sensor (3) to sensor table (13)...2312
            7. When replacing differential pressure sensor (19), install it according to the following procedure...2312
              A. Lightly tighten mounting bolt (20) of differential pressure sensor (19)...2312
              B. Install connectors of differential pressure sensor pipes (5) and (6) to differential pressure sensor (19)...2312
              C. Tighten mounting bolt (20) of differential sensor (19) to the specified torque...2312
            8. When replacing KDOC inlet sensor (1), install it according to the following procedure...2312
              A. Install KDOC inlet sensor (1) and tighten the nut lightly...2312
              B. Install wiring harness clamp (4) for KDOC inlet temperature sensor (1)...2312
              C. Install connector of KDOC inlet temperature sensor (1) to sensor table (13)...2312
            MEMORANDUM...2313
        KCCV Assembly...2314
          Removal...2314
            1. Open the engine hood...2314
            2. Disconnect wiring harness clamp (1)...2314
            3. Disconnect wiring harness connector P57 (2)...2314
            4. Disconnect hose clamp (3)...2314
            5. Disconnect following hoses (4), (5), and (6). [*1]...2314
            6. Remove cover (7)...2314
            7. Remove two mounting bolts (8) and remove KCCV ventilator assembly (9) and bracket (10) together...2314
            8. Disconnect bracket (10) from KCCV ventilator assembly (9)...2315
          Installation...2315
        Air Cleaner Assembly...2316
          Removal...2316
            1. Open the side cover on the right side of the machine and disconnect connector P23 of air cleaner clogging sensor (1)...2316
            2. Disconnect wiring harness clamps (3) and (4) of the air cleaner clogging sensor...2316
            3. Open engine hood (5) and remove air cleaner top cover (6) according to the following procedure...2316
              A. Lift up air cleaner top cover (6) to disconnect it from the air inlet of air cleaner (7)...2317
              B. Lift up and remove air cleaner top cover (6) slantways so that it does not interfere with frame (A)...2317
            4. After removing the air cleaner top cover, cover the air inlet of air cleaner (7) with a vinyl sheet etc...2317
            5. Disconnect connector P55 of mass air flow and temperature sensor (8)...2317
            6. Remove hose clamp (9). [*1]...2317
            7. Remove air cleaner band (10). [*2]...2317
            8. Remove air cleaner (7)...2317
            9. After removing air cleaner (7), cover its hose connecting port with a vinyl sheet etc...2317
            10. When replacing air cleaner (7), remove air cleaner clogging sensor (1), mass air flow and temperature sensor (8), air inlet seal (11), and joint (12)...2317
          Installation...2318
        Air Conditioner Compressor Assembly...2319
          Removal...2319
            1. Collect the refrigerant (R134a) from the air conditioner circuit. [*1]...2319
            2. Open the engine hood and remove fan guard (1)...2319
            3. Disconnect hose clamp (2)...2319
            4. Disconnect hose clamp (3)...2319
            5. Disconnect solenoid clutch connector AC03 (4) of the air conditioner compressor...2319
            6. Remove air conditioner compressor belt (5) according to the following procedure. [*2]...2319
              A. Loosen two mounting bolts (6)...2320
              B. Move air conditioner compressor assembly (7) and bracket (8) together in the loosening direction of belt (5)...2320
              C. Remove loosened air conditioner compressor belt (5)...2320
            7. Disconnect two air conditioner hoses (9) and (10). [*3]...2320
            8. Disconnect air conditioner ground cable (11)...2320
            9. Remove four mounting bolts (12), and then remove air conditioner compressor assembly (7) from bracket (8). [*4]...2320
          Installation...2320
        Air Conditioner Condenser Assembly...2321
          Removal...2321
            1. Collect the refrigerant (R134a) from the air conditioner circuit. [*1]...2321
            2. Open the engine hood and side cover on the right side of the machine and remove cover (1) and frame (2)...2321
            3. Disconnect hoses (4) and (5) from air conditioner condenser assembly (3). [*2]...2321
            4. Remove eight mounting bolts (6) and remove air conditioner condenser assembly (3). [*3]...2321
            5. Remove eight mounting bolts (7), and then remove bracket (8) from air conditioner condenser assembly (3)...2321
          Installation...2322
      DRIVE ASSEMBLY...2323
        Removal...2323
          1. Remove the sprocket. For details, see “Removal and installation of sprocket”...2323
          2. Remove cover (1)...2323
          3. Disconnect drain hose (2), travel speed selector hose (3), and motor hoses (4) and (5)...2323
          4. Remove the 24 mounting bolts and lift off the final drive assembly (6). [*1]...2323
        Installation...2323
        Disassembly...2324
          1. Remove the drain plug to drain the oil from the final drive case...2324
          2. Cover...2324
            A. Place the final drive on block [1] and remove the mounting bolts...2324
            B. Using eyebolt [2], remove cover (1)...2324
          3. Remove spacer (2)...2325
          4. No. 1 carrier assembly...2325
            A. Remove No. 1 carrier assembly (3)...2325
            B. Disassemble the No. 1 carrier assembly according to the following procedure...2325
            i. Push in pin (5) to drive out shaft (6) from carrier (7)...2325
            ii. Remove thrust washer (8), gear (9), bearing (10), and thrust washer (11)...2325
          5. Remove spacer (4), No. 1 sun gear (12), and No. 2 sun gear (13)...2325
          6. Remove thrust washer (14) from No. 2 carrier assembly (15)...2326
          7. No. 2 carrier assembly...2326
            A. Sling No. 2 carrier assembly (15) with wires, etc. and remove it...2326
            B. Disassemble No. 2 carrier assembly according to the following procedure...2326
            i. Push in pin (16) to drive out shaft (17) from carrier (18)...2326
            ii. Remove thrust washer (19), gear (20), bearing (21), and thrust washer (22)...2326
          8. Nut...2326
            A. Remove lock plate (23) from locknut (24)...2326
            B. Using tool E1, remove locknut...2327
          9. Hub assembly...2327
            A. Using eyebolts [3], remove hub assembly (25) from the travel motor...2327
            B. Disassemble hub assembly (25) according to the following procedure...2327
            i. Remove bearing (26) from hub (32)...2327
            ii. Remove floating seal (27) from hub (32)...2327
            iii. Remove bearings (28) and (29)...2328
            C. Remove floating seal (30) from travel motor (31)...2328
            D. Using puller [4], remove bearing (34) and collar (33) together...2328
        Assembly...2329
          1. Hub assembly...2329
            A. Using the push tool, press fit bearings (28) and (29)...2329
            B. Using tool E3, install floating seal (27) to hub (32)...2329
            C. Install collar (33) and bearing (34) to travel motor (31)...2329
            D. Using tool E3, install floating seal (30) (which is hidden and not seen behind tool E3) to travel motor (31)...2329
            E. Using eyebolts [3], set hub assembly (25) to the travel motor. Using the push tool, lightly hit the bearing to press fit it...2330
          2. Nut Install the nut according to the following procedure...2330
            A. Rotate the hub two – three turns...2330
            B. Using tool E2, press the bearing inner race...2330
            C. While the bearing is pressed, rotate the hub at least five turns in one direction...2330
            D. Release the pressing force...2330
            E. Press the bearing again...2330
            F. Under the condition in E above, measure dimension (a)...2330
            G. Measure thickness (b) of nut (24)...2330
            H. Obtain (a) – (b) = (c)...2330
            I. Using tool E1, tighten nut (24) until dimension (c) is as follows...2330
            J. Using push-pull gauge [5], measure the tangential force of the hub in its revolving direction on the motor case...2331
            K. Install lock plate (23), fitting it to the motor spline...2331
          3. No. 2 carrier assembly...2331
            A. Assemble the No. 2 carrier assembly according to the following procedure...2331
            i. Install bearing (21) to gear (20) and fit top and bottom thrust washers (19) and (22), and then set the gear assembly to carrier (18)...2331
            ii. Aligning the pin holes of shaft (17) and carrier, lightly hit the shaft with a plastic hammer, etc. to install...2331
            iii. Insert pin (16)...2331
            B. Install No. 2 carrier assembly (15)...2332
          4. Install thrust washer (14) to No. 2 carrier assembly (15)...2332
          5. Install spacer (4) and No. 2 sun gear (13)...2332
          6. No. 1 carrier assembly...2332
            A. Assemble the No. 1 carrier assembly according to the following procedure...2332
            i. Install bearing (10) to gear (9) and fit top and bottom thrust washers (8) and (11), and then set the gear assembly to carrier (7)...2332
            ii. Aligning the pin holes of shaft (6) and carrier, lightly hit the shaft with a plastic hammer, etc. to install...2333
            iii. Insert pin (5)...2333
            B. Install No. 1 carrier assembly (4)...2333
          7. Install No. 1 sun gear shaft (12)...2333
          8. Install spacer (2)...2333
          9. Using eyebolts [2], install cover (1) and tighten the mounting bolts...2334
        Swing Motor and Swing Machinery Assembly...2335
          Removal...2335
            1. Remove soft swing hoses (1) and (2), if equipped...2335
            2. Remove work equipment hoses:...2335
            3. Remove swing hoses:...2335
            4. Lift and remove the swing motor and swing machinery assembly (14)...2336
          Installation...2336
            1. Bleed air from the hydraulic pump circuit. For details, see “Bleeding Air From Hydraulic Circuit” on page 30-149...2336
        Swing Machinery...2337
          Disassembly...2337
            1. Oil draining...2337
            2. Swing motor assembly...2337
              A. Set the swing motor and swing machinery assembly on block [1]...2337
              B. Remove ten mounting bolts, and sling and remove swing motor assembly (1)...2337
            3. Remove No. 1 sun gear (2)...2337
            4. No. 1 carrier assembly...2338
              A. Remove No. 1 carrier assembly (3)...2338
              B. Disassemble No. 1 carrier assembly according to the following procedure. Remove snap ring (4), then remove shaft (5), planetary gear (6), bearing (7), thrust washer (8), and plate (9)...2338
            5. Remove the mounting bolts and ring gear (10)...2338
            6. Remove No. 2 sun gear (11)...2338
            7. Remove mounting bolt (12) for No. 2 carrier assembly (13)...2339
            8. No. 2 carrier assembly...2339
              A. Sling and remove No. 2 carrier assembly (13)...2339
              B. Disassemble the No. 2 carrier assembly according to the following procedure...2339
              i. Push in pin (14) and drive out shaft (15) from carrier (16)...2339
              ii. Remove thrust washer (17), planetary gear (18), bearing (19), and thrust washer (20)...2339
              iii. Remove plate (21)...2339
            9. Shaft assembly...2339
              A. Reverse case and pinion assembly (24) and remove 12 mounting bolts (23) of cover assembly (22)...2339
              B. Reverse case and pinion assembly (24) and place them on the press stand...2339
              C. Remove pinion shaft assembly (25) using push tool [2] and tool D1...2340
              D. Disassemble the pinion shaft assembly according to the following procedure...2340
              i. Using the push tool, remove cover assembly (22) and bearing (26) from shaft (27)...2340
              ii. Remove oil seal (28) from cover (29)...2340
            10. Bearing...2340
          Assembly...2341
            1. Bearing...2341
            2. Cover assembly...2341
              A. Using tool (push tool kit) D4, press fit oil seal (28) to cover (29)...2341
              B. Install cover assembly (22) to case (31) and tighten mounting bolts (23)...2341
            3. Case assembly...2341
              A. Reverse case assembly (32) and set it to shaft (27)...2341
              B. Press fit the bearing inner race by using push tool [5] and tools D5 and D6...2341
              C. Bearing...2342
            4. No. 2 carrier assembly...2342
              A. Install plate (21) to carrier (16)...2342
              B. Install bearing (19) to planetary gear (18). Fit upper and lower thrust washers (17) and (20), and then set the planetary gear assembly to carrier (16)...2342
              C. Align the pin holes on the shaft and the carrier, and install shaft (15) by tapping it by using a plastic hammer...2342
              D. Insert pin (14)...2342
            5. Install No. 2 carrier assembly (13) according to the following procedure...2343
              A. Set No. 2 carrier assembly (13) to the case...2343
              B. Tighten bolt (12)...2343
              C. Install the O-ring to the case...2343
            6. Install No. 2 sun gear (11)...2343
            7. Using eyebolts (M12 x 1.75), install ring gear (10)...2343
            8. No. 1 carrier assembly...2344
              A. Assemble the No. 1 carrier assembly according to the following procedure...2344
              i. Press fit shaft (5) to the carrier in the direction of the arrow until the snap ring groove is seen...2344
              ii. After installing snap ring (4), push it back from the opposite side until snap ring (4) contacts tightly with face (P) of the carrier...2344
              iii. After installing plate (9), install thrust washer (8), bearing (7), planetary gear (6), and snap ring (4)...2344
              B. Install No. 1 carrier assembly (3)...2344
            9. No. 1 sun gear assembly...2345
            10. Swing motor assembly...2345
        Swing Circle Assembly...2346
          Removal...2346
            1. Remove the revolving frame assembly. For details, see “Removal and installation of revolving frame assembly”...2346
            2. Sling swing circle assembly (1) by 3-point lifting...2346
            3. Remove 46 mounting bolts, and then lift swing circle assembly (1) to remove. [*1]...2346
          Installation...2346
      UNDERCARRIAGE AND FRAME...2347
        Track Shoe Assembly...2347
          Separation...2347
            1. Turn the upper structure by 90°...2347
            2. Loosen lubricator (1) to decrease the track shoe tension. [*1]...2347
            3. Position master pin (2)...2347
              A. Lift tracks (3) by stretching the work equipment against ground...2347
              B. Move master pin (2) to a position above the idler where it can be removed easily...2347
              C. Relieve the extended work equipment, and lower the machine...2347
            4. Remove track shoes (5) on the right and left sides of master pin (2) of track (3). [*2]...2348
            5. Using tool N, remove master pin (2). [*3]...2348
            6. Move guide pin [1] and place block [2] under track shoe (3) to support in front of the idler...2348
            7. Pull out guide pin [1] and remove block [2] so that track shoe (3) can be separated...2348
            8. Move the machine slowly in reverse to separate the track shoe (3). [*4]...2348
          Installation...2349
            1. While tensing wire [3] with a forklift truck, work equipment, etc., move the machine forward slowly to wind track shoe (3)...2349
            2. By using bar [4], hammer [5], etc., wind track shoe (3) and match the pin holes of link (6)...2349
            3. Drive guide pin [1] into link (6)...2349
            1. Remove mud, dirt, and rust from the mating faces of shoe (5) and link and the seating faces of bolt (7) and nut...2350
            2. Install shoe (5)...2350
        Sprocket...2352
          Removal...2352
            1. Separate track shoe assembly. For details, see “Track Shoe Assembly” on page 50-208...2352
            2. Swing the work equipment 90°, then push up the chassis with the work equipment and place block [1] between the track frame and the track...2352
            3. Remove the mounting bolt, then sling and remove sprocket (1)...2352
          Installation...2352
        Idler and Idler Cushion Assembly...2353
          Removal...2353
            1. Separate track shoe assembly. For details, see “Track Shoe Assembly” on page 50-208...2353
            2. Set wire [1] to idler and idler cushion assembly (1) and move it forward with bar [2] to a position where you can sling it easily...2353
            3. While balancing idler and idler cushion assembly (1) with wire [1] and chain block [3], sling and remove them from track frame (2)...2353
            4. Disconnect idler cushion assembly (4) from idler assembly (3)...2353
          Installation...2353
        Idler...2354
          Disassembly...2354
            1. Remove nut (1) and pull out bolt (2) to remove support (3)...2354
            2. Remove floating seal (4) from support (3) and idler (5)...2354
            3. Pull out idler (5) from shaft and support assembly (6)...2354
            4. Remove floating seal (7) on the opposite side from idler (5) and shaft and support assembly (6)...2354
            5. Remove nut (8), pull out bolt (9), and then remove support (10) from shaft (11)...2355
            6. Remove bushing (12) from idler (5)...2355
          Assembly...2355
            1. Press fit bushings (12) (on both sides) to idler (5)...2355
            2. Fit the O-ring and install support (10) to shaft (11) with bolt (9) and tighten nut (8)...2355
            3. Using tool H1, install floating seal (7) to idler (5) and shaft and support assembly (6)...2356
            4. Install shaft and support assembly (6) to idler (5)...2356
            5. Similarly, using tool H1, install floating seal (4) to idler (5) and support (3)...2356
            6. Fit the O-ring, set support (3), install bolt (2), and tighten nut (1)...2357
            7. Using tool H2, add oil and tighten the plug...2357
        Idler Cushion...2358
          Disassembly...2359
            1. Remove piston assembly (2) from idler cushion assembly (1)...2359
            2. Disassembling idler cushion...2359
              A. Set idler cushion assembly (1) on tool M1...2359
              B. Apply hydraulic pressure gradually to compress the spring and remove lock plate (3) and nut (4)...2359
              C. Remove yoke (6), cylinder (7), collar (8), and dust seal (9) from spring (5)...2359
            3. Disassembly of the piston assembly...2359
              A. Remove lock plate (11) from piston assembly (10), then remove valve (12)...2359
              B. Remove snap ring (13), then remove U-packing (14) and ring (15)...2359
          Assembly...2360
            1. Assembly of piston (2)...2360
              A. Install ring (15) and U-packing (14) to piston assembly (10) and secure them with snap ring (13)...2360
              B. Lightly tighten valve (12), and secure it with lock plate (11)...2360
            2. Assembly of idler cushion...2360
              A. Using tool M2, install dust seal (9) to cylinder (7)...2360
              B. Install cylinder (7), spacer (16), collar (8), and yoke (6) to spring (5), and install the assembly to tool M1...2360
              C. Apply hydraulic pressure slowly to compress the spring, and then tighten nut (4) so that the installed length of the spring is dimension (a) and secure it with lock plate (3)...2360
              D. Remove idler cushion assembly (1) from tool M1...2361
            3. Install piston assembly (2) to the idler cushion assembly (1)...2361
        Track Roller/Carrier Roller...2362
          Disassembly...2362
            1. Remove pin (1), then remove collar (2)...2362
            2. Remove floating seals (3) from collar (2) and roller (4)...2362
            3. Pull out roller (4) from shaft (5) and collar (8) assembly...2362
            4. Remove floating seals (6) on the other side from roller (4), and the assembly of shaft (5) and collar (8)...2362
            5. Remove pin (7) and then collar (8) from shaft (5)...2362
            6. Remove bushings (9) and (10) from roller (4)...2362
          Assembly...2363
            1. Using push tool [1], press fit bushings (9) and (10) to roller (4)...2363
            2. Install O-ring (11), install collar (8) to shaft (5) and install pin (7)...2363
            3. Using tool K, install floating seal (6a) to collar (8)...2363
            4. Using tool K, install floating seals (6b) and (3b) to roller (4)...2363
            5. Install shaft (5) to roller (4)...2363
            6. Turn over the assembly of roller (4) and shaft (5)...2363
            7. Using tool K, install floating seal (3a) to collar (2)...2364
            8. Install O-ring (12), then install collar (2) to shaft (5) with pin (1)...2364
            9. Apply standard pressure to roller oil filler port, and check leakage of air from seal...2364
            10. Fill track roller assembly with oil, then tighten plug (13)...2364
        Revolving Frame Assembly...2365
          Removal...2365
            1. Remove the work equipment assembly, referring to removal and installation of “Work Equipment Assembly (Road Builder)” on page 50-275...2365
            2. Remove the counterweight assembly, referring to removal and installation of “Counterweight Assembly” on page 50-230...2365
            3. Remove the engine hood assembly, referring to removal and installation of “Engine Hood Assembly” on page 50-149...2365
            4. Remove boom cylinder guard. Only applies to Logging front (not shown)...2365
            5. Disconnect hoses (1) of the boom cylinder...2365
            6. Sling the boom cylinder assembly (2)...2365
            7. Remove plate (3) and pin (4), then sling and remove boom cylinder assembly (2)...2366
            8. Disconnect hoses (6) to (12) of center swivel joint (5)...2366
            9. Pull out pin (13) from center swivel joint (5) to disconnect stopper plate (14) from center swivel joint (5)...2366
            10. Set slings to revolving frame assembly (15)...2366
            11. Remove 35 mounting bolts (16), then sling and remove revolving frame assembly (15). [*1]...2366
          Installation...2367
            MEMORANDUM...2368
        Counterweight Assembly...2369
          Removal...2369
            1. Open the side cover on the left side of the machine and disconnect intermediate connector A40 (1) of the rear view camera...2369
            2. Disconnect connector L09 (2) of rear working lamp (if installed)...2369
              A. Turn valve handle (3) to close valve...2370
              B. Remove bolts (4) and cover (5)...2370
              C. Attach drain hose to valve (6). Prepare a container(s) to capture the drained fuel. Open valve and drain the additional fuel tank...2370
              D. Turn lever (7a) on valve (7b) 90 degrees clockwise to close the valve. Place a catch pan under valve (7b) and hose (8) to catch any remaining fuel in hose (8). Remove hose (8) from valve (7b) and drain into catch pan...2371
            3. Set slings to the counterweight assembly...2371
            4. Using tools Z1 and Z2 remove: four mounting bolts (9) - standard counterweight six mounting bolts (9) - additional fuel tank counterweight...2371
            5. Sling and remove counterweight assembly (10). [*2]...2371
            1. Remove cover (11)...2371
            2. Remove bolts (14) to remove cover (12). [*3]...2372
            3. Remove two bolts (15)...2372
            4. Disconnect rear view camera connector A45 (16) and remove rear view camera assembly (17)...2372
          Installation...2373
      HYDRAULIC SYSTEM...2374
        Center Swivel Joint Assembly...2374
          Removal...2374
            1. Disconnect eight hoses (1) to (8) between the center swivel joint and travel motor...2374
            2. Disconnect hoses (10) to (16) of center swivel joint (9)...2374
            3. Pull out pin (17) from center swivel joint (9) to disconnect stopper plate (18) from center swivel joint (9)...2375
            4. Remove four mounting bolts (19) of center swivel joint (9). [*1]...2375
            5. Sling and remove center swivel joint (9). [*2]...2375
          Installation...2376
            MEMORANDUM...2377
          Disassembly...2378
          Disassembly...2378
            1. Remove cover (1)...2378
            2. Remove snap ring (2)...2378
            3. By using tool S, pull swivel rotor (4) and ring (3) out of swivel shaft (5)...2378
            4. Remove dust seal (6) from cover (7)...2378
            5. Remove O-ring (8) and slipper seal (9) from swivel rotor (4)...2378
          Assembly...2379
            1. Install slipper seal (9) and O-ring (8) to swivel rotor (4)...2379
            2. Install cover (7) to swivel shaft (5)...2379
            3. Install dust seal (6) to cover (7)...2379
            4. Place swivel shaft (5) on the block. Using the push tool, install swivel rotor (4) to the shaft while lightly tapping the swivel rotor with a plastic hammer...2379
            5. Install ring (3) and secure it with snap ring (2)...2379
            6. Fit the O-ring and install cover (1)...2379
        Hydraulic Tank Assembly...2380
          Removal...2380
            1. Swing the upper structure counterclockwise by 45° and stop it, and then remove undercovers (1), (2A), and (2B)...2380
            2. Remove drain plug (3) to drain oil from the hydraulic tank. [*1]...2380
            3. Open the engine hood...2380
            4. Remove handrail (4A), (4B), (4C), and plate (5)...2380
            5. Remove cover (6)...2380
            6. Remove control valve covers (7)...2380
            7. Disconnect hydraulic hoses (8), (9), (10), and (11) at the inside upper part of the hydraulic tank...2381
            8. Disconnect hydraulic hoses (12), (13), (14), (15) and (16) at the inside lower part of the hydraulic tank...2381
            9. Disconnect hose clamp (17)...2381
            10. Disconnect engine wiring harness (18) and move it to a place where it is not an obstacle to the work...2381
            11. Disconnect hose clamp (19)...2381
            12. Disconnect hydraulic oil temperature sensor connector CN-P22 (20)...2381
            13. Remove two mounting bolts (21) and cushion (22)...2381
            14. Remove suction tube (22) from hydraulic tank assembly (23). [*1]...2382
            15. Remove bracket (24)...2382
            16. Remove hydraulic tank cover (25)...2382
            17. Set slings to tank assembly (23) and remove four mounting bolts (26) on right and left sides each...2382
            18. 18.Sling and remove tank assembly (23)...2382
          Installation...2383
            1. Install suction tube (22) to hydraulic tank assembly (23) according to the following procedure...2383
              A. Apply adhesive to the inserted portion (j) of the suction hose (hatched area)...2383
              B. Install the hose clamps according to the following procedure...2383
            2. Install the MIKALOR clamp according to the following procedure...2383
        Main Pump Assembly...2384
          Removal...2384
            1. Remove undercover (1)...2384
            2. Remove drain plug (3) and drain the hydraulic oil...2384
            3. Remove drain plug (4) and drain the damper oil...2385
            4. Removal of covers...2385
              A. Open the side cover on the left side of the machine and remove KDPF water drain tube (5). [*1]...2385
              B. Remove handrail (5.5)...2385
              C. 2) Remove covers (6), (7), and (8)...2386
              D. 3) Remove frame (9)...2386
              E. 4) Remove covers (10) and (11)...2386
            5. Disconnect connectors (12) to (14)...2386
            6. Disconnect hoses (15) to (17)...2386
            7. Disconnect connectors (18) and (19)...2387
            8. Disconnect hoses (20) to (25)...2387
            9. Disconnect connector (26)...2387
            10. Disconnect six wiring harness clamps (27) around the main pump...2387
            11. Disconnect hose clamp (28)...2387
            12. Remove four mounting bolts (29) and disconnect pump suction tube (30)...2387
            13. Remove the tube clamp and damper case oil filler pipe (31). [*2]...2387
            14. Remove blocks (32) and (33) to sling main pump assembly (34)...2387
            15. Remove bolt (35) at the center of gravity of main pump assembly (34)...2387
            16. Install eyebolt [1]...2388
            17. Set wire [2] to main pump assembly (34) and remove mounting bolt (36)...2388
            18. Sling and remove main pump assembly (34). [*3]...2388
          Installation...2389
            MEMORANDUM...2390
        Control Valve Assembly...2391
          Removal...2391
            1. Remove undercovers (1) and (2)...2391
            2. Remove drain plug (3) and drain the hydraulic oil...2391
            3. Open the engine hood...2392
            4. Remove U-bolt (4) to remove air intake tube (5) from the KVGT. [*1]...2392
            5. Remove step (6)...2392
            6. Remove frame (7)...2392
            7. Remove KCCV ventilator assembly (8). For details, see removal and installation of “KCCV Assembly” on page 50-175...2392
            8. Remove control valve top cover (9)...2392
            9. Remove air cleaner top cover (10) according to the following procedure...2392
              A. Lift up air cleaner top cover (10) to disconnect it from the air inlet of air cleaner (11)...2392
              B. Lift up and remove air cleaner top cover (10) slantways so that it will not interfere with frame (12)...2392
            10. After removing the air cleaner top cover, cover the air inlet of the air cleaner with a vinyl sheet etc...2393
            11. Remove frames (13)...2393
            12. Remove covers (14) and (15)...2393
            13. Loosen hose clamp (16) and remove air intake hose (17) from air cleaner (11). [*2]...2393
            14. After removing the air intake hose, cover the air inlet of air cleaner (11) with a vinyl sheet etc...2393
            15. Disconnect the following hoses on the top of the control valve...2393
            16. Disconnect the following hoses of the junction block...2394
            17. Disconnect the following connectors of the junction block...2394
            18. Disconnect following hoses from the rear of control valve...2394
            19. Disconnect the following connectors on the rear of the control valve. [*3]...2394
            20. Disconnect the following hoses on the right of control valve...2395
            21. Disconnect the following connectors on the right of the control valve...2395
            22. Disconnect four boom cylinder hoses (67)...2395
            23. Remove boom tube mounting clamps (68) and (69)...2396
            24. Disconnect the following hoses from the swing motor and securely attach to the control valve. Hose (70), (71), (72), and (73)...2396
              A. Disconnect tubes (74), (75), and (76) from the control valve...2396
              B. Disconnect hoses (77) and (78) from arm hold valve (Log Loader front only)...2396
              C. Disconnect hoses (79), (80), (81), and (82) from the swivel joint...2396
              D. Disconnect hoses (83), (84), (85), (86), (87), and (88) [Log Loader only] from the boom foot area...2397
            25. Disconnect the following hoses on the bottom of control valve...2397
            26. Disconnect the following hoses and tubes on the rear of the control valve...2398
            27. Disconnect the following connectors...2398
            28. Set slings to the control valve assembly and remove four mounting bolts (97) from the bottom...2398
            29. Sling and remove control valve assembly (98)...2398
          Installation...2399
          Disassembly...2400
          Replacing Procedures of Pressure Compensation Valve Seal...2401
            1. Remove piston (2), plug (3) and spring (4) from pressure compensation valve (1)...2401
            2. Remove seals (5) and (6) from piston (2)...2401
            3. Set tool T1 to piston (2) and push in seal (5) slowly with the hands so that it expands evenly...2401
            4. Repeat the same process to install another seal (6). Set tool L2 to piston (2) from the same direction and push in seal (6) slowly so that it expands evenly...2401
            5. Install settling tool L3 to piston (2) and keep it installed for approximately 1 minute so that seals (5) and (6) fit in...2401
            6. Fit plug (3) and spring (4) to piston (2), then install pressure compensation valve (1)...2402
          Assembly...2402
        Work Equipment PPC Valve...2406
          Disassembly...2406
          Assembly...2407
            1. When installing the joint, apply a drop (approximately 0.02 g) of Loctite (No. 262) to two places at threaded hole (A) in the valve body...2407
            2. Drop LOCTITE to the following positions...2407
        Travel PPC Valve...2408
          Disassembly...2408
            1. Remove screw (19) and remove damper assembly (18)...2408
            2. Remove mounting bolts (17) and remove case (16), shaft (15) and lever (13) as a unit...2408
            3. Remove mounting bolts (11) to remove plate (10)...2408
            4. Remove seal (9) and collar (8)...2408
            5. Remove pistons (7) to remove retainers (6), springs (5) and (4) and shims (3)...2408
            6. Remove valves (2) from valve body (1)...2408
          Assembly...2409
      WORK EQUIPMENT...2410
        Bucket Assembly...2410
          Removal...2410
          Installation...2411
        Arm Assembly...2412
          Removal...2412
            1. Remove the bucket assembly. For details, see removal and installation of “Bucket Assembly” on page 50-271...2412
            2. Secure the linkage to the arm with a wire...2412
            3. Set block [3] between the arm cylinder and boom...2412
            4. Remove plate (1) and pull out arm cylinder head pin (2). [*1]...2412
            5. Start the engine, and retract the piston rod, then tie the cylinder rod to the arm by using a wire to prevent the piston rod from coming out...2412
            6. Disconnect two bucket cylinder hoses (3)...2412
            7. Disconnect two attachment hoses (4)...2412
            8. Remove plate (5) and pull out boom top pin (6). [*2]...2412
            9. Start the engine, then raise the boom and remove arm assembly (7)...2412
          Installation...2413
        Work Equipment Assembly (Road Builder)...2414
          Removal...2414
            1. Disconnect grease hose (1)...2414
            2. Sling the boom cylinder assembly (2)...2414
            3. Remove lock bolt and nut (3). [*1]...2414
            4. Remove plate (4) and remove boom cylinder head pin (5). [*2]...2414
            5. Start the engine and then retract the piston rod...2414
            6. Stop the engine, and release the pressure remaining in the circuit...2415
            7. Remove two attachment hoses (6)...2415
            8. Disconnect two bucket cylinder hoses (7) and three arm cylinder hoses (8)...2415
            9. Disconnect working lamp intermediate connector A13 (9)...2415
            10. Sling work equipment assembly (10), and then remove plate (11) and boom foot pin (12). [*3]...2415
            11. Remove work equipment assembly (13)...2415
          Installation...2416
            MEMORANDUM...2417
        Work Equipment Assembly (Log Loader)...2418
          Removal...2418
            1. Disconnect grease hose (1)...2418
            2. Sling the boom cylinder guard (2)...2418
            3. Remove bolts (3) and carefully remove guard...2418
            4. Sling boom cylinders (4)...2418
            5. Remove pin lock bolts (5), plate (6), and pins (7)...2419
            6. Start the engine and then retract the piston rod...2419
            7. Stop the engine, and release the pressure remaining in the circuit...2419
            8. Remove hoses (8) at boom foot area...2419
            9. Disconnect working lamp intermediate connector A13 (9)...2419
            10. Sling work equipment assembly (10), and then remove guard brace (11) and boom foot pin (12)...2419
            11. Start the machine and slowly back the machine out from under the work equipment. Then lower the work equipment to the ground...2419
          Installation...2420
        Work Equipment Cylinder (Road Builder)...2421
          Disassembly...2421
            1. Disconnection of cylinder assembly and piston rod assembly...2421
              A. Remove the piping from the cylinder assembly...2421
              B. Remove the 12 mounting bolts to disconnect cylinder head assembly (1)...2421
              C. Pull out piston rod assembly (2)...2421
            2. Disassembly of piston rod assembly...2422
              A. Set piston rod assembly (2) on tool U1...2422
              B. By using a hexagonal wrench (6 mm), remove lock screw (3) at the end of piston assembly (4)...2422
              C. By using tool U2, remove piston assembly (4)...2422
              D. Remove plunger (5)...2423
              E. Remove collar (6)...2423
              F. Remove cylinder head assembly (7)...2423
              G. Remove cap (8), take out twelve balls (9), and remove plunger (10)...2423
            3. Disassembly of piston assembly...2423
              A. Remove two rings (11)...2423
              B. Remove two wear rings (12)...2423
              C. Remove piston ring (13)...2423
              D. Remove the O-ring and two backup rings (14)...2423
            4. Disassembly of cylinder head assembly...2423
              A. Remove the O-ring and backup ring (15)...2423
              B. Remove snap ring (16), then remove dust seal (17)...2423
              C. Remove rod packing (18) and buffer ring (19)...2423
              D. Remove snap ring (30)...2423
              E. Remove bushing (20)...2423
          Assembly...2424
            1. Assembly of cylinder head...2424
              A. By using tool U6, press fit bushing (20)...2424
              B. Install snap ring (30)...2424
              C. Install buffer ring (19) and rod packing (18)...2424
              D. By using tool U6, install dust seal (17) and secure it with snap ring (16)...2424
              E. Install backup ring (15) and O-ring...2424
            2. Assembly of piston...2424
              A. Set piston ring (13) on tool U3, and rotate the handle eight to ten turns to expand piston ring (13)...2424
              B. Remove piston ring (13) from tool U3 and install it to the piston...2424
              C. By using tool U4, compress piston ring (13)...2424
              D. Install two backup rings (14) and O-ring...2425
              E. Install two wear rings (12)...2425
              F. Install two rings (11)...2425
            3. Assembly of piston rod...2425
              A. Set piston rod assembly (2) to tool U1...2425
              B. Install cylinder head assembly (7)...2425
              C. Fit the O-ring and backup ring to collar (6), and then install them to the piston rod...2425
              D. Install plunger (5)...2425
              E. Set plunger (10) to piston rod assembly (2), and then install twelve balls (9) and cap (8)...2425
              F. When reusing both of piston rod assembly (2) and piston assembly (4), assemble them in the following procedure. (When replacing either or both of them with new ones, see step G)...2426
              i. By using tool U2, install piston assembly (4) to piston rod assembly (2)...2426
              ii. Install screw (3) to fix piston assembly (4) and piston rod assembly (2)...2426
              G. When replacing either or both of piston rod assembly (2) and piston assembly (4) with new ones, assemble them in the following procedure...2426
              i. By using tool U2, tighten piston rod assembly (4) to end (b) of the rod...2426
              ii. Make a screw hole for the lock screw to the threaded portion between piston rod assembly (2) and piston assembly (4)...2427
              iii. Install screw (3) to fix piston assembly (4) and piston rod assembly (2)...2427
            4. Connection of cylinder assembly and piston rod assembly...2427
              A. Set piston rod assembly (2) on tool U1...2427
              B. Install the cylinder assembly to piston rod assembly (2)...2427
              C. Tighten the mounting bolts of cylinder head assembly (1)...2428
              D. Install the piping...2428
            MEMORANDUM...2429
      CAB AND ITS ATTACHMENTS...2430
        Operator's Cab Assembly...2430
          Removal...2430
            1. Remove the machine monitor assembly. For details, see removal and installation of “Machine Monitor Assembly” on page 50-350...2430
            2. Remove the floor mat...2430
            3. Remove cover (1) first, and then remove cover (2)...2430
            4. Remove cover and duct assembly (3)...2430
            5. Remove box (9) (five bolts)...2431
            6. Remove box (10) (three bolts)...2431
            7. Remove cover (13) (three bolts)...2431
            8. Remove cover (14) (seven bolts)...2431
            9. Remove duct (16)...2431
            10. Remove cover (17)...2431
            11. Remove plate (20)...2432
            12. Pull up lock pin (21) to unlock and remove duct (22)...2432
            13. Remove ducts (23) and (24)...2432
            14. Disconnect connectors (26) to (29) from KOMTRAX terminal (C)...2432
            15. Remove connector (30) from the clip at the operator's cab...2433
            16. Release connectors (31) to (35) from the clips at the operator's cab and disconnect the connectors...2433
            17. Disconnect radio antenna (36)...2433
            18. Remove four bolts (37) and remove pump controller assembly (A). Neatly arrange and place the assembly on the floor apart from the operator's cab...2433
            19. Disconnect connectors (38) to (40) from air conditioner controller assembly (B)...2433
            20. Remove two bolts (41) and remove air conditioner controller assembly (B). Neatly arrange and place the assembly on the floor apart from the operator's cab...2433
            21. Remove ducts (42) and (43)...2434
            22. Disconnect connector (44)...2434
            23. Remove ducts (45) to (47)...2434
            24. Remove clamp (49)...2434
            25. Disconnect window washer hose (50)...2434
            26. Cut cable ties (52) holding window washer hose (50) and harness (51)...2434
            27. Remove cover (53)...2435
            28. Remove cover (54) and handrails from the rear of the operator's cab...2435
            29. Remove brackets (55)...2435
            30. Remove cover (56) from the side of the hydraulic tank...2435
            31. Remove panels (57) through (65) and remove eleven bolts (66), and six bolts (67)...2436
            32. Support cab (69) using lifting points (68), and remove cab (69)...2436
          Installation...2436
        Operator Cab Glass (Fixed Glass)...2437
          Removal of Side Windows (4)...2438
            1. Rear Window: Turn handle (5) to the unlocked position...2438
            2. Rear Window: Remove screw (6)...2438
            3. Rear Window: Turn handle (5) to the locked position...2438
            4. Rear Window: Remove screws (7) and (8), and remove handle assembly...2439
            5. Rear Window: Support window with suction cups. Remove screws (9) and plates (3)...2439
            6. Using seal cutter [1], cut the adhesive between broken window glass (13) and operator's cab (metal sheet) (14)...2439
            7. Remove the window glass...2439
          Installation...2440
            1. Using a knife and scraper, remove the remaining adhesive from the metal sheets (glass sticking surfaces) of the operator's cab...2440
            2. Remove oil, dust, and dirt, etc. from the sticking surfaces of cab and window with white gasoline...2440
            3. Replace any missing rubber spacers (10), locating them between weld beads. Attach with Locktite LT-1...2440
            4. Apply 5mm diameter butyl rubber bead (11) to mating surface of cab shell, spacing the bead (11) 17.5 mm from window opening (12). Join the two ends of the bead together to close the loop...2440
            5. Place window (4) inside rubber tabs (10) and press it into butyl bead (11). Use a flashlight to inspect the contacting surface between the window (4) and the butyl bead (11). Make sure that there is full contact around the entire perimeter...2441
            6. Align plates (3) with screw holes and install screws (9), hand tight. Starting at the center of each plate and simultaneously working out to both ends, torque the screws. Torque screws (9): 49 NM {5 kg}...2441
        Front Window Assembly...2442
          Removal...2442
            1. Raise the front window assembly to the ceiling and lock it...2442
            2. Remove front lower window (2)...2442
            3. Remove bracket (3) at the left corner (two screws) and bracket (4) at the right corner (two screws). [*1]...2442
            4. Release the lock of front window assembly (1)...2443
            5. Carefully slide front window assembly (1) down until the lower part of front window assembly (1) is detached from the operator's cab through the ends from which the corner brackets are removed in Step 2 (rail missing ends) and support the lower pa...2443
            6. Remove pin (9). [*2]...2444
            7. Lower front window assembly (1) completely...2444
            8. Carefully slide front window assembly (1) down to detach the top of the front window assembly from the operator's cab through the ends from which the left and right corner brackets are removed in Step 2 (rail missing ends)...2444
          Installation...2445
            1. Open and close front window assembly (1) to check that it does not interfere with the rails and that the rollers are not caught...2445
            2. If there is any problem opening or closing the front window assembly (1), loosen mounting bolts (16) of roller adjustment bracket (15) and adjust the condition of the front window, and then tighten the mounting bolts again...2445
            3. Pull up front window assembly (1) to the ceiling and lock it...2445
            4. Install right corner bracket (4)...2445
            5. Install left corner bracket (3)...2446
            6. Adjust the locks for the front window assembly (1) in its “closed” position according to the following procedure...2446
              A. Install right and left corner brackets (4) and (3) in roughly right positions so that front window glass (19) is closely attached to cab side trim seal (20)...2446
              B. Check the working condition of right and left locks (22) and (21) when opening and closing front window assembly (1)...2446
              i. Loosen lock fixing bolt (23) inside the cover, move lock (21) forward, and then tighten the bolt again. (The same applies to the right side.)...2446
              ii. After moving the lock, check the contact between front window glass (19) and cabside trim seal (20) which was checked in step 1)...2446
              iii. Repeat the work in 1] and 2] until the contact of front window glass (19) and the working condition of right and left locks (22) and (21) are both acceptable, and then tighten the mounting bolts of the right and left corner brackets (tighten to ...2446
            7. After the adjustment, splash water heavily over the front window glass and check that the water does not leak into the cab...2446
            8. Adjust the locks for front window assembly (1) in its “open” position...2446
              A. After adjusting the locks for the front window assembly (1) in its “closed” position in steps 6 and 7, pull up front window assembly (1) to the ceiling...2446
              B. Check the locks at the rear right and left of the operator's cab on the following items with front window assembly (1) in its “open” position...2447
              C. Close front window assembly (1)...2447
              D. Loosen locknuts (26) of right and left rubber stoppers (24) and move the stoppers backward so that front window assembly (1) does not touch the stoppers when it is locked in its “open” position...2447
              E. Loosen lock nut (27) at both sides, and adjust the position of striker bolt (28)...2447
              F. Adjustment of right and left rubber stoppers (24)...2448
            9. Adjust anti-vibration stoppers (30) of front window assembly (1)...2449
              A. Adjust and lock anti-vibration stopper (30) at both sides so that surface (d) of stopper (D) is in contact with surface (c) of anti- vibration stopper (30) when front window assembly (1) is pulled up...2449
            10. Check the latching efforts of front window assembly (1)...2449
        Floor Frame Assembly...2450
          Removal...2450
            1. Remove operator's cab assembly (1), referring to removal and installation of “Operator's Cab Assembly” on page 50-291...2450
            2. Collect the refrigerant (R134a) from the air conditioner circuit. [*1]...2450
            3. Remove undercover (2)...2451
            4. Loosen drain valve (3) at the bottom of the radiator to drain the coolant. (Drain hose: inside diameter f7 mm)...2451
            5. Collect the refrigerant (R134a) from the air conditioner circuit. [*1]...2451
            6. Remove cover (4)...2451
            7. Loosen drain valve (5) to drain coolant. Drain hose: inside diameter f7 mm (0.276 in)...2451
            8. Remove cover...2451
            9. Disconnect ground cables...2451
            10. Inside the riser, remove clamps (6) and (7)...2452
            11. Disconnect PPC hoses (8) from manifold block (9)...2452
            12. Disconnect cab harness (10) from extension wiring harness. Remove bracket (12) and clamp (11), and carefully lay extension harness to the side disconnect ground strap (13) from the riser...2453
            13. Disconnect cab side A/C hoses (14) from machine side A/C hoses (15). Disconnect heater hoses (16)...2454
            14. Pull PPC, A/C, and heater hoses through cylinder brackets (17)...2454
            15. Disconnect A/C drain hose (18) from the bottom of the A/C-heater unit...2454
            16. Sling and remove floor frame assembly (19)...2454
          Installation...2456
            MEMORANDUM...2458
        Air Conditioner Unit Assembly...2459
          Removal...2459
            1. Collect the refrigerant (R134a) from the air conditioner circuit. [*1]...2459
            2. Drain coolant from bottom of the radiator...2459
            3. Pull up front window assembly (1) to the ceiling and lock it...2459
            4. Remove front lower window (2)...2459
            5. Remove floor mat (3)...2459
            6. Remove box (8) (five bolts)...2460
            7. Remove box (9) (three bolts)...2460
            8. Pull up cover (12) (three bolts) to remove...2460
            9. Remove cover (13) (seven bolts)...2460
            10. Remove duct (15) (two bolts)...2460
            11. Remove cover (16) (three bolts) and bracket (41) (two bolts)...2460
            12. Remove plate (19) (two bolts)...2461
            13. Pull up lock pin (20) to unlock and remove duct (21)...2461
            14. Remove ducts (24) to (28). [*2]...2461
            15. Remove cable tie (39) of the left console wiring harness...2461
            16. Remove cable tie (40) of the floor wiring harness...2462
            17. Remove four bolts (29) and remove pump controller assembly (A). Arrange the assembly neatly and place it on the floor apart from the operators cab...2462
            18. Disconnect connectors (30) to (32) from air conditioner controller assembly (B)...2462
            19. Disconnect connectors (42) to (45)...2462
            20. Remove KOMTRAX terminal (C) (four bolts)...2462
            21. 48 inch riser: Enter riser 7 inch riser: Remove undercover (33)...2463
            22. Remove bolt (34), then disconnect tubes (35) of the air conditioner. [*3]...2463
            23. Disconnect heater core hoses (36). [*4]...2463
            24. Remove six mounting bolts (37) and remove air conditioner unit assembly (38)...2463
          Installation...2464
        Operator's Seat...2465
          Removal...2465
            1. Pull lever (1) and move operator's seat (2) backward...2465
            2. Remove two bolts (3) (with hexagonal socket) and two reinforcing plates (4), on the seat rail at the front side of operator's seat. [*1]...2465
            3. Pull lever (1) again and move operator's seat (2) forward and fold the backrest forward...2466
            4. Remove two bolts (5) (with hexagonal socket) and two reinforcing plates (7), on the seat rail at the rear side of operator's seat. [*1]...2466
            5. Disconnect connector (6) of the operator's seat...2466
            6. Remove the operator's seat...2466
          Installation...2467
            1. Using four bolts (13), install adjusters (11) and (12) loosely to frame (10). At the same time, install two wires (14) for releasing slide lock. Check that right and left locks work properly...2467
            2. Slide adjusters (11) and (12) backward and install them loosely to base (16) using two bolts (15). Place washer (17) between adjusters (11), (12) and base (16)...2467
            3. Slide adjusters (11) and (12) forward and install them loosely to base (16) using two bolts (15)...2467
            4. Slide adjusters (11) and (12) backward and forward approximately three times to make sure that they slide smoothly...2467
            5. Make sure that they are locked at the midpoint of the sliding move, then tighten four bolts (13)...2467
            6. Slide the seat assembly backward and forward approximately three times. After making sure that they are locked in the rearmost position, tighten two bolts (15) of the front side...2467
            7. Slide the seat assembly backward and forward approximately three times again. After making sure that they are locked in the rearmost position, tighten two bolts (15) of the rear side...2467
            8. If a large operating effort is required (target is maximum 15 kgf {33 lbf}), repeat adjustment and make sure right and left locks work properly at respective positions...2467
            MEMORANDUM...2468
        Seat Belt...2469
          Removal...2469
            1. Pull lever (1) and move operator's seat (2) backward...2469
            2. Remove two hexagonal socket head bolts (3) from the seat rails. [*1]...2469
            3. Pull lever (1) again and move operator's seat (2) forward and fold the backrest forward...2469
            4. Remove two hexagonal socket head bolts (4) from the seat rails. [*1]...2469
            5. Disconnect connector (5)...2469
            6. Remove operator seat (2)...2470
            7. Remove mounting bolt (6) of seat belt (7) (one on each side) to remove seat belt (7). [*2]...2470
          Installation...2470
        Front Upper Wiper Assembly...2471
          Removal...2471
            1. Check that wiper blade (1) is at stowed position (to the R.H. stay)...2471
            2. Remove six screw (2) and remove cover (3)...2471
            3. Disconnect connectors M05 (4)...2472
            4. Open cap (5), remove nut (6) and remove wiper arm (7)...2472
            5. Remove cap (8), nut (9), washer (10) and packing (11)...2472
            6. Remove six mounting bolts (12) and remove wiper motor assembly (13)...2472
          Installation...2472
            1. Install wiper motor assembly (13)...2472
            2. Install packing (11), washer (10) and tighten nut (9) to the specified torque...2473
            3. Install cap (8) and wiper arm (7)...2473
            4. Tighten nut (6) and close cap (5)...2473
            5. Reconnect connector M05 (4)...2474
            6. Install cover (3) using screws (2)...2474
              A. Check the operation of wiper arm while the front window is dry...2474
              i. Push wiper switch (16) three times consecutively, check that wiper arm (7) makes one round trip and then stows to the R.H. stay...2474
              ii. Repeat Step 1] again...2475
              iii. Push wiper switch (16), and check clearance “b” with trim seal (17). Dimension “b” is when the following dimension of wiper blade (15) reaches to the highest point...2475
              B. Check the operation of wiper arm while the front window is wet with washing fluid...2475
              i. Keep pushing window washer switch (18) for a few seconds to wet the front window throughout, then hand off the switch...2475
              ii. Check that wiper arm (7) makes two round trips and then stows to the R.H. stay...2476
              iii. Repeat Step i again...2476
              iv. Check that wiper arm (7) makes round trips in odd number and then stows to the R.H. stay...2476
              v. Keep pushing window washer switch (18) to operate the wiper, and check following...2476
              C. If any abnormality is found in the above checks, perform the installation adjustment of wiper arm in Step 3...2476
            7. Perform the subsequent installation in the reverse order of removal...2476
        Front Lower Wiper Assembly...2477
          Removal...2477
            1. Remove two screws (1) and remove cover (2)...2477
            2. Disconnect connectors M01 (3)...2477
            3. Open cap (4), remove nut (5) and remove wiper arm (6)...2478
            4. Remove cap (7), nut (8), washer (9) and packing (10)...2478
            5. Remove two mounting bolts (11) and remove wiper motor assembly (12)...2478
          Installation...2478
            1. Install wiper motor assembly (12) using bolts (11)...2478
            2. Reconnect connector M01 (3)...2479
            3. Reinstall cover (2) using bolts (1)...2479
            4. Install packing (10), washer (9), and tighten nut (8). Install cap (7) and wiper arm (6)...2479
              A. Turn the battery disconnect switch to the ON position...2480
              B. Check that the work equipment lock lever is in the LOCK position, and then start the engine...2480
      ELECTRIC SYSTEM...2481
        Engine Controller Assembly...2481
          Removal...2481
            1. Open the engine hood...2481
            2. Remove KCCV assembly (1). For details, see removal and installation of “KCCV Assembly” on page 50-175...2481
            3. Remove step (2) and two frames (3)...2481
            4. Remove control valve top cover (4)...2481
            5. Remove air cleaner top cover (5) according to the following procedure...2481
              A. Lift up air cleaner top cover (5) to disconnect it from the air inlet of air cleaner (6)...2481
              B. Lift up and remove air cleaner top cover (5) slantways so that it does not interfere with frame (A)...2481
            6. After removing the air cleaner top cover, cover the air inlet of air cleaner (6) with a vinyl sheet etc...2481
            7. Remove frame (7)...2482
            8. Remove cover (8)...2482
            9. Remove bolt (10) of wiring harness (9). [*1]...2482
            10. Disconnect wiring harness connector CE03 (12) from engine controller (12). [*2]...2482
            11. Disconnect wiring harness clamps (14) and (15)...2482
            12. Disconnect engine oil pressure switch connector (16)...2482
            13. Disconnect connector E24 (17) from wiring harness (9) according to the following procedure. [*3]...2482
              A. Slide lever (red) (19) toward you to unlock...2482
              B. Grab and pull out connector (17) while pressing locking tab (20)...2482
            14. Disconnect clamp (21) of wiring harness (9). [*1]...2483
            15. Disconnect connector ECM (26) of wiring harness (9) from engine controller (11). [*1]...2483
            16. Remove two nuts (23) and bracket (18). [*4]...2483
            17. Remove four mounting bolts (24) to remove engine controller (11). [*5]...2483
          Installation...2483
            1. Install connector ECM (26) of wiring harness (9) to engine controller (11)...2483
            2. Tighten wiring harness (9) with bolt (10)...2483
            3. Tighten connector ECM (26) with bolt (22)...2483
            4. Install wiring harness (9) with clamp (21)...2483
            1. Install connector of wiring harness (9) to the clamp of bracket (18)...2484
            2. Fit connector (17) and slide its outside portion deep until it is locked...2484
            3. Push in lever (red) (19) deep to lock connector (17)...2484
        Pump Controller Assembly...2485
          Removal...2485
            1. Pull up cover (1) (three bolts) to remove...2485
            2. Remove bolts (2) to remove plate (3)...2485
            3. Disconnect connectors (4) and (5) according to the following procedure...2486
            4. Remove four bolts (6) to remove pump controller (A)...2486
          Installation...2487
            1. Cut and remove cable tie (2)...2487
            2. Move lever (3) upward...2487
            3. Lightly press part (A) on both sides of connector cover (1) to release tabs (B)...2487
            4. Arc connector cover (1) around tab (C) to remove the cover...2487
            1. Push in right and left sliders (4) as far as they go...2487
            2. Move lever (3) on connector cover (1) from the top position to the left position (locked position) as shown in the following figure...2488
            3. Set tab (C) to the connector and place connector cover (1)...2488
            4. Put tabs (B) in to install connector cover (1)...2488
            5. Using a new cable tie (2), bind connector cover (1) and harness (6)...2488
        Machine Monitor Assembly...2489
          Removal...2489
            1. Pull up front window assembly (1) to the ceiling and lock it...2489
            2. Remove front lower window (2)...2489
            3. Remove rubber panel (3) (two bolts)...2489
            4. Remove three mounting screws of cover (4)...2489
            5. Remove connector (6) and then remove cover (4)...2490
            6. Remove duct (10) (one bolt)...2490
            7. Insert a flat-head screwdriver in slit (7) and pull it upward to remove cover (9) while releasing lug (8)...2490
            8. Loosen mounting bolts (19) of cover and duct assembly (18)...2491
            9. Remove four mounting bolts (11) of machine monitor (12)...2491
            10. Disconnect connectors (13) to (16)...2491
          Installation...2492
        Pump Swash Plate Sensor...2493
          Removal...2493
            1. Open the side cover on the left side of the machine and remove covers (1) and (2)...2493
            2. Disconnect wiring harness clamps (3) and (4)...2493
            3. Disconnect connectors (5) and (6)...2493
            4. Remove swash plate sensor mounting bolts (7) (2 pieces) to remove front pump swash plate sensor (8) and rear pump swash plate sensor (9)...2493
          Installation...2493
            MEMORANDUM...2494
        Mass Air Flow and Temperature Sensor...2495
          Removal...2495
            1. Open engine hood (1) and remove air cleaner top cover (2) according to the following procedure...2495
              A. Lift up air cleaner top cover (2) to disconnect it from the air inlet of air cleaner (3)...2495
              B. Lift up and remove air cleaner top cover (2) slantways so that it does not interfere with frame (A)...2495
              C. After removing the air cleaner top cover, cover the air inlet of air cleaner (3) with a vinyl sheet etc...2495
            2. Disconnect connector P55 (5) of mass air flow and temperature sensor (4)...2495
            3. Remove mass air flow and temperature sensor (4). [*1]...2495
          Installation...2496
        KOMTRAX Terminal Assembly...2497
          Removal...2497
            1. Remove box (1) (five bolts)...2497
            2. Remove box (2) (three bolts)...2497
            3. Remove cover (5) (three bolts)...2497
            4. Remove cover (6) (seven bolts)...2498
            5. Disconnect connectors (8) to (11)...2498
            6. Remove KOMTRAX terminal (C) (four bolts)...2498
          Installation...2498
            MEMORANDUM...2499
    60 - MAINTENANCE STANDARD...2500
      ENGINE AND COOLING SYSTEM...2503
        Engine Mounts...2503
        Cooling System...2505
          MEMORANDUM...2506
      POWER TRAIN...2507
        Swing Circle...2507
        Swing Machinery...2509
        Final Drive...2511
          Sprocket...2513
      UNDERCARRIAGE AND FRAME...2515
        Track Frame and Idler Cushion...2515
        Idler...2517
        Track and Carrier Roller...2519
        Track Shoe...2521
          MEMORANDUM...2524
        Triple Grouser Shoe...2525
        Double Grouser Shoe...2526
      HYDRAULIC SYSTEM...2527
        Hydraulic Tank...2527
        Main Pump...2528
        Control Valve...2529
          General View...2529
          Sectional View (1/5)...2531
          Sectional View (2/5)...2533
          Sectional View (3/5)...2535
          Sectional View (4/5)...2537
          Sectional View (5/5)...2539
        Swing Motor...2541
        Travel Motor...2545
        PPC Valve...2549
          Work Equipment and Swing PPC Valve...2549
          Travel PPC Valve...2552
          EPC Valve...2555
        Solenoid Valve...2557
          MEMORANDUM...2559
        Center Swivel Joint...2560
      WORK EQUIPMENT...2561
        Dimensions of Components...2561
          Road Builder...2561
        Dimensions of Arm...2566
          Log Loader...2566
        Dimensions of Arm...2570
          Road Builder...2570
        Dimensions of Bucket...2573
          Road Builder...2573
        Boom Cylinder...2576
          Road Builder...2576
        Boom Cylinder...2577
          Log Loader...2577
        Arm Cylinder...2578
          Road Builder...2578
        Arm Cylinder...2579
          Log Loader...2579
        Bucket Cylinder...2580
          Road Builder...2580
        Heel Cylinder...2581
          Log Loader...2581
    80 - AIR CONDITIONER...2582
      AIR CONDITIONER...2585
        Precautions for Refrigerant...2585
        Air Conditioner Component...2586
          1. Compressor...2587
          2. Condenser...2587
          3. Receiver drier...2587
          4. Hot water piping...2587
          5. Hot water return piping...2587
          6. Refrigerant piping...2587
          7. Dual pressure switch...2587
          8. Sight glass...2587
          9. Air conditioner controller...2587
          10. Air conditioner unit...2587
          11. Recirculation air filter...2587
          12. Fresh air filter...2587
          13. Machine monitor...2587
          14. Sunlight sensor...2587
        Structure and Function of Refrigeration System...2589
        Overview of Refrigeration System...2590
        Air Conditioner Unit...2592
          1. Evaporator...2593
          2. Heater core...2593
          3. Expansion valve...2593
          4. Blower fan and blower motor...2593
          5. Air mix servomotor...2593
          6. Air mix door...2593
          7. Vent (mode) changeover servomotor...2593
          8. Rear door...2593
          9. Foot door...2593
          10. Defroster door...2593
          11. FRESH/RECIRC air changeover servo motor...2593
          12. FRESH/RECIRC air changeover door...2593
          13. Power transistor...2593
          14. Evaporator temperature sensor...2593
          15. Inside air temperature sensor...2593
          Function...2593
          Functions of Major Components...2594
        Dual Pressure Switch...2598
        Air Conditioner Controller...2598
        Air Conditioner Compressor...2599
          1. Pulley...2599
          2. Magnetic clutch...2599
          3. Relief valve...2599
        Air Conditioner Condenser...2600
        Receiver Drier...2601
        Sunlight Sensor...2602
          1. Connector...2602
          2. Sensor...2602
        Outside Air Temperature Sensor...2602
          1. Connector...2602
          2. Sensor...2602
          MEMORANDUM...2603
        Procedure for Testing and Troubleshooting...2604
          1. After basic check, find the troubled section according to the detected trouble of the air conditioner...2604
          2. Narrow down the sections with the self-diagnosis function (See ‘Testing with Self-Diagnosis Function” on page 80-35)...2604
          3. After finding out the troubled section, inspect the component parts in that section and repair the troubled part...2604
          Basic Inspection and Troubleshooting Sequence...2604
        Air Conditioner Circuit Diagram and Arrangement of Connector Pins...2606
        System Diagram...2607
        Air Conditioner Controller Input and Output Signals...2608
          1. Performing CAN communication with the machine monitor, the air conditioner controller controls the air conditioner unit by inputting switches associated with air conditioning...2609
          2. The air conditioner controller controls three servomotors located inside the air conditioner unit in order to adjust the temperature (air mix), perform vent (mode) changeover, and perform FRESH/RECIRC air changeover...2609
          3. The air conditioner controller controls the ON/OFF condition of the compressor clutch relay (i.e., a switch for activating the compressor)...2609
          4. The air conditioner controller controls the air flow volume using the power transistor...2609
          5. The air conditioner controller detects the evaporator temperature using the evaporator temperature sensor. ...2609
          6. In order to prevent freezing of the evaporator, the air conditioner controller controls the compressor by turning the compressor clutch relay ON and OFF...2609
          7. When performing automatic air conditioning, the air conditioner controller controls the inside air temperature to the set temperature and adjusts the air flow according to the data from the sunlight sensor, the outside air temperature sensor, and ...2609
          8. It has the self-diagnosis function. If a failure is detected, it notifies the failure to the machine monitor via CAN communication. The failure is displayed as failure code [879***] on “Electrical Systems” screen of the machine monitor...2609
        Parts and Connectors Layout...2610
        Layout of Air Conditioner Related Parts and Connectors...2611
          1. Each fuse in fuse box F01: Open the cover of the fuse box at the right rear of the operator's cab...2611
          2. Air conditioner controller: *1...2611
          3. Air conditioner unit...2611
          4. Sunlight sensor...2612
          5. Machine monitor...2612
          6. Dual pressure switch...2612
          7. Air conditioner compressor...2612
          8. Outside (air) temperature sensor...2613
        Testing Air Leakage (Duct)...2613
          1. Lift front window assembly (1) to the ceiling and lock it...2613
          2. Remove front lower window (2)...2613
          3. Remove floor mat (3)...2613
          4. Remove cover (4) first, and then remove cover (5)...2613
          5. Remove fuel spray prevention cap (6)...2613
          6. Remove cap (7-1)...2613
          7. Remove fuel cover (7)...2613
          8. Remove drink box (8) (five bolts)...2614
          9. Remove magazine box (9) (three bolts)...2614
          10. Pull up cover (12) (three bolts) to remove...2614
          11. Remove cover (13) (seven bolts)...2614
          12. Check the following ducts and pins for disconnection...2614
        Testing with Self-Diagnosis Function...2616
        How to Enter Air Conditioner “Electrical Systems” Screen in Service Mode of the Machine Monitor...2617
          1. On the normal operation screen, while pressing number key [4], press [1], [2], and [3] in this order...2617
          2. On the service menu screen, press [F3] twice, and then select “03 Abnormality Record”...2617
          3. Press [F6] to confirm...2617
          4. On the Abnormality Record screen, press [F3] once, and then select “02 Electrical Systems”...2617
          5. Press [F6] to confirm...2617
        Testing Vent (Mode) Changeover...2619
          1. Remove drink box (1) (five bolts)...2619
          2. Remove magazine box (2) (three bolts)...2619
          3. Remove cover (5) (three bolts)...2619
          4. Remove cover (6) (seven bolts)...2619
          5. Remove ducts (8) and (9)...2620
          6. Turn the battery disconnect switch to the “ON“ position...2620
          7. Start the engine and turn the air conditioner power “ON“...2620
          8. Operate the vent changeover switch on the machine monitor...2620
          9. Check the opening/closing operation of rear door (11) and defroster door (12) of air conditioner unit (10)...2620
          10. After finishing the inspection, turn the starting switch to the OFF position...2620
        Testing FRESH/RECIRC Air Changeover...2621
          1. Open outside air filter cover (1) and remove outside air filter (2)...2621
          2. Start the engine and turn the air conditioner power “ON“...2621
          3. Operate the FRESH/RECIRC air selector switch on the machine monitor...2621
          4. Check the opening/closing operation of FRESH/RECIRC air changeover rear door (3) through the fresh air inlet on the left side of the cab...2621
          5. After finishing the inspection, turn the starting switch to the OFF position...2621
        Testing Sunlight Sensor...2622
          1. Remove the machine monitor cover. For details, See ‘Testing Air Leakage (Duct)” on page 80-32, Steps 6 and 7...2622
          2. Check connector P31 at the rear of the sunlight sensor. (Check whether the connector is coming off.)...2622
          3. Disconnect connector P31, remove the sunlight sensor, and measure the voltage between the terminals on the sensor side using a circuit tester in voltage range...2622
        Testing (Dual) Pressure Switch for Refrigerant...2623
          1. Open riser door (48 inch riser) or remove rear panel access (7 inch riser)...2623
          2. Disconnect the dual pressure switch connector P17...2623
          3. Ensure that the resistance between the switch-side terminals from connector P17 is shorted (ON). (If not shorted (OFF), the dual pressure switch will detect a refrigerant pressure abnormality.)...2623
        Testing Relay...2624
          1. Check the contact of the connector R21. (Check whether the connector has been partially disconnected.)...2624
          2. Turn the starting switch ON (do not start the engine), turn the main power of the air conditioner ON, and turn the air conditioner switch. If the compressor relay is normal, it is turned ON. Check whether its clicks...2624
            A. When the evaporator temperature is 3° C or below (depending on the input voltage from the evaporator temperature sensor)...2624
            B. When the pressure switch detects abnormality (it is turned OFF)...2624
          1. The coil resistance between terminals (1) and (2) is 300 – 500 W...2624
          2. While voltage (DC 20 - 30 V) is not applied between terminals (1) (+) and (2), terminals (3) and (4) are connected...2624
          3. While voltage (DC 20 - 30 V) is applied between terminals (1) (+) and (2), terminals (3) and (5) are connected...2624
        Troubleshooting Chart 1...2625
          1. Cooling trouble...2625
          2. Heating trouble...2625
        Troubleshooting Chart 2...2626
          1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow setting...2626
          2. During cooling, the blower fan motor is normal but the flow of air is very light...2626
          3. Pressure abnormality (high-pressure/low-pressure) during cooling...2626
          4. During cooling, the compressor will not operate smoothly, or at all...2627
          5. During heating, blower fan motor is normal but air flow alone is insufficient...2627
          6. Engine coolant temperature or volume abnormalities during heating or cooling...2627
          7. Fan speed abnormalities during cooling...2627
          8. Other abnormalities...2628
        Information Mentioned in Troubleshooting Table...2629
          Information in Troubleshooting Table...2629
        Failure Code List Related to Air Conditioner...2630
        879AKA - A/C Inner Sensor Open Circuit...2631
        879AKB - A/C Inner Sensor Short Circuit...2631
        879BKA - A/C Outer Sensor Open Circuit...2632
          1. Turn starting switch to “OFF” position...2632
          2. Disconnect connector AC01...2632
          1 Turn starting switch to the “OFF” position...2632
          2 Disconnect connectors P18 and AC01...2632
        879BKB - A/C Outer Sensor Short Circuit...2634
          1. Turn starting switch to “OFF” position...2634
          2. Disconnect connector AC01...2634
          1 Turn starting switch to the “OFF” position...2634
          2 Disconnect connectors P18 and AC01...2634
          1. Turn starting switch to “OFF” position...2634
          2. Disconnect connectors P18 and AC01...2634
        879CKA - Ventilating Sensor Open Circuit...2636
        879CKB - Ventilating Sensor Short Circuit...2637
        879DKZ - Sunlight Sensor Open or Short Circuit...2638
          1. See “Testing Sunlight Sensor” on page 80-41...2638
          1 Turn starting switch to the “OFF” position...2638
          2 Disconnect connectors P31...2638
        879EMC - Ventilation Damper Abnormality...2640
        879FMC - Air Mix Damper Abnormality...2641
        879GKX - Refrigerant Abnormality...2642
          1. See “Testing (Dual) Pressure Switch for Refrigerant”...2642
          1 Turn starting switch to the “OFF” position...2642
          2 Disconnect connector AC01 and AC05...2642
        A-1 Troubleshooting for Power Supply System (The Air Conditioner Does Not Operate)...2644
        A-2 Troubleshooting of Compressor System (Air is Not Cooled)...2646
          1 Turn starting switch to the “OFF” position...2646
          2 Disconnect the connector AC03 from the air conditioner compressor and connect a T-adapter to the male side...2646
          MEMORANDUM...2649
        A-3 Troubleshooting of Blower Motor System (Air Does Not Come Out or Air Flow is Normal)...2650
        A-4 Troubleshooting for FRESH/RECIRC Air Changeover...2652
        Troubleshooting with Gauge Pressure...2654
          [Measurement Condition for Pressure]...2654
        Testing Refrigerant Pressure...2657
          Check...2658
            1. Close the high-pressure valve (6) and low-pressure valve (7) of gauge manifold (1)...2658
            2. Connect red high-pressure charging hose (2) to the HI side of gauge manifold (1) and blue low-pressure charging hose (3) to the LO side of the gauge manifold...2658
            3. Connect quick joint (4) to red high-pressure charging hose (2)...2658
            4. Connect quick joint (5) to blue low-pressure charging hose (3)...2658
            5. Connect quick joint (4) to service valve (8) of the high-pressure refrigerant piping and connect quick joint (5) to service valve (9) of the low-pressure refrigerant piping...2658
            6. Check the pressures indicated on high-pressure side (HI) and low-pressure side (LO) of gauge manifold (1)...2658
        Precautions for Disconnecting and Connecting Refrigerant Piping...2660
          Disconnection...2660
          Connection...2660
        Tightening Torque for Joint Portion of Refrigerant Piping...2661
          1. Engine...2661
          2. Compressor...2661
          3. Condenser...2661
          4. Receiver drier...2661
          5. Air conditioner unit...2661
        Handling of Compressor Oil...2662
          Oil Level Control of Compressor...2662
          Refilling of Compressor Oil...2662
            1. Prepare an oil container and drain oil from the old compressor...2663
            2. Measure the quantity of the drained oil with a measuring cylinder, and note the quantity...2663
            3. Drain below-mentioned quantity of oil from the new compressor. Quantity to be drained = 180 cc - “Noted quantity” Example: If 30 cc was drained from the removed compressor, the amount to be drained from the new compressor would be 150 cc (i.e...2663
            MEMORANDUM...2665
    90 DIAGRAMS AND SCHEMATICS...2666
      HYDRAULIC CIRCUIT DIAGRAM...2667
      Symbols in Hydraulic Circuit Diagram...2667
      Hydraulic Circuit Diagram (1/2)...2670
      Hydraulic Circuit Diagram (2/2)...2671
      ELECTRICAL SYSTEM...2672
        Symbols in Electrical Circuit Diagrams...2672
        Air Conditioner Electrical Circuit Diagram...2675
        Electrical Circuit Diagram - Log Loader Unique...2676
        Electrical Circuit Diagram (1/6)...2677
        Electrical Circuit Diagram (2/6)...2678
        Electrical Circuit Diagram (3/6)...2679
        Electrical Circuit Diagram (4/6)...2680
        Electrical Circuit Diagram (5/6)...2681
        Electrical Circuit Diagram (6/6)...2682
        Cab Diagram...2684
        Connector List and Stereogram...2684
          Chassis...2684
          Operator’s Compartment...2685
          Cab...2686
          Engine Compartment...2687

Komatsu Log Loader/Road Builder Excavator PC390LL Repair Service Manuals