Komatsu Hydraulic Excavator PC138USLC-11 Shop Manual SEN06589-16 PDF
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Komatsu Hydraulic Excavator PC138USLC-11 Shop Manual SEN06589-16 – PDF DOWNLOAD
SERIAL NUMBERS 50001 and up
Description
Komatsu Hydraulic Excavator PC138USLC-11 Shop Manual SEN06589-16 – PDF DOWNLOAD
FILE DETAILS:
Komatsu Hydraulic Excavator PC138USLC-11 Shop Manual SEN06589-16 – PDF DOWNLOAD
Language : English
Pages :3360
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu Hydraulic Excavator PC138USLC-11 Shop Manual SEN06589-16 – PDF DOWNLOAD
SERIAL NUMBERS 50001 and up
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the
same as the terminology in the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effectively.
TABLE OF CONTENTS:
Komatsu Hydraulic Excavator PC138USLC-11 Shop Manual SEN06589-16 – PDF DOWNLOAD
SERIAL NUMBERS 50001 and up
Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 22
Foreword, Safety, Basic Information 28
How to Read the Shop Manual 28
Safety Notice for Operation 30
Precautions to Prevent Fire 38
Procedures If Fire Occurs 40
Precautions When You Discard Waste Materials 41
Procedures for Exhaust Gas Regulations 42
Precautions for DEF 43
General Character and Precautions for Handling 43
Precautions When You Add 43
Precautions for Storage 43
Precautions for Fire Hazard and Leakage 43
Other Precautions 43
Store DEF 44
Precautions When You Handle Hydraulic Equipment 45
Precautions When You Disconnect and Connect Pipings 48
Precautions When You Handle Electrical Equipment 55
Precautions When You Handle Fuel System Equipment 57
Precautions When You Handle Intake System Equipment 58
Practical Use of KOMTRAX 59
Disconnect and Connect Push-Pull Type Coupler 60
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 60
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 61
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 62
Precautions for Disconnection and Connection of Connectors 64
Disconnect and Connect Deutsch Connector 68
How to Disconnect and Connect Slide Lock Type Connector 69
Disconnect and Connect Connector with Lock to Pull 71
Disconnect and Connect Connector with Lock to Push 72
Disconnect and Connect Connector with Housing to Rotate 74
How to Read the Codes for Electric Cable 75
Explanation of Terms for Maintenance Standard 79
Standard Tightening Torque Table 82
Conversion Table 89
01 Specification 95
Table of Contents 96
Abbreviation List 97
Specifications 103
Specification Drawing 103
Specification Drawing PC138USLC-11 103
Working Range Drawings 105
Working Range Drawings PC138USLC-11 105
Specifications 106
Specifications PC138USLC-11 106
Weight Table 110
Weight Table PC138USLC-11 110
Table of Fuel, Coolant, and Lubricants 112
10 Structure and Function 113
Table of Contents 114
Abbreviation List 117
Urea SCR System 123
Layout Drawing of Urea SCR System 123
Urea SCR System Diagram 125
Function of Urea SCR System 126
Function of DEF System (Applicable Machine: 50001 to 62010) 126
Function of DEF System (Serial No:62011 and up) 128
Inducement Strategy 130
Function that Calls for Attention of the Operator for Urea SCR System to Stay Functional 143
Component Parts of Urea SCR System 150
DEF Mixing Tube 150
SCR Assembly 151
DEF Tank 153
DEF Pump 155
DEF Injector 156
DEF Hose 157
DEF Tank Heating Valve 158
Boot-up System 159
Layout Drawing of Boot-Up System (Serial No: 50001 to 62010) 159
Layout Drawing of Boot-Up System (Serial No:62011 and up) 160
System Operating Lamp System 161
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 161
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 161
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 161
Function of System Operating Lamp System (Machine with Gateway Function Controller) (Serial No: 50001 to 62010) 162
Function of System Operating Lamp System (Machine with Gateway Function Controller) (Serial No: 62011 and Up) 163
Battery Disconnect Switch 164
Function of Battery Disconnect Switch (Applicable Machine: 50001 to 62010) 164
Function of Battery Disconnect Switch (Serial No:62011 and up) 164
Engine System 166
Layout Drawing of Engine System 166
Engine Control System 168
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) 168
System Diagram of Engine Control System (Machine with Gateway Function Controller) 169
Function of Engine Control System (Machine with KOMTRAX Terminal) 169
Function of Engine Control System (Machine with Gateway Function Controller) 171
Auto-Deceleration System 174
System Diagram of Auto-Deceleration System 174
Function of Auto-Deceleration System 174
Operation of Auto-Deceleration System 175
Engine Automatic Warm-up System 176
System Diagram of Engine Automatic Warm-up System 176
Function of Engine Automatic Warm-up System 177
Overheat Prevention System 178
Function of Overheat Prevention System 178
Turbocharger Protection System 180
Function of Turbocharger Protection System 180
Automatic Idle Stop System 181
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 181
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) 181
Function of Automatic Idle Stop System 182
Component Parts of Engine System 185
PTO 185
Variable Flow Turbocharger 186
EGR System 189
EGR Valve 192
EGR Cooler 195
KCCV System 197
KCCV Ventilator 200
Exhaust Throttle Valve 202
KDOC 203
Cooling System 205
Layout Drawing of Cooling System 205
Specifications of Cooling System 206
Control System 207
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 207
Layout Drawing of Control System (Machine with Gateway Function Controller) 209
Machine Monitor System 211
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 211
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 212
Function of Machine Monitor System 213
KomVision System 214
Layout Drawing of KomVision System 214
System Diagram of KomVision System 216
Function of KomVision System 216
KOMTRAX System 218
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 218
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 218
Function of KOMTRAX System 219
Component Parts of Control System 220
Machine Monitor 220
KomVision Controller 237
KomVision Camera 241
KOMTRAX Terminal 242
Gateway Function Controller 244
Communication Terminal 247
Pump Controller 249
Resistor for PC-EPC Valve 254
CAN Terminating Resistor 255
Engine Controller 256
Fuel Control Dial 263
Hydraulic System 265
Layout Drawing of Hydraulic System 265
CLSS 267
Structure of CLSS 267
Function of CLSS 268
Engine and Pump Combined Control System 270
Engine and Pump Combined Control System Diagram 270
Function of Engine and Pump Combined Control System 271
Component Parts of Hydraulic System 275
Hydraulic Tank 275
Main Pump 277
Control Valve 304
Work Equipment System 364
Layout Drawing of Work Equipment System 364
Structure of Valve Control 367
PPC Lock System 368
System Diagram of PPC Lock 368
Function of PPC Lock System 368
Work Equipment and Travel Automatic Lock System 369
System Diagram of Lock Lever Automatic Lock System 369
Function of Work Equipment and Travel Automatic Lock System 369
Operation of Lock Lever Automatic Lock System 370
Attachment Oil Flow Adjuster System 371
Attachment Oil Flow Adjuster System Diagram 371
Function of Attachment Oil Flow Adjuster System 372
Tool Control System 373
Tool Control System Diagram 373
Component Parts of Work Equipment System 375
Work Equipment and Swing PPC Valve 375
1st-Line Attachment PPC Valve (with EPC Valve) 380
Blade PPC Valve 388
Solenoid Valve 390
Variable Back Pressure Solenoid Valve 395
Multi-Control Valve 396
Arm Dump Quick Return Valve 397
1st-Line Attachment Variable Relief Valve 399
Pilot Circuit Accumulator 402
Attachment Circuit Accumulator (For Low Pressure Circuit) 403
Swing System 404
Layout Drawing of Swing System 404
Swing Control System Diagram 406
Function of Swing Control System 407
Component Parts of Swing System 409
Swing Motor 409
Swing Machinery 419
Swing Circle 421
Travel System 422
Layout Drawing of Travel System 422
System Diagram of Travel Control System 424
Function of Travel Control System 425
Component Parts of Travel System 428
Travel Motor 428
Travel PPC Valve 441
Center Swivel Joint 445
Undercarriage and Frame 447
Layout Drawing of Undercarriage 447
Specifications of Undercarriage 447
Idler Cushion 448
Structure of Idler Cushion 448
Specifications of Idler Cushion 448
Work Equipment 449
Structure of Work Equipment 449
Function of Work Equipment 450
Work Equipment Clearance Adjustment Shim 451
Function of Work Equipment Clearance Adjustment Shim 451
Bucket Clearance Adjustment Shim 452
Function of Bucket Clearance Adjustment Shim 452
CAB Related Parts 453
ROPS CAB 453
Structure of ROPS CAB (Machine with KOMTRAX Terminal) 453
Structure of ROPS CAB (Machine with Gateway Function Controller) 454
Function of ROPS CAB 454
CAB Mount 455
Structure of CAB Mount 455
Function of CAB Mount 455
Remove Wiring Harness Out of Cab 457
20 Standard Value Table 459
Table of Contents 460
Abbreviation List 461
Standard Value Table for Engine 467
Standard Value Table for Engine: PC138USLC-11 467
Standard Value Table for Machine 471
Standard Value Table for Machine: PC138USLC-11 471
Machine Posture and Procedures to Measure Performance 485
30 Testing and Adjusting 489
Table of Contents 490
Precautions Before Work 493
Abbreviation List 494
Related Information on Testing and Adjusting 500
Differences In Machine Monitor Symbols 500
Tools for Testing and Adjusting 501
Sketch of Tools for Testing and Adjusting 508
Engine and Cooling System 510
Examine Engine Speed 510
How to Examine Engine Speed 510
Examine Exhaust Gas Color 513
How to Examine Exhaust Gas Color with the Handy Smoke Checker 513
How to Examine Exhaust Gas Color with Smoke Meter 514
Examine the Clearance of Exhaust Throttle Valve 515
Measure Clearance of the Exhaust Throttle Valve 515
Examine and Adjust Valve Clearance 518
Check Valve Clearance 518
Adjust Valve Clearance 519
Examine Compression Pressure 520
How to Examine Compression Pressure 520
Examine Blowby Pressure 523
How to Examine Blowby Pressure 523
Examine Engine Oil Pressure 525
How to Examine Engine Oil Pressure 525
Visual Check Inside of EGR Valve 527
How to do the Visual Check Inside of EGR Valve 527
Clean Inside of EGR Valve 529
How to Clean Inside of EGR Valve 529
Examine Fuel Pressure 532
How to Examine Fuel Pressure 532
Examine Fuel Return Rate and Leakage 534
How to Examine Fuel Return Rate and Leakage 535
Bleed Air from Fuel System 538
How to Bleed Air from Fuel System 538
Examine Fuel Circuit for Leakage 540
How to Examine Fuel System for Leakage 540
Handle Cylinder Cut-out Mode Operation 542
Handle No-Injection Cranking Operation 543
Examine and Adjust Air Conditioner Compressor Belt Tension 544
How to Examine Air Conditioner Compressor Belt 544
How to Adjust Air Conditioner Compressor Belt 544
Examine Alternator Belt 546
How to Examine Alternator Belt 546
Examine Automatic Tensioner 547
How to Examine Automatic Tensioner 547
Examine Cooling Fan Speed 549
How to Examine Cooling Fan Speed 549
Write Injector Compensation Value to Engine Controller 550
Write Injector Compensation Value 550
Examine SCR Related Functions 556
Examine DEF Pump Raised Pressure 560
Examine Injection Volume from DEF Injector 563
Examine DEF Line Heater Relay 1 568
Examine DEF Line Heater Relay 2 572
Examine DEF Pump Heater Relay 575
Examine DEF Tank Heater Valve 579
Examine SCR Denitration Efficiency 583
Clean DEF Tank 586
How to Clean DEF Tank 586
Bleed Air from Coolant Circuit of DEF Tank 591
How to Bleed Air from Coolant Circuit of DEF Tank 591
Clean DEF Pump 593
How to Clean DEF Pump 593
Power Train 599
Examine Swing Circle Bearing Clearance 599
How to Examine Swing Circle Bearing Clearance 599
Undercarriage and Frame 600
Examine and Adjust Track Tension 600
How to Examine Track Tension 600
How to Adjust Track Tension 600
Hydraulic System 602
Release Remained Pressure in Hydraulic Circuit 602
How to Release Remained Pressure from Hydraulic Tank 602
How to Release Remained Pressure in Hydraulic Cylinder Circuit 602
How to Release Remained Pressure from Swing Motor Circuit 604
How to Release Remained Pressure from Travel Motor Circuit 604
Examine and Adjust Oil Pressure in Work Equipment, Swing, Travel, and Blade Circuits 605
How to Examine Oil Pressure in Work Equipment, Swing, Travel, and Blade Circuits 605
How to Adjust Oil Pressure in Work Equipment, Swing, Travel, and Blade Circuits 611
Examine Oil Pressure of Control Circuit 614
Examine Oil Pressure in Control Circuit 614
Examine and adjust oil pressure in pump PC control circuit 616
How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 616
How to Examine PC-EPC Valve Outlet Pressure 617
How to Adjust Oil Pressure in Pump PC Control Circuit 618
Examine and Adjust Oil Pressure in Pump LS Control Circuit 620
Examine LS Differential Pressure with Machine Monitor 620
Examine LS Differential Pressure by Testing Tool 622
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 623
Adjust LS Valve 625
Examine Outlet Pressure of Solenoid Valve 626
How to Examine Outlet Pressure of Solenoid Valve 626
Operating Condition of Solenoid Valve 627
How to Examine Outlet Pressure in Variable Back Pressure Solenoid Valve 628
Operating Condition of Variable Back Pressure Solenoid Valve 630
Examine PPC Valve Outlet Pressure 631
Examine Outlet Pressure in PPC Valve 631
Examine Attachment Circuit Oil Pressure 633
How to Examine Attachment Circuit Oil Pressure 633
Adjust Play of Work Equipment and Swing PPC Valves 634
How to Adjust Play of Work Equipment and Swing PPC Valves 634
Examine and Adjust Travel Deviation 635
How to Examine Travel Deviation 635
Adjust Travel Deviation 635
Examine Parts Which Cause Hydraulic Drift of Work Equipment 638
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 638
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 638
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 639
Examine Oil Leakage 640
How to Examine Oil Leakage from Boom Cylinder 640
How to Examine Oil Leakage from Arm Cylinder 641
How to Examine Oil Leakage from Bucket Cylinder 641
How to Examine Oil Leakage from Blade Cylinder 642
How to Examine Oil Leakage from Swing Motor 642
How to Examine Oil Leakage from Travel Motor 643
Bleed Air from Hydraulic System 644
How to Bleed Air from Hydraulic System 645
CAB Related Parts 648
Examine CAB Tipping Stopper 648
How to Examine Cab Tipping Stopper 648
How to Adjust Mirrors 649
Procedure to Adjust Machine Left Front Mirror (A) 649
Procedure to Adjust Machine Rear Mirror (B) 649
How to Examine and Adjust Slide Door 651
How to Examine and Adjust Slide Door When It is Closed and Locked 651
How to Examine and Adjust Slide Door When It is Open and Locked 663
Electrical System 676
Set and Operate Machine Monitor 676
Operator Mode 680
Function to Show Technician Identification Status Screen 680
Function to Show Operator Identification Input Screen 680
Examine Function by LCD (Liquid Crystal Display) 681
Examine Function of Service Meter 681
Usage Limitation and Maintenance Password Change Function 681
Service Mode 685
How to Operate Service Mode 685
How to See Pre-defined Monitoring Information 687
How to Examine Self-Define Monitor Information 693
Abnormality Record Menu 705
How to See Maintenance Record 709
Maintenance Mode Setting 710
Set Phone Number Entry 713
Default Menu 715
Diagnostic Tests Menu 727
Adjustment Menu 736
No-Injection Cranking Operation 750
KOMTRAX Settings Menu 752
Show Service Message 756
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 758
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 763
Start Up KOMTRAX System (Machine with Gateway Function Controller) 765
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 771
Adjust Rearview Camera Angle 773
How to Adjust Rearview Camera Angle 773
Adjust KomVision Camera Angle 776
How to Adjust KomVision Camera Angle 777
Adjust KomVision Related Function 779
Setting of KomVision (Main Setting) 780
Setting of KomVision (Camera Setting) 783
Setting of KomVision (Camera Calibration) 785
Set Region of Bluetooth(R) Compatible Radio 798
Set Region of Bluetooth(R) Compatible Radio 798
Handle Voltage Circuit of Engine Controller 800
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 801
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) 802
Examine Diodes 803
Examine Diodes by Digital Tester 803
How to Examine Diodes by Analog Tester 803
Pm Clinic 804
Pm Clinic Service 804
Pm Clinic Check Sheet: PC138USLC-11 805
40 Troubleshooting 815
Table of Contents 816
Precautions Before Work 827
Abbreviation List 828
Related Information to Troubleshooting 834
General Troubleshooting Points 834
Troubleshooting Points for Urea SCR System 835
Sequence of Events in Troubleshooting 847
Checks Before Troubleshooting 849
Inspection Procedure Before Troubleshooting 851
Walk-Around Check 851
Test in Accordance with Testing Procedure 853
Examine Fuel Level and Type 853
Examine Fuel Prefilter 854
Examine Water Separator, Drain Water and Sediment 854
How to Replace Fuel Prefilter Cartridge 855
Examine Fuel Main Filter 856
Examine Engine Oil Level (Oil Quantity in Oil Pan) 857
Examine Oil Level in PTO Gear Case 858
Examine Coolant Level (Reservoir Tank) 859
Examine Air Cleaner Clogging 860
Clean Outer Element 860
Replace Element 863
Examine Hydraulic Oil Level 864
Examine Hydraulic Oil Strainer 865
Examine Hydraulic Oil Filter 866
Examine Oil Level in Swing Machinery Case 867
Examine Oil Level in Final Drive Case 868
Bleed Air from Fuel System 868
Bleed Air from Hydraulic System 868
How to Examine Electric Equipment 868
Preparation for Troubleshooting of Electrical System 874
Preparation for Troubleshooting of Machine Monitor 874
Preparation for Troubleshooting of Engine Controller 874
Preparation for Troubleshooting of Pump Controller 875
Preparation for Troubleshooting of KOMTRAX Terminal 875
Preparation for Troubleshooting of Gateway Function Controller 876
How to Disconnect and Connect Connector with a Special Lock 877
Procedure for Troubleshooting 881
Symptom and Troubleshooting Numbers 884
Information Shown in Troubleshooting Table 889
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 891
Connector List and Layout (Machine with KOMTRAX Terminal) 894
Connector List and Layout (Machine with Gateway Function Controller) 907
Connector Contact Connection Table 920
T-Branch Box and T-Branch Adapter Table 960
Fuse Location Table 966
Precautions When You Replace KDOC 968
Failure Code Table 969
Troubleshooting by Failure Code (Display of Code) 986
Failure Code [879AKA] 986
Failure Code [879AKB] 988
Failure Code [879BKA] 990
Failure Code [879BKB] 992
Failure Code [879CKA] 994
Failure Code [879CKB] 995
Failure Code [879DKZ] 996
Failure Code [879EMC] 999
Failure Code [879FMC]1000
Failure Code [879GKX]1001
Failure Code [989L00]1003
Failure Code [989M00]1004
Failure Code [989N00]1005
Failure Code [A1U0N3]1006
Failure Code [A1U0N4]1009
Failure Code [A900FR]1012
Failure Code [A900N6]1013
Failure Code [A900NY]1014
Failure Code [AA10NX]1015
Failure Code [AB00KE]1017
Failure Code [AQ10MB]1020
Failure Code [AQ10N3]1022
Failure Code [AS00R2]1024
Failure Code [AS00R3]1025
Failure Code [AS00R4]1026
Failure Code [AS00R5]1027
Failure Code [AS00R6]1028
Failure Code [AS00ZK]1029
Failure Code [AS10KM]1030
Failure Code [AS10NR]1031
Failure Code [AS10NT]1033
Failure Code [AU10QA]1034
Failure Code [B@BAZG]1035
Failure Code [B@BAZK]1036
Failure Code [B@BCNS]1038
Failure Code [B@HANS]1039
Failure Code [CA115]1041
Failure Code [CA122]1043
Failure Code [CA123]1047
Failure Code [CA131]1051
Failure Code [CA132]1054
Failure Code [CA144]1057
Failure Code [CA145]1061
Failure Code [CA153]1064
Failure Code [CA154]1068
Failure Code [CA187]1072
Failure Code [CA221]1074
Failure Code [CA222]1078
Failure Code [CA227]1081
Failure Code [CA234]1082
Failure Code [CA238]1084
Failure Code [CA239]1086
Failure Code [CA249]1088
Failure Code [CA256]1091
Failure Code [CA271]1094
Failure Code [CA272]1097
Failure Code [CA322]1099
Failure Code [CA324]1103
Failure Code [CA331]1107
Failure Code [CA332]1111
Failure Code [CA343]1115
Failure Code [CA351]1116
Failure Code [CA352]1117
Failure Code [CA356]1120
Failure Code [CA357]1123
Failure Code [CA386]1127
Failure Code [CA435]1128
Failure Code [CA441]1130
Failure Code [CA442]1133
Failure Code [CA449]1134
Failure Code [CA451]1135
Failure Code [CA452]1138
Failure Code [CA515]1141
Failure Code [CA516]1143
Failure Code [CA553]1146
Failure Code [CA555]1148
Failure Code [CA556]1150
Failure Code [CA559]1152
Failure Code [CA689]1158
Failure Code [CA691]1163
Failure Code [CA692]1166
Failure Code [CA697]1169
Failure Code [CA698]1170
Failure Code [CA731]1171
Failure Code [CA778]1174
Failure Code [CA1117]1181
Failure Code [CA1664]1183
Failure Code [CA1669]1186
Failure Code [CA1673]1188
Failure Code [CA1677]1190
Failure Code [CA1678]1192
Failure Code [CA1682]1194
Failure Code [CA1683]1202
Failure Code [CA1684]1205
Failure Code [CA1686]1208
Failure Code [CA1691]1210
Failure Code [CA1694]1214
Failure Code [CA1695]1219
Failure Code [CA1696]1220
Failure Code [CA1712]1223
Failure Code [CA1713]1227
Failure Code [CA1714]1230
Failure Code [CA1715]1232
Failure Code [CA1776]1234
Failure Code [CA1777]1237
Failure Code [CA1843]1241
Failure Code [CA1844]1244
Failure Code [CA1885]1248
Failure Code [CA1887]1251
Failure Code [CA1896]1254
Failure Code [CA1938]1258
Failure Code [CA1942]1261
Failure Code [CA1961]1263
Failure Code [CA2185]1264
Failure Code [CA2186]1266
Failure Code [CA2249]1268
Failure Code [CA2272]1269
Failure Code [CA2311]1273
Failure Code [CA2349]1274
Failure Code [CA2353]1277
Failure Code [CA2357]1280
Failure Code [CA2636]1282
Failure Code [CA2637]1286
Failure Code [CA2765]1289
Failure Code [CA2771]1290
Failure Code [CA2976]1298
Failure Code [CA3142]1302
Failure Code [CA3143]1303
Failure Code [CA3144]1304
Failure Code [CA3146]1308
Failure Code [CA3147]1309
Failure Code [CA3148]1310
Failure Code [CA3151]1314
Failure Code [CA3165]1322
Failure Code [CA3229]1326
Failure Code [CA3231]1330
Failure Code [CA3232]1334
Failure Code [CA3235]1339
Failure Code [CA3239]1343
Failure Code [CA3241]1347
Failure Code [CA3242]1351
Failure Code [CA3251]1355
Failure Code [CA3313]1359
Failure Code [CA3314]1361
Failure Code [CA3315]1362
Failure Code [CA3419]1366
Failure Code [CA3421]1368
Failure Code [CA3497]1370
Failure Code [CA3498]1371
Failure Code [CA3543]1372
Failure Code [CA3545]1380
Failure Code [CA3547]1383
Failure Code [CA3558]1385
Failure Code [CA3559]1388
Failure Code [CA3562]1391
Failure Code [CA3563]1394
Failure Code [CA3567]1399
Failure Code [CA3568]1403
Failure Code [CA3571]1410
Failure Code [CA3572]1413
Failure Code [CA3574]1416
Failure Code [CA3575]1421
Failure Code [CA3577]1424
Failure Code [CA3578]1427
Failure Code [CA3582]1430
Failure Code [CA3583]1441
Failure Code [CA3596]1444
Failure Code [CA3649]1450
Failure Code [CA3681]1453
Failure Code [CA3682]1460
Failure Code [CA3713]1467
Failure Code [CA3717]1471
Failure Code [CA3718]1473
Failure Code [CA3724]1475
Failure Code [CA3725]1476
Failure Code [CA3748]1479
Failure Code [CA3755]1483
Failure Code [CA3866]1486
Failure Code [CA3867]1491
Failure Code [CA3868]1495
Failure Code [CA3899]1500
Failure Code [CA3911]1503
Failure Code [CA3912]1508
Failure Code [CA3918]1511
Failure Code [CA3921]1514
Failure Code [CA3928]1516
Failure Code [CA3932]1517
Failure Code [CA3933]1520
Failure Code [CA3934]1523
Failure Code [CA3935]1527
Failure Code [CA3936]1530
Failure Code [CA4152]1532
Failure Code [CA4155]1537
Failure Code [CA4156]1540
Failure Code [CA4157]1544
Failure Code [CA4159]1547
Failure Code [CA4164]1549
Failure Code [CA4165]1552
Failure Code [CA4166]1555
Failure Code [CA4168]1557
Failure Code [CA4169]1560
Failure Code [CA4171]1563
Failure Code [CA4249]1567
Failure Code [CA4251]1570
Failure Code [CA4261]1573
Failure Code [CA4277]1577
Failure Code [CA4281]1581
Failure Code [CA4459]1587
Failure Code [CA4461]1590
Failure Code [CA4533]1595
Failure Code [CA4534]1596
Failure Code [CA4731]1598
Failure Code [CA4732]1600
Failure Code [CA4739]1602
Failure Code [CA4768]1604
Failure Code [CA4769]1607
Failure Code [CA4842]1610
Failure Code [CA4952] (Machine with KOMTRAX Terminal)1615
Failure Code [CA4952] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)1617
Failure Code [CA4952] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)1619
Failure Code [CA5115]1621
Failure Code [CA5179]1625
Failure Code [CA5181]1628
Failure Code [CA5271]1631
Failure Code [CA5272]1634
Failure Code [CA5273]1637
Failure Code [CA5274]1640
Failure Code [CA5275]1642
Failure Code [CA5276]1645
Failure Code [CA5277]1648
Failure Code [CA5387]1650
Failure Code [CA5388]1654
Failure Code [CA5389]1657
Failure Code [CA5391]1662
Failure Code [CA5392]1668
Failure Code [CA5393]1670
Failure Code [CA5394]1673
Failure Code [CA5395]1676
Failure Code [CA5396]1679
Failure Code [CA5631]1681
Failure Code [CA5938]1683
Failure Code [D110KB]1685
Failure Code [D19JKZ]1687
Failure Code [D811MC] (Machine with KOMTRAX Terminal)1690
Failure Code [D811MC] (Machine with Gateway Function Controller)1691
Failure Code [D862KA] (Machine with KOMTRAX Terminal)1692
Failure Code [D862KA] (Machine with Gateway Function Controller)1693
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal)1695
Failure Code [D8ALKA] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)1698
Failure Code [D8ALKA] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)1701
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal)1704
Failure Code [D8ALKB] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)1706
Failure Code [D8ALKB] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)1708
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal)1710
Failure Code [D8AQKR] (Machine with Gateway Function Controller)1715
Failure Code [D8G1KT]1720
Failure Code [D8G6KT]1721
Failure Code [DA20MC]1722
Failure Code [DA22KK]1723
Failure Code [DA25KP]1727
Failure Code [DA26KP]1732
Failure Code [DA29KQ]1734
Failure Code [DA2LKA] (Machine with KOMTRAX Terminal)1737
Failure Code [DA2LKA] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)1740
Failure Code [DA2LKA] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)1743
Failure Code [DA2LKB] (Machine with KOMTRAX Terminal)1746
Failure Code [DA2LKB] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)1748
Failure Code [DA2LKB] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and up)1750
Failure Code [DA2QKR] (Machine with KOMTRAX Terminal)1752
Failure Code [DA2QKR] (Machine with Gateway Function Controller)1759
Failure Code [DA2RKR] (Machine with KOMTRAX Terminal)1766
Failure Code [DA2RKR] (Machine with Gateway Function Controller)1773
Failure Code [DAF0KM]1780
Failure Code [DAF0MB]1781
Failure Code [DAF0MC]1782
Failure Code [DAF8KB]1783
Failure Code [DAF9KQ]1785
Failure Code [DAFGMC]1787
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal)1788
Failure Code [DAFLKA] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)1791
Failure Code [DAFLKA] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)1794
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal)1797
Failure Code [DAFLKB] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)1799
Failure Code [DAFLKB] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)1801
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal)1803
Failure Code [DAFQKR] (Machine with Gateway Function Controller)1809
Failure Code [DAZ9KQ]1815
Failure Code [DAZQKR] (Machine with KOMTRAX Terminal)1817
Failure Code [DAZQKR] (Machine with Gateway Function Controller)1822
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal)1827
Failure Code [DB2QKR] (Machine with Gateway Function Controller)1834
Failure Code [DB2RKR] (Machine with KOMTRAX Terminal)1841
Failure Code [DB2RKR] (Machine with Gateway Function Controller)1849
Failure Code [DB90MC]1857
Failure Code [DBP0KM]1858
Failure Code [DBP0KT]1859
Failure Code [DBP5KB]1860
Failure Code [DBP5KY]1863
Failure Code [DBPQKR] (Machine with KOMTRAX Terminal)1866
Failure Code [DBPQKR] (Machine with Gateway Function Controller)1872
Failure Code [DDNRKA]1878
Failure Code [DDNRKY]1881
Failure Code [DDNS00]1884
Failure Code [DFB1KZ]1886
Failure Code [DFB2KZ]1889
Failure Code [DFB3L8]1892
Failure Code [DFB4L8]1894
Failure Code [DFB5KZ]1896
Failure Code [DFB6KZ]1899
Failure Code [DGH2KA]1902
Failure Code [DGH2KB]1904
Failure Code [DHA4KA]1906
Failure Code [DHPAMA]1908
Failure Code [DHS3MA]1911
Failure Code [DHS4MA]1914
Failure Code [DHS8MA]1917
Failure Code [DHS9MA]1920
Failure Code [DHSAMA]1923
Failure Code [DHSBMA]1926
Failure Code [DHSCMA]1929
Failure Code [DHSDMA]1932
Failure Code [DHSFMA]1935
Failure Code [DHSGMA]1938
Failure Code [DHSHMA]1941
Failure Code [DHSJMA]1944
Failure Code [DHSKMA]1947
Failure Code [DHSLMA]1949
Failure Code [DKULKA]1951
Failure Code [DKULKB]1953
Failure Code [DKULKY]1955
Failure Code [DLM5KA]1957
Failure Code [DLM5MB]1961
Failure Code [DR10KA]1963
Failure Code [DR12KA]1967
Failure Code [DR20KA]1969
Failure Code [DR21KX]1971
Failure Code [DR40KA]1974
Failure Code [DUMBKA] (Machine with KOMTRAX Terminal)1976
Failure Code [DUMBKA] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)1979
Failure Code [DUMBKA] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)1982
Failure Code [DUMBKB] (Machine with KOMTRAX Terminal)1985
Failure Code [DUMBKB] (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010)1987
Failure Code [DUMBKB] (Machine with Gateway Function Controller) (Applicable Machine: 62011 and Up)1989
Failure Code [DV20KB]1991
Failure Code [DW43KA]1993
Failure Code [DW43KB]1995
Failure Code [DW43KY]1997
Failure Code [DW45KA]1999
Failure Code [DW45KB]2003
Failure Code [DW45KY]2007
Failure Code [DW4CKY]2009
Failure Code [DW91KA]2011
Failure Code [DW91KB]2014
Failure Code [DW91KY]2016
Failure Code [DWA2KA]2018
Failure Code [DWA2KB]2021
Failure Code [DWA2KY]2023
Failure Code [DWJ0KA]2025
Failure Code [DWJ0KB]2028
Failure Code [DWJ0KY]2031
Failure Code [DWK2KA]2033
Failure Code [DWK2KB]2036
Failure Code [DWK2KY]2038
Failure Code [DWN5KA]2040
Failure Code [DWN5KB]2043
Failure Code [DWN5KY]2045
Failure Code [DWNSKA]2047
Failure Code [DWNSKB]2049
Failure Code [DWNSKY]2051
Failure Code [DXA8KA]2053
Failure Code [DXA8KB]2057
Failure Code [DXE4KA]2059
Failure Code [DXE4KB]2062
Failure Code [DXE4KY]2064
Failure Code [DXEKKA]2066
Failure Code [DXEKKB]2069
Failure Code [DXEKKY]2071
Failure Code [DY20KA]2073
Failure Code [DY20MA]2076
Failure Code [DY2CKB]2079
Failure Code [DY2DKB]2083
Failure Code [DY2EKB]2086
Failure Code [F311KA]2089
Failure Code [F311KB]2091
Failure Code [F312KA]2093
Failure Code [F312KB]2095
Failure Code [F313KA]2097
Failure Code [F313KB]2099
Failure Code [F314KA]2101
Failure Code [F314KB]2103
Failure Code [F316KB]2105
Failure Code [F316KY]2107
Failure Code [F318KB]2109
Failure Code [F318KY]2111
Failure Code [F31AKB]2113
Failure Code [F31AKY]2115
Failure Code [F31BKB]2117
Failure Code [F31BKY]2119
Failure Code [F31CKB]2121
Failure Code [F31CKY]2123
Failure Code [F31DKB]2125
Failure Code [F31DKY]2127
Failure Code [F31EKB]2129
Failure Code [F31EKY]2131
Failure Code [FS10ZE]2133
Troubleshooting of Electrical System (E-Mode)2134
Engine Does Not Start (Engine Does Not Crank)2134
Manual Preheating System Does Not Operate2140
While Preheating is in Operation, Preheating Monitor Does Not Come On2143
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing2145
Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation2148
Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation2149
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation2150
Charge Level Monitor Comes On in Red While Engine is in Operation2151
Fuel Level Monitor Comes On in Red While Engine is in Operation2152
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation2153
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation2154
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation2155
Fuel Gauge Does Not Move from Minimum or Maximum2156
Display of Fuel Gauge is Different from Actual Fuel Level2158
Engine Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum2159
Display of Engine Coolant Temperature Gauge is Different from Actual Coolant Temperature2160
DEF Level is Not Shown Correctly2161
Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum2164
Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature2166
Some Areas of Machine Monitor Screen are Not Shown2167
Function Switch Does Not Operate2168
Automatic Warm-up System Does Not Operate (in Cold Weather)2169
Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated2170
Auto-Decelerator is Not Operated or Canceled with Lever2171
Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated2172
When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed2173
Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated2174
Travel Speed Does Not Change Even When You Change Travel Speed2175
Alarm Buzzer Does Not Stop2176
Service Meter is Not Shown While Starting Switch is in OFF Position2177
Service Mode Cannot be Selected2178
All Work Equipment, Swing, Travel Do Not Operate2179
All Work Equipment, Swing, Travel Cannot be Locked2182
Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position2184
While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated2186
Work Equipment Does Not Operate While Lock Lever Automatic Release Switch is in Release Position2188
Travel Alarm Does Not Operate During Travel2190
Travel Alarm Does Not Stop When Machine Stops2192
Horn Does Not Sound2193
Horn Does Not Stop2195
Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated2196
Windshield Wiper Does Not Operate When Wiper Switch is Operated2197
When Window Washer Switch is Operated, Window Washer Does Not Operate2199
“Boom Raise” is Not Shown Correctly with Monitoring Function2200
“Boom Lower” is Not Shown Correctly with Monitoring Function2201
“Arm OUT” is Not Shown Correctly with Monitoring Function2202
“Arm IN” is Not Shown Correctly with Monitoring Function2203
Bucket DUMP is Not Shown Correctly with Monitoring Function2204
Bucket CURL is Not Shown Correctly with Monitoring Function2205
Swing is Not Shown Correctly with Monitoring Function2206
Travel is Not Shown Correctly with Monitoring Function2207
Service is Not Shown Correctly with Monitoring Function2208
Blade RAISE is Not Shown Correctly with Monitoring Function2211
Blade LOWER is Not Shown Correctly with Monitoring Function2212
KOMTRAX System Does Not Operate Correctly2213
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)2214
Information Shown in Troubleshooting Table (H-Mode)2214
Failure Mode and Cause Table2215
All Work Equipment, Swing and Travel Do Not Work2224
All Work Equipment, Swing, and Travel Lack Speed or Power2225
Fine Control Performance or Response is Unsatisfactory2227
Unusual Noise is Heard from Around Hydraulic Pump2228
Engine Speed Drops Largely or Engine Stops2229
Boom Speed or Power is Low2231
Arm Speed or Power is Low2234
Bucket Speed or Power is Low2237
Blade Speed or Power is Low2240
Work Equipment Does Not Move in Single Operation2242
Hydraulic Drift of Boom is Large2243
Hydraulic Drift of Arm is Large2244
Hydraulic Drift of Bucket is Large2245
Hydraulic Drift of Blade is Large2246
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves2248
Time Lag of Work Equipment is Large2249
Attachment Circuit Cannot be Changed2250
Oil Flow in Attachment Circuit Cannot be Changed2251
In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower2252
In Mixed Operation of Swing and Travel, Travel Speed Falls Largely2253
In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low2254
Machine Does Not Travel Straight2255
Machine is Not Steered Well or Steering Power is Low2258
Travel Speed is Low2260
One of Tracks Does Not Run2262
Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast2264
Upper Structure Does Not Swing in Two Directions of Right and Left2265
Machine Swings Only in One Direction2266
Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left2267
Swing Acceleration or Swing Speed is Low in Only One Direction2268
Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)2269
Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)2270
Shock is Large When Upper Structure Stops Swing Operation2271
Large Unusual Noise is Made When Upper Structure Stops Swing Operation2272
Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)2273
Swing Drift on a Slope is Large (While Swing Parking Brake is Released)2274
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)2275
Unusual Noise is Heard from Around Fan2276
Troubleshooting of Engine (S-Mode)2277
Information Shown in Troubleshooting Table (S-Mode)2277
Engine Does Not Crank When Starting Switch is Turned to Start Position2278
Engine Cranks but No Exhaust Smoke Comes Out2279
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)2280
Engine Startability is Unsatisfactory2281
Engine Does Not Pick Up Smoothly2283
Engine Stops During Operation2285
Engine Does Not Rotate Smoothly2287
Engine Lacks Output (or Lacks Power)2288
Exhaust Smoke is Black2290
Engine Oil Consumption is Excessive2292
Engine Oil Becomes Dirty Quickly2293
Fuel Consumption is Excessive2294
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)2295
Engine Oil Pressure Drops2296
Fuel Mixes Into Engine Oil2297
Water Mixes Into Engine Oil (Milky)2298
Coolant Temperature Increases Too High (Overheat)2299
Unusual Noise is Heard2300
Vibration is Excessive2302
Air Cannot be Bled from Fuel Circuit2303
Active Regeneration is Done Frequently2304
Active Regeneration Continues Long2305
White Smoke is Exhausted During Active Regeneration2306
DEF Consumption is Excessive2307
There is an Unusual Smell (Irritating Odor)2309
Foreign Materials Enter DEF (DEF Increases)2310
50 Disassembly and Assembly2311
Table of Contents2312
Precautions Before Work2317
Abbreviation List2318
Related Information on Disassembly and Assembly2324
How to Read This Manual2324
Coating Materials List2325
Special Tool List2330
Sketches of Special Tools2343
Engine and Cooling System2346
Remove and Install Supply Pump Assembly (When Counterweight Assembly is Not Removed)2346
Remove Supply Pump Assembly (When Counterweight Assembly is Not Removed)2346
Install Supply Pump Assembly (When Counterweight Assembly is Not Removed)2351
Remove and Install Supply Pump Assembly (When Counterweight Assembly is Removed)2358
Remove Supply Pump Assembly (When Counterweight Assembly is Removed)2358
Install Supply Pump Assembly (When Counterweight Assembly is Removed)2360
Remove and Install Injector Assembly2364
How to Remove Injector Assembly2364
How to Install Injector Assembly2371
Remove and Install Cylinder Head Assembly2382
How to Remove Cylinder Head Assembly2382
How to Install Cylinder Head Assembly2397
Remove and Install EGR Valve Assembly2417
Remove EGR Valve Assembly2417
Install EGR Valve Assembly2419
Remove and Install EGR Cooler Assembly2421
How to Remove EGR Cooler Assembly2421
How to Install EGR Cooler Assembly2424
Remove and Install Starter Assembly2427
Remove Starting Motor Assembly2427
Install Starting Motor Assembly2431
Remove and Install Air Conditioner Compressor Belt2436
Remove Air Conditioner Compressor Belt2436
Install Air Conditioner Compressor Belt2437
Remove and Install Alternator Belt2439
Remove Alternator Belt2439
Install Alternator Belt2441
Remove and Install Automatic Tensioner2443
Remove Automatic Tensioner2443
Install Automatic Tensioner2443
Remove and Install Radiator Assembly2444
How to Remove Radiator Assembly2444
How to Install Radiator Assembly2446
Remove and Install Hydraulic Oil Cooler Assembly2450
How to Remove Hydraulic Oil Cooler Assembly2450
How to Install Hydraulic Oil Cooler Assembly2455
Remove and Install Aftercooler Assembly2460
Remove Aftercooler Assembly2460
Install Aftercooler Assembly2461
Remove and Install Fan Clutch Assembly2464
How to Remove Fan Clutch Assembly2464
How to Install Fan Clutch Assembly2470
Remove and Install Engine and Main Pump Assembly2478
Remove Engine and Main Pump Assembly2479
Install Engine and Main Pump Assembly2489
Remove and Install Engine Front Oil Seal2502
How to Remove Engine Front Oil Seal2502
How to Install Engine Front Oil Seal2503
Remove and Install Engine Rear Oil Seal2505
How to Remove Engine Rear Oil Seal2505
How to Install Engine Rear Oil Seal2506
Remove and Install Fuel Cooler Assembly2510
Remove Fuel Cooler Assembly2510
Install Fuel Cooler Assembly2512
Remove and Install KDOC Assembly2514
How to Remove KDOC Assembly2514
How to Install KDOC Assembly2518
Remove and Install KDOC and SCR Assembly2521
Remove KDOC and SCR Assembly2521
Install KDOC and SCR Assembly2528
Remove and Install Fuel Tank Assembly2535
Remove Fuel Tank Assembly2535
Install Fuel Tank Assembly2543
Remove and Install DEF Tank Assembly2550
How to Remove DEF Tank Assembly2550
How to Install DEF Tank Assembly2556
Remove and Install DEF Tank Sensor Flange Assembly2563
How to Remove DEF Tank Sensor Flange Assembly2563
How to Install DEF Tank Sensor Flange Assembly2569
Remove and Install DEF Tank Sensor2576
How to Remove DEF Tank Sensor2576
How to Install DEF Tank Sensor2577
Remove and Install DEF Tank Strainer2584
Remove DEF Tank Strainer2584
Install DEF Tank Strainer2584
Remove and Install SCR Assembly2585
How to Remove SCR Assembly2585
How to Install SCR Assembly2589
Remove and Install KDOC and SCR Assembly Bracket2594
Remove KDOC and SCR Assembly Bracket2594
Install KDOC and SCR Assembly Bracket2597
Remove and Install Bellows Pipe Assembly2602
Remove Bellows Pipe Assembly2602
Install Bellows Pipe Assembly2605
Remove and Install KCCV Assembly2609
Remove KCCV Assembly2609
Install KCCV Assembly2610
Remove and Install Exhaust Throttle Valve2612
Remove Exhaust Throttle Valve2612
Install Exhaust Throttle Valve2618
Remove and Install DEF Mixing Tube2624
Remove DEF Mixing Tube2624
Install DEF Mixing Tube2629
Remove and Install DEF Injector2633
Remove DEF Injector2633
Install DEF Injector2637
Remove and Install DEF Pump2642
Remove DEF Pump2642
Install DEF Pump2646
Remove and Install DEF Hose2650
Remove DEF Hose2650
Install DEF Hose2660
Remove and Install Air Cleaner Assembly2670
Remove Air Cleaner Assembly2670
Install Air Cleaner Assembly2672
Remove and Install Air Conditioner Compressor Assembly2676
Remove Air Conditioner Compressor Assembly2676
How to Install Air Conditioner Compressor Assembly2678
Remove and Install Air Conditioner Condenser Assembly2681
How to Remove Air Conditioner Condenser Assembly2681
How to Install Air Conditioner Condenser Assembly2682
Power Train2684
Remove and Install Travel Motor and Final Drive Assembly2684
Remove Travel Motor and Final Drive Assembly2684
Install Travel Motor and Final Drive Assembly2687
Disassemble and Assemble Travel Motor and Final Drive Assembly (Applicable Machine: 50001 to 54383)2690
How to Disassemble Travel Motor and Final Drive Assembly (Applicable Machine: 50001 to 54383)2700
How to Assemble Travel Motor and Final Drive Assembly (Applicable Machine: 50001 to 54383)2717
Disassemble and Assemble Travel Motor and Final Drive Assembly (Applicable Machine: 54384 and up)2734
How to Disassemble Travel Motor and Final Drive Assembly (Applicable Machine: 54384 and Up)2745
How to Assemble Travel Motor and Final Drive Assembly (Applicable Machine: 54384 and Up)2763
Remove and Install Swing Motor and Swing Machinery Assembly2783
Remove Swing Motor and Swing Machinery Assembly2783
Install Swing Motor and Swing Machinery Assembly2786
Disassemble and Assemble Swing Machinery Assembly2789
Disassemble Swing Machinery Assembly2789
Assemble Swing Machinery Assembly2792
Remove and Install Swing Circle Assembly2799
Remove Swing Circle Assembly2799
Install Swing Circle Assembly2800
Undercarriage and Frame2801
Separate and Connect Track Assembly2801
Separate Track Assembly2801
Install Track Assembly2803
Remove and Install Sprocket2806
Remove Sprocket2806
Install Sprocket2806
Remove and Install Idler and Idler Cushion Assembly2808
Remove Idler and Idler Cushion Assembly2808
Install Idler and Idler Cushion Assembly2808
Disassemble and Assemble Idler Assembly2810
Disassemble Idler Assembly2810
Assemble Idler Assembly2811
Disassemble and Assemble Idler Cushion Assembly2815
Disassemble Idler Cushion Assembly2815
Assemble Idler Cushion Assembly2817
Disassemble and Assemble Track Roller Assembly2820
Disassemble Track Roller Assembly2820
Assemble Track Roller Assembly2822
Remove and Install Revolving Frame Assembly2825
Remove Revolving Frame Assembly2825
Install Revolving Frame Assembly2828
Remove and Install Counterweight Assembly2831
Remove Counterweight Assembly2831
Install Counterweight Assembly2837
Hydraulic System2844
Remove and Install Center Swivel Joint Assembly2844
Remove Center Swivel Joint Assembly2844
Install Center Swivel Joint Assembly2847
Disassemble and Assemble Center Swivel Joint Assembly2852
Disassemble Center Swivel Joint Assembly2852
Assemble Center Swivel Joint Assembly2853
Remove and Install Hydraulic Tank Assembly2854
Remove Hydraulic Tank Assembly2854
How to Install Hydraulic Tank Assembly2858
Remove and Install Main Pump Assembly2863
Remove Main Pump Assembly2863
Install Main Pump Assembly2868
Remove and Install Control Valve Assembly2874
How to Remove Control Valve Assembly2875
How to Install Control Valve Assembly2884
Disassemble and Assemble Control Valve Assembly2895
Assemble Control Valve Assembly2895
Replace Pressure Reducing Valve Cartridge Assembly2898
Disassemble and Assemble Work Equipment PPC Valve Assembly2901
Disassemble Work Equipment PPC Valve Assembly2901
How to Assemble Work Equipment PPC Valve Assembly2902
Disassemble and Assemble Travel PPC Valve Assembly2904
Disassemble Travel PPC Valve Assembly2904
How to Assemble Travel PPC Valve Assembly2904
Work Equipment2906
Remove and Install Blade Assembly2906
Remove Blade Assembly2906
Install Blade Assembly2907
Remove and Install Work Equipment Assembly2909
Remove Work Equipment Assembly2910
Install Work Equipment Assembly2916
Disassemble and Assemble Work Equipment Cylinder Assembly2922
How to Disassemble Work Equipment Cylinder Assembly2923
How to Assemble Work Equipment Cylinder Assembly2925
CAB Related Parts2932
Remove and Install Operator Cab Assembly2932
How to Remove Operator Cab Assembly2932
Install Operator CAB Assembly2936
Remove and Install Slide Door2940
How to Remove Slide Door2940
How to Install Slide Door2940
Remove and Install Operator Cab Glass (Adhered Glass)2942
Remove Operator CAB Glass (Adhered Glass)2943
Install Operator CAB Glass (Adhered Glass)2944
Remove and Install Front Window Assembly2953
Remove Front Window Assembly2953
Install Front Window Assembly2956
Remove and Install Floor Frame Assembly2957
How to Remove Floor Frame Assembly2957
How to Install Floor Frame Assembly2967
Remove and Install Air Conditioner Unit Assembly2978
Remove Air Conditioner Unit Assembly2978
Install Air Conditioner Unit Assembly2984
Remove and Install Operator Seat2990
Remove Operator’s Seat2990
Install Operator’s Seat2990
How to Remove and Install Seat Belt2992
How to Remove Seat Belt2992
How to Install Seatbelt2993
Remove and Install Work Equipment Control Lever Assembly2994
How to Remove Work Equipment Control Lever Assembly2994
How to Install Work Equipment Control Lever Assembly3000
Remove and Install Front Wiper Assembly3008
Remove Front Wiper Assembly3008
Install Front Wiper Assembly3013
Electrical System3021
Remove and Install Engine Controller Assembly3021
Remove Engine Controller Assembly3021
Install Engine Controller Assembly3023
Remove and Install Pump Controller Assembly3024
Remove Pump Controller Assembly3024
Install Pump Controller Assembly3026
Remove and Install KomVision Controller Assembly3029
Remove KomVision Controller Assembly3029
Install KomVision Controller Assembly3031
Remove and Install Machine Monitor Assembly3033
Remove Machine Monitor Assembly3033
Install Machine Monitor Assembly3036
Remove and Install Mass Air Flow and Temperature Sensor3039
How to Remove Mass Air Flow and Temperature Sensor3039
How to Install Mass Air Flow and Temperature Sensor3040
Remove and Install KCCV Crankcase Pressure Sensor3041
How to Remove KCCV Crankcase Pressure Sensor3041
How to Install KCCV Crankcase Pressure Sensor3043
Remove and Install SCR Temperature Sensor3045
Remove SCR Temperature Sensor3045
Install SCR Temperature Sensor3046
Remove and Install Rearview Camera3048
Remove Rearview Camera3048
Install Rearview Camera3049
Remove and Install KomVision Camera3051
Remove KomVision Camera3051
Install KomVision Camera3053
Remove and Install KOMTRAX Terminal Assembly3056
Remove KOMTRAX Terminal Assembly3056
Install KOMTRAX Terminal Assembly3058
Remove and Install Gateway Function Controller Assembly3060
How to Remove Gateway Function Controller Assembly3060
How to Install Gateway Function Controller Assembly3062
Remove and Install Communication Terminal Wiring Harness3064
Remove Communication Terminal Wiring Harness3064
Install Communication Terminal Wiring Harness3067
Remove and Install Communication Terminal3072
How to Remove Communication Terminal3072
How to Install Communication Terminal3073
60 Maintenance Standard3075
Table of Contents3076
Abbreviation List3077
Engine and Cooling System3083
Maintenance Standard for Engine Mount3083
Maintenance Standard for PTO3084
Maintenance Standard for Cooling System3085
Power Train3086
Maintenance Standard for Swing Circle3086
Maintenance Standard for Swing Machinery3087
Maintenance Standard for Sprocket3089
Undercarriage and Frame3090
Maintenance Standard for Track Frame and Idler Cushion3090
Maintenance Standard for Idler3092
Maintenance Standard for Track Roller3093
Maintenance Standard for Carrier Roller3094
Maintenance Standard for Track Shoes3095
Maintenance Standard for Triple Shoes3098
Maintenance Standard for Road Liner3099
Hydraulic System3100
Maintenance Standard for Hydraulic Tank3100
Maintenance Standard for Main Pump3101
Maintenance Standard for PC-EPC Valve3105
Maintenance Standard for Swing Motor3106
Maintenance Standard for Travel Motor (Applicable Machine: 50001 to 54383)3109
Maintenance Standard for Travel Motor (Applicable Machine: 54384 and up)3110
Maintenance Standard for Control Valve3111
Maintenance Standard for Work Equipment and Swing PPC Valve3122
Maintenance Standard for Blade PPC Valve3125
Maintenance Standard for Travel PPC Valve3127
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)3130
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve3131
Maintenance Standard for Solenoid Valve3133
Maintenance Standard for Variable Back Pressure Solenoid Valve3136
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure)3137
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)3138
Maintenance Standard for Attachment Circuit Accumulator (For Low Pressure Circuit)3139
Maintenance Standard for Center Swivel Joint3140
Work Equipment3141
Maintenance Standard for Work Equipment Linkage3141
Dimensions of Arm3146
Dimensions of Bucket3148
Maintenance Standard for Boom Cylinder3150
Maintenance Standard for Arm Cylinder3151
Maintenance Standard for Bucket Cylinder3152
Maintenance Standard for Blade Cylinder3153
CAB Related Parts3154
Maintenance Standard for CAB Mount3154
80 Appendix3155
Table of Contents3156
Precautions Before Work3158
Abbreviation List3159
Air Conditioner System3165
Precautions for Refrigerant3165
Air Conditioner Component3166
Specifications of Air Conditioner3168
Structure and Function of Refrigeration Cycle3169
Outline of Refrigeration Cycle3170
Component Parts of Air Conditioner System3172
Air Conditioner Unit3172
Configuration Diagram of Air Conditioner Unit3172
Function of Air Conditioner Unit3174
Component Parts of Air Conditioner Unit3175
Function of Evaporator as Air Conditioner Unit Component3175
Function of Heater Core as Air Conditioner Unit Component3175
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component3175
Function of Servo Motor as Air Conditioner Unit Component3176
Structure of Expansion Valve as Air Conditioner Unit Component3177
Function of Expansion Valve as Air Conditioner Unit Component3177
Operate Expansion Valve as Air Conditioner Unit Component3177
Function of Dual Pressure Switch3178
Air Conditioner Controller3179
Structure of Air Conditioner Controller3179
Compressor3180
Structure of Compressor3180
Specifications of Compressor3180
Function of Compressor3180
Condenser3181
Structure of Condenser3181
Specifications of Condenser3181
Function of Condenser3181
Air Conditioner Related Sensors3183
Structure of Sunlight Sensor3183
Function of Sunlight Sensor3183
Structure of Outside Temperature Sensor3183
Function of Outside Air Temperature Sensor3183
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner3185
Circuit Diagram and Configuration of Connector Pins of Air Conditioner3187
System Diagram of Air Conditioner3189
Input and Output Signals of Air Conditioner Controller3190
Function of Air Conditioner Controller3191
Locations of Air Conditioner Parts and Layout of Connectors3192
Examine Air Leakage (Duct)3201
How to Examine Air Leakage (Duct)3201
Examine Air Conditioner with Self-Diagnosis Function3203
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor3204
Examine Vent (Mode) Changeover3205
How to Examine Vent (Mode) Changeover3205
Examine Fresh/Recirc Air Changeover3206
How to Examine Fresh/Recirc Air Changeover3206
Examine Sunlight Sensor3207
How to Examine Sunlight Sensor3207
Examine Refrigerant (Dual) Pressure Switch3208
How to Examine Refrigerant (Dual) Pressure Switch3208
Examine Relay3210
How to Examine Relay3210
Air Conditioner Troubleshooting Chart 13211
Air Conditioner Troubleshooting Chart 23212
Information Shown in Troubleshooting Table3215
Failure Code [879AKA]3216
Failure Code [879AKB]3218
Failure Code [879BKA]3220
Failure Code [879BKB]3222
Failure Code [879CKA]3224
Failure Code [879CKB]3225
Failure Code [879DKZ]3226
Failure Code [879EMC]3229
Failure Code [879FMC]3230
Failure Code [879GKX]3231
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)3233
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)3235
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)3238
Troubleshooting for Fresh/Recirc Air Changeover3240
Troubleshooting by Gauge Pressure3242
Connect Service Tool3244
How to Connect Service Tool3244
Precautions for Disconnection and Connection of Air Conditioner Piping3246
Handle Compressor Oil3248
Replace Desiccant3250
90 Circuit Diagrams3253
Table of Contents3254
Abbreviation List3256
Hydraulic Circuit Diagram3262
Symbols Used in Hydraulic Circuit Diagram3262
Hydraulic Circuit Diagram (Blade Less Specification, Machine with 1st-Line Attachment is Applicable)3267
Hydraulic Circuit Diagram (Blade Specification, Machine with 1st-Line Attachment is Applicable)3269
Hydraulic Circuit Diagram (Blade Specification, Machine with 1st-Line Attachment is Applicable and Arm Crane Specification)3271
Hydraulic Circuit Diagram (Machine with Multi-Control Valve)3273
Hydraulic Circuit Diagram (Machine with Tool Control System)3275
Electrical Circuit Diagram3277
Symbols Used in Electric Circuit Diagram3277
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (1/9)3281
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (2/9)3283
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (3/9)3285
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (4/9)3287
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (5/9)3289
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (6/9)3291
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (7/9)3293
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (8/9)3295
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (9/9)3297
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (1/10)3299
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (2/10)3301
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (3/10)3303
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (4/10)3305
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (5/10)3307
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (6/10)3309
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (7/10)3311
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (8/10)3313
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (9/10)3315
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Applicable Machine: 50001 to 62010) (10/10)3317
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No: 62011 and up) (1/10)3319
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No: 62011 and up) (2/10)3321
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No: 62011 and up) (3/10)3323
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No: 62011 and up) (4/10)3325
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No: 62011 and up) (5/10)3327
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No: 62011 and up) (6/10)3329
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No: 62011 and up) (7/10)3331
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No: 62011 and up) (8/10)3333
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No: 62011 and up) (9/10)3335
Electrical Circuit Diagram (Machine with Gateway Function Controller) (Serial No: 62011 and up) (10/10)3337
Index3339
IMAGES PREVIEW OF THE MANUAL:
S.M 28/12/24
