Komatsu HYDRAULIC EXCAVATOR PC210LC-11 Shop Manual SEN06695-11 PDF

Description

Komatsu HYDRAULIC EXCAVATOR PC210LC-11 Shop Manual SEN06695-11 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HYDRAULIC EXCAVATOR PC210LC-11 Shop Manual SEN06695-11 – PDF DOWNLOAD

Language : English
Pages :2852
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC210LC-11 Shop Manual SEN06695-11 – PDF DOWNLOAD

SERIAL NUMBERS 502361 and up

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC210LC-11 Shop Manual SEN06695-11 – PDF DOWNLOAD

SERIAL NUMBERS 502361 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 21
Foreword, Safety, Basic Information 24
How to Read the Shop Manual 24
Safety Notice for Operation 26
Precautions to Prevent Fire 34
Procedures If Fire Occurs 36
Precautions When You Discard Waste Materials 37
Procedures for Exhaust Gas Regulations 38
Precautions for DEF 39
General Character and Precautions for Handling 39
Precautions When You Add 39
Precautions for Storage 39
Precautions for Fire Hazard and Leakage 39
Other Precautions 39
Store DEF 40
Precautions When You Handle Hydraulic Equipment 41
Precautions When You Disconnect and Connect Pipings 44
Precautions When You Handle Electrical Equipment 51
Precautions When You Handle Fuel System Equipment 53
Precautions When You Handle Intake System Equipment 54
Practical Use of KOMTRAX 55
Disconnect and Connect Push-Pull Type Coupler 56
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 58
Precautions for Disconnection and Connection of Connectors 60
Disconnect and Connect Deutsch Connector 64
How to Disconnect and Connect Slide Lock Type Connector 65
Disconnect and Connect Connector with Lock to Pull 67
Disconnect and Connect Connector with Lock to Push 68
Disconnect and Connect Connector with Housing to Rotate 70
How to Read the Codes for Electric Cable 71
Explanation of Terms for Maintenance Standard 75
Standard Tightening Torque Table 78
Conversion Table 85
01 Specification 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: PC210LC-11 93
Working Range Drawings 95
Working Range: PC210LC-11 95
Specifications 96
Specifications: PC210LC-11 96
Weight Table 99
Weight Table: PC210LC-11 99
Table of Fuel, Coolant, and Lubricants 101
10 Structure and Function 103
Table of Contents 104
Urea SCR System 107
Layout Drawing of Urea SCR System 108
Urea SCR System Diagram 113
Function of Urea SCR System 114
Function of DEF System 114
Inducement Strategy 116
Component Parts of Urea SCR System 124
DEF Mixing Tube 124
SCR Assembly 124
DEF Tank 127
DEF Pump 129
DEF Injector 130
DEF Hose 131
DEF Tank Heating Valve 132
Boot-up System 133
Layout Drawing of Boot-up System 133
System Operating Lamp System 135
System Diagram of System Operating Lamp System 135
Function of Operation Lamp System 135
Battery Isolator 137
Function of Battery Isolator 137
Engine System 138
Layout Drawing of Engine System 138
Specifications of Engine System 139
Function of Engine System 139
Engine Control System 140
System Diagram of Engine Control 140
Function of Engine Control System 141
Auto-Deceleration System 144
System Diagram of Auto-Deceleration System 144
Function of Auto-Deceleration System 144
Operation of Auto-Deceleration System 145
Engine Automatic Warm-up System 146
System Diagram of Engine Automatic Warm-up System 146
Function of Engine Automatic Warm-up System 147
Overheat Prevention System 148
Overheat Prevention System Diagram 148
Function of Overheat Prevention System 149
Turbocharger Protection System 151
System Diagram of Turbocharger Protection System 151
Function of Turbocharger Protection System 152
Automatic Idle Stop System 153
System Diagram of Automatic Idle Stop System 153
Function of Automatic Idle Stop System 153
Component Parts of Engine System 156
VGT 156
EGR System 160
EGR Valve 162
EGR Cooler 164
KCCV System 165
KCCV Ventilator 167
KDPF 169
Cooling System 174
Layout Drawing of Cooling System 174
Specifications of Cooling System 175
Fan Speed Control System of Fan Clutch 176
Fan Speed Control System Diagram of Fan Clutch 176
Function of Fan Speed Control System of Fan Clutch 177
Engine Output Control System of Fan Clutch 178
Engine Output Control System Diagram of Fan Clutch 178
Function of Engine Output Control System of Fan Clutch 178
Component Parts of Cooling System 180
Fan Clutch 180
Control System 181
Layout Drawing of Control System 181
Machine Monitor System 184
System Diagram of Machine Monitor System 184
KomVision System 185
Layout Drawing of KomVision System 185
System Diagram of KomVision System 187
Function of KomVision System 187
KOMTRAX System 189
System Diagram of KOMTRAX System 189
Function of KOMTRAX System 189
Component Parts of Control System 190
Machine Monitor 190
KomVision Controller 204
KomVision Camera 208
KOMTRAX Terminal 208
Pump Controller 211
Resistor for PC-EPC Valve 215
CAN Terminating Resistor 215
Engine Controller 217
Fuel Control Dial 223
Hydraulic System 225
Layout Drawing of Hydraulic System 225
CLSS 231
Structure of CLSS 231
Operation of Unload Valve and LS Pressure 233
Pump Swash Plate Angle (Oil Flow) Control 234
Pressure Compensation Control 250
Engine and Pump Combined Control System 253
Engine and Pump Combined Control System Diagram 253
Function of Engine and Pump Combined Control System 254
Pump and Valve Control System 259
Pump and Valve Control System Diagram 259
Function of Pump and Valve Control System 260
Component Parts of Hydraulic System 262
Hydraulic Tank 262
Main Pump 264
Control Valve 289
Work Equipment System 353
Layout Drawing of Work Equipment System 353
Structure of Valve Control 358
One-Touch Power Maximizing System 360
System Diagram of One-Touch Power Maximizing System 360
Function of One-Touch Power Maximizing System 361
PPC Lock System 362
System Diagram of PPC Lock 362
Function of PPC Lock System 362
Work Equipment and Travel Automatic Lock System 363
System Diagram of Lock Lever Automatic Lock System 363
Function of Work Equipment and Travel Automatic Lock System 363
Operation of Lock Lever Automatic Lock System 364
Attachment Oil Flow Adjuster System 365
Attachment Oil Flow Adjuster System Diagram 365
Function of Attachment Oil Flow Adjuster System 366
Tool Control System 367
Tool Control System Diagram 367
Component Parts of Work Equipment System 369
Work Equipment and Swing PPC Valve 369
1st-Line Attachment PPC Valve (with EPC Valve) 375
2nd-Line Attachment PPC Valve 381
Solenoid Valve 383
Boom Anti-drop Valve 386
Arm Anti-Drop Valve 390
Attachment Circuit Selector Valve (For High Pressure) 394
Attachment Circuit Selector Valve (For Low Pressure) 396
Pilot Circuit Accumulator 399
Attachment Circuit Accumulator 400
Swing System 401
Layout Drawing of Swing System 401
Swing Control System Diagram 405
Function of Swing Control System 405
Component Parts of Swing System 409
Swing Motor 409
Swing Machinery 420
Swing Circle 421
Travel System 423
Layout Drawing of Travel System 423
System Diagram of Travel Control System 427
Function of Travel Control System 427
Component Parts of Travel System 429
Travel Motor 429
Final Drive 441
Travel PPC Valve 443
Center Swivel Joint 448
Undercarriage and Frame 450
Layout Drawing of Undercarriage 450
Specifications of Undercarriage 451
Work Equipment 452
Structure of Work Equipment 452
Function of Work Equipment 453
Work Equipment Clearance Adjustment Shim 454
Function of Work Equipment Clearance Adjustment Shim 454
Bucket Clearance Adjustment Shim 455
Function of Bucket Clearance Adjustment Shim 455
CAB Related Parts 456
ROPS CAB 456
Structure of ROPS CAB 456
Function of ROPS CAB 456
CAB Mount 457
Structure of CAB Mount 457
Function of CAB Mount 457
CAB Tipping Stopper 458
Structure of CAB Tipping Stopper 458
Function of CAB Tipping Stopper 458
20 Standard Value Table 459
Table of Contents 460
Standard Value Table for Engine 461
Standard Value Table for Engine: PC210LC-11 461
Standard Value Table for Machine 465
Standard Value Table for Machine: PC210LC-11 465
Machine Posture and Procedures to Measure Performance 478
Standard Value Table for Electricity 482
Standard Value Table for Electricity 482
30 Testing and Adjusting 493
Table of Contents 494
Precautions Before Work 497
Related Information on Testing and Adjusting 498
Tools for Testing and Adjusting 498
Sketch of Tools for Testing and Adjusting 505
Engine and Cooling System 507
Examine Engine Speed 507
How to Examine Engine Speed 507
Examine Boost Pressure 510
How to Examine Boost Pressure on Machine Monitor 510
How to Examine Boost Pressure by Testing Tool 511
Examine Exhaust Gas Color 512
How to Examine Exhaust Gas Color with the Handy Smoke Checker 512
How to Examine Exhaust Gas Color with Smoke Meter 513
Examine Mass Air Flow and Temperature Sensor 515
How to Examine Mass Air Flow and Temperature Sensor 515
Examine and Adjust Valve Clearance 517
Check Valve Clearance 517
Adjust Valve Clearance 518
Examine Compression Pressure 520
How to Examine Compression Pressure 520
Examine Blowby Pressure 525
How to Examine Blowby Pressure 525
Examine Engine Oil Pressure 527
How to Examine Engine Oil Pressure 527
Examine EGR Valve and VGT Oil Pressure 528
How to Examine EGR Valve and VGT Oil Pressure 528
Examine Fuel Pressure 530
How to Examine Fuel Pressure 531
Examine Fuel Discharge, Return and Leakage 536
How to Examine Fuel Discharge, Return, and Leakage 537
Bleed Air from Fuel System 543
How to Bleed Air from Fuel System 543
Examine Fuel Circuit for Leakage 544
How to Examine Fuel System for Leakage 544
Handle Cylinder Cut-out Mode Operation 546
Handle No-Injection Cranking Operation 547
Examine and Adjust Air Conditioner Compressor Belt Tension 548
How to Examine Air Conditioner Compressor Belt 548
How to Adjust Air Conditioner Compressor Belt 548
Examine Fan Belt and Alternator Belt 550
How to Examine Fan Belt and Alternator Belt 550
Examine Automatic Tensioner 551
How to Examine Automatic Tensioner 551
Examine Cooling Fan Speed 552
How to Examine Cooling Fan Speed 552
Write Correction for Ash in Soot Accumulation to Engine Controller 553
How to Write Correction for Ash in Soot Accumulation to Engine Controller 553
Examine SCR Related Functions 554
Examine DEF Pump Raised Pressure 557
Examine Injection Volume from DEF Injector 560
Examine DEF Line Heater Relay 1 563
Examine DEF Line Heater Relay 2 566
Examine DEF Pump Heater Relay 569
Examine DEF Tank Heater Valve 572
Examine SCR Denitration Efficiency 575
Clean DEF Tank 579
How to Clean DEF Tank 579
Clean DEF Pump 583
How to Clean DEF Pump 583
Bleed Air from Coolant Circuit of DEF Tank 590
How to Bleed Air from Coolant Circuit of DEF Tank 590
Power Train 592
Examine Swing Circle Bearing Clearance 592
How to Examine Swing Circle Bearing Clearance 592
Undercarriage and Frame 593
Examine and Adjust Track Tension 593
How to Examine Track Tension 593
How to Adjust Track Tension 593
Hydraulic System 595
Release Remained Pressure in Hydraulic Circuit 595
How to Release Remained Pressure in Hydraulic System 595
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 596
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 597
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 603
Examine Oil Pressure of Control Circuit 606
Examine Oil Pressure in Control Circuit 606
Examine and adjust oil pressure in pump PC control circuit 608
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 608
Examine PC-EPC Valve Outlet Pressure 609
How to Adjust Oil Pressure in Pump PC Control Circuit 610
Examine and Adjust Oil Pressure in Pump LS Control Circuit 612
Examine LS Differential Pressure with Machine Monitor 612
Examine LS Differential Pressure by Testing Tool 613
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 616
How to Examine LS-EPC Valve Outlet Pressure 617
Adjust LS Valve 618
Examine Outlet Pressure of Solenoid Valve 619
How to Examine Outlet Pressure of Solenoid Valve 619
Operating Condition of Solenoid Valve 620
Examine PPC Valve Outlet Pressure 623
Examine Outlet Pressure in PPC Valve 623
Adjust Play of Work Equipment and Swing PPC Valves 625
How to Adjust Play of Work Equipment and Swing PPC Valves 625
Measure and Adjust Quick Coupler Control Valve Output Pressure 626
Examine Pump Swash Plate Sensor 628
How to Examine pump swash plate sensor 628
Examine Parts Which Cause Hydraulic Drift of Work Equipment 629
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 629
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 629
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 630
Examine Oil Leakage 631
How to Examine Oil Leakage from Boom Cylinder 631
How to Examine Oil Leakage from Arm Cylinder 631
How to Examine Oil Leakage from Bucket Cylinder 632
How to Examine Oil Leakage from Swing Motor 633
How to Examine Oil Leakage from Travel Motor 633
Bleed Air from Hydraulic System 634
How to Bleed Air from Hydraulic System 636
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 638
Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 638
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 642
Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 642
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 646
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 646
CAB Related Parts 653
Examine CAB Tipping Stopper 653
How to Examine Cab Tipping Stopper 653
How to Adjust Mirrors 654
Procedure to Adjust Machine Left Front Mirror (A) 654
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 655
Procedure to Adjust Machine Right Front Mirror (B) 656
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 657
Procedure to Adjust Machine Right Side Mirror (C) 658
Electrical System 660
Set and Operate Machine Monitor 660
Operator Mode 663
Function to Show Technician Identification Status Screen 664
Function to Show Operator Identification Input Screen 664
Examine Function by LCD (Liquid Crystal Display) 665
Examine Function of Service Meter 665
Usage Limitation and Maintenance Password Change Function 665
Service Mode 668
How to Operate Service Mode 668
How to See Pre-defined Monitoring Information 670
How to See Pre-defined Monitoring Information 671
How to Examine Self-Define Monitor Information 678
Abnormality Record Menu 689
How to See Maintenance Record 693
How to See Maintenance Record 695
Maintenance Mode Setting 696
Maintenance Mode Setting 700
Set Phone Number Entry 703
Default Menu 704
Diagnostic Tests Menu 716
Adjustment Menu 727
No-Injection Cranking Operation 759
KOMTRAX Settings Menu 760
Show Service Message 762
How to Start Up KOMTRAX Terminal 764
Adjust Rearview Camera Angle 769
How to Adjust Rearview Camera Angle 769
Adjust KomVision Camera Angle 772
How to Adjust KomVision Camera Angle 773
Adjust KomVision Related Function 777
Setting of KomVision (Main Setting) 777
Setting of KomVision (Camera Setting) 779
Setting of KomVision (Camera Calibration) 781
KomVision screen – Check 12 m visibility 794
Set Region of Bluetooth(R) Compatible Radio 797
Set Region of Bluetooth(R) Compatible Radio 797
Handle Voltage Circuit of Engine Controller 799
Handle Battery Isolator Switch 800
Examine Diodes 801
Examine Diodes by Digital Tester 801
How to Examine Diodes by Analog Tester 801
Pm Clinic 802
Pm Clinic Service 802
Pm Clinic Check Sheet 803
40 Troubleshooting 815
Table of Contents 816
Precautions Before Work 827
Related Information to Troubleshooting 828
General Troubleshooting Points 828
Troubleshooting Points for Urea SCR System 829
Sequence of Events in Troubleshooting 843
Checks Before Troubleshooting 845
Inspection Procedure Before Troubleshooting 847
Walk-Around Check 847
Test in Accordance with Testing Procedure 849
Examine Fuel Level and Type 849
Examine for Impure Ingredient in Fuel 849
Examine Fuel Prefilter 850
Examine Water Separator, Drain Water and Sediment 850
How to Replace Fuel Prefilter Cartridge 851
Examine Fuel Main Filter 852
Examine Engine Oil Level (Oil Quantity in Oil Pan) 854
Examine Coolant Level (Reservoir Tank) 855
Examine Air Cleaner Clogging 855
Clean Outer Element 856
Replace Element 858
Examine Hydraulic Oil Level 859
Examine Hydraulic Oil Strainer 860
Examine Hydraulic Oil Filter 861
Examine Oil Level in Swing Machinery Case 862
Examine Oil Level in Damper Case 863
Examine Oil Level in Final Drive Case 863
Bleed Air from Fuel System 864
Bleed Air from Hydraulic System 864
How to Examine Electric Equipment 864
Preparation for Troubleshooting of Electrical System 872
Procedure for Troubleshooting 882
Symptom and Troubleshooting Numbers 885
Information Shown in Troubleshooting Table 889
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 891
Connector List and Layout 894
Connector Contact Connection Table 907
T-Branch Box and T-Branch Adapter Table 947
Fuse Location Table 953
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 956
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 960
Failure Code Table 962
Troubleshooting by Failure Code (Display of Code) 980
Failure Code [6AZ0ZG] 980
Failure Code [879AKA] 982
Failure Code [879AKB] 983
Failure Code [879BKA] 984
Failure Code [879BKB] 986
Failure Code [879CKA] 988
Failure Code [879CKB] 989
Failure Code [879DKZ] 990
Failure Code [879EMC] 992
Failure Code [879FMC] 993
Failure Code [879GKX] 994
Failure Code [989L00] 996
Failure Code [989M00] 997
Failure Code [989N00] 998
Failure Code [A1U0N3] 999
Failure Code [A1U0N4]1001
Failure Code [A900FR]1003
Failure Code [A900N6]1004
Failure Code [A900NY]1005
Failure Code [AA10NX]1006
Failure Code [AB00KE]1008
Failure Code [AQ10N3]1011
Failure Code [AS00N3]1013
Failure Code [AS00R2]1015
Failure Code [AS00R3]1016
Failure Code [AS00R4]1017
Failure Code [AS00R5]1018
Failure Code [AS00R6]1019
Failure Code [AS00ZK]1020
Failure Code [AS10KM]1021
Failure Code [AS10NR]1022
Failure Code [AS10NT]1023
Failure Code [B@BAZG]1024
Failure Code [B@BAZK]1025
Failure Code [B@BCNS]1027
Failure Code [B@BCQA]1028
Failure Code [B@BCZK]1030
Failure Code [B@HANS]1032
Failure Code [CA115]1033
Failure Code [CA122]1034
Failure Code [CA123]1036
Failure Code [CA131]1038
Failure Code [CA132]1040
Failure Code [CA144]1042
Failure Code [CA145]1044
Failure Code [CA153]1046
Failure Code [CA154]1049
Failure Code [CA187]1051
Failure Code [CA221]1053
Failure Code [CA222]1055
Failure Code [CA227]1057
Failure Code [CA234]1058
Failure Code [CA238]1059
Failure Code [CA239]1061
Failure Code [CA249]1063
Failure Code [CA256]1065
Failure Code [CA271]1067
Failure Code [CA272]1069
Failure Code [CA322]1071
Failure Code [CA323]1073
Failure Code [CA324]1075
Failure Code [CA325]1077
Failure Code [CA331]1079
Failure Code [CA332]1081
Failure Code [CA343]1083
Failure Code [CA351]1084
Failure Code [CA352]1085
Failure Code [CA356]1088
Failure Code [CA357]1090
Failure Code [CA386]1092
Failure Code [CA428]1093
Failure Code [CA429]1095
Failure Code [CA435]1097
Failure Code [CA441]1099
Failure Code [CA442]1102
Failure Code [CA449]1103
Failure Code [CA451]1104
Failure Code [CA452]1106
Failure Code [CA488]1108
Failure Code [CA515]1109
Failure Code [CA516]1111
Failure Code [CA553]1113
Failure Code [CA555]1114
Failure Code [CA556]1115
Failure Code [CA559]1116
Failure Code [CA595]1119
Failure Code [CA687]1120
Failure Code [CA689]1122
Failure Code [CA691]1125
Failure Code [CA692]1127
Failure Code [CA697]1129
Failure Code [CA698]1130
Failure Code [CA731]1131
Failure Code [CA778]1133
Failure Code [CA1117]1138
Failure Code [CA1664]1139
Failure Code [CA1669]1141
Failure Code [CA1673]1142
Failure Code [CA1677]1143
Failure Code [CA1678]1144
Failure Code [CA1682]1145
Failure Code [CA1683]1147
Failure Code [CA1684]1149
Failure Code [CA1686]1151
Failure Code [CA1691]1152
Failure Code [CA1694]1155
Failure Code [CA1695]1158
Failure Code [CA1696]1159
Failure Code [CA1712]1161
Failure Code [CA1713]1164
Failure Code [CA1714]1166
Failure Code [CA1715]1167
Failure Code [CA1776]1168
Failure Code [CA1777]1171
Failure Code [CA1843]1174
Failure Code [CA1844]1176
Failure Code [CA1879]1179
Failure Code [CA1881]1181
Failure Code [CA1883]1183
Failure Code [CA1885]1186
Failure Code [CA1887]1188
Failure Code [CA1921]1190
Failure Code [CA1922]1193
Failure Code [CA1942]1198
Failure Code [CA1993]1199
Failure Code [CA2185]1202
Failure Code [CA2186]1203
Failure Code [CA2249]1205
Failure Code [CA2271]1206
Failure Code [CA2272]1209
Failure Code [CA2288]1212
Failure Code [CA2311]1213
Failure Code [CA2349]1214
Failure Code [CA2353]1217
Failure Code [CA2357]1219
Failure Code [CA2381]1220
Failure Code [CA2382]1223
Failure Code [CA2383]1226
Failure Code [CA2386]1229
Failure Code [CA2387]1231
Troubleshooting Flowchart1235
Failure Code [CA2555]1236
Failure Code [CA2556]1239
Failure Code [CA2637]1242
Failure Code [CA2639]1244
Failure Code [CA2771]1247
Failure Code [CA2777]1253
Failure Code [CA2976]1256
Failure Code [CA3133]1258
Failure Code [CA3134]1261
Failure Code [CA3135]1263
Failure Code [CA3142]1266
Failure Code [CA3143]1267
Failure Code [CA3144]1268
Failure Code [CA3146]1270
Failure Code [CA3147]1271
Failure Code [CA3148]1272
Failure Code [CA3151]1274
Failure Code [CA3165]1280
Failure Code [CA3229]1282
Failure Code [CA3231]1284
Failure Code [CA3232]1286
Failure Code [CA3235]1290
Failure Code [CA3239]1292
Failure Code [CA3241]1295
Failure Code [CA3242]1298
Failure Code [CA3251]1301
Failure Code [CA3253]1303
Failure Code [CA3254]1306
Failure Code [CA3255]1309
Failure Code [CA3256]1313
Failure Code [CA3311]1315
Failure Code [CA3312]1317
Failure Code [CA3313]1320
Failure Code [CA3314]1321
Failure Code [CA3315]1322
Failure Code [CA3316]1324
Failure Code [CA3317]1325
Failure Code [CA3318]1326
Failure Code [CA3319]1328
Failure Code [CA3321]1329
Failure Code [CA3322]1331
Failure Code [CA3419]1333
Failure Code [CA3421]1335
Failure Code [CA3497]1337
Failure Code [CA3498]1338
Failure Code [CA3543]1339
Failure Code [CA3545]1346
Failure Code [CA3547]1348
Failure Code [CA3558]1349
Failure Code [CA3559]1351
Failure Code [CA3562]1353
Failure Code [CA3563]1355
Failure Code [CA3567]1358
Failure Code [CA3568]1361
Failure Code [CA3571]1365
Failure Code [CA3572]1367
Failure Code [CA3574]1369
Failure Code [CA3575]1371
Failure Code [CA3577]1373
Failure Code [CA3578]1375
Failure Code [CA3582]1377
Failure Code [CA3583]1383
Failure Code [CA3596]1385
Failure Code [CA3649]1387
Failure Code [CA3681]1389
Failure Code [CA3682]1394
Failure Code [CA3713]1399
Failure Code [CA3717]1402
Failure Code [CA3718]1403
Failure Code [CA3725]1404
Failure Code [CA3741]1407
Failure Code [CA3748]1408
Failure Code [CA3751]1410
Failure Code [CA3755]1412
Failure Code [CA3866]1414
Failure Code [CA3867]1418
Failure Code [CA3868]1421
Failure Code [CA3899]1425
Failure Code [CA3911]1427
Failure Code [CA3912]1431
Failure Code [CA3932]1433
Failure Code [CA3933]1435
Failure Code [CA3934]1437
Failure Code [CA3935]1440
Failure Code [CA3936]1442
Failure Code [CA4151]1444
Failure Code [CA4152]1448
Failure Code [CA4155]1452
Failure Code [CA4156]1455
Failure Code [CA4157]1458
Failure Code [CA4158]1460
Failure Code [CA4159]1461
Failure Code [CA4161]1462
Failure Code [CA4162]1465
Failure Code [CA4163]1468
Failure Code [CA4164]1469
Failure Code [CA4165]1471
Failure Code [CA4166]1473
Failure Code [CA4168]1474
Failure Code [CA4169]1477
Failure Code [CA4171]1479
Failure Code [CA4249]1482
Failure Code [CA4251]1484
Failure Code [CA4259]1486
Failure Code [CA4261]1489
Failure Code [CA4277]1492
Failure Code [CA4281]1495
Failure Code [CA4459]1498
Failure Code [CA4461]1501
Failure Code [CA4658]1504
Failure Code [CA4731]1508
Failure Code [CA4732]1509
Failure Code [CA4739]1510
Failure Code [CA4768]1511
Failure Code [CA4769]1513
Failure Code [CA4842]1516
Failure Code [CA4952]1520
Failure Code [CA5115]1522
Failure Code [CA5179]1525
Failure Code [CA5181]1527
Failure Code [CA5383]1529
Failure Code [D110KB]1531
Failure Code [D19JKZ]1533
Failure Code [D811MC]1536
Failure Code [D862KA]1537
Failure Code [D8ALKA]1538
Failure Code [D8ALKB]1540
Failure Code [D8AQKR]1542
Failure Code [DA20MC]1544
Failure Code [DA22KK]1545
Failure Code [DA25KP]1548
Failure Code [DA26KP]1551
Failure Code [DA29KQ]1553
Failure Code [DA2LKA]1555
Failure Code [DA2LKB]1557
Failure Code [DA2QKR]1559
Failure Code [DA2RKR]1562
Failure Code [DAF0KM]1563
Failure Code [DAF0MB]1564
Failure Code [DAF0MC]1565
Failure Code [DAF8KB]1566
Failure Code [DAF9KQ]1570
Failure Code [DAFGMC]1571
Failure Code [DAFLKA]1572
Failure Code [DAFLKB]1574
Failure Code [DAFQKR]1576
Failure Code [DAZ9KQ]1577
Failure Code [DAZQKR]1578
Failure Code [DB2QKR]1583
Failure Code [DB2RKR]1588
Failure Code [DBP0KM]1593
Failure Code [DBP0KT]1594
Failure Code [DBP5KB]1595
Failure Code [DBP5KY]1598
Failure Code [DBPQKR]1600
Failure Code [DDNRKA]1605
Failure Code [DDNRKY]1607
Failure Code [DDNS00]1609
Failure Code [DFB1KZ]1611
Failure Code [DFB2KZ]1613
Failure Code [DFB3L8]1615
Failure Code [DFB4L8]1617
Failure Code [DFB5KZ]1619
Failure Code [DFB6KZ]1621
Failure Code [DGH2KA]1623
Failure Code [DGH2KB]1625
Failure Code [DHA4KA]1627
Failure Code [DHAAMA]1629
Failure Code [DHACMA]1631
Failure Code [DHPAMA]1633
Failure Code [DHPBMA]1636
Failure Code [DHS3MA]1639
Failure Code [DHS4MA]1642
Failure Code [DHS8MA]1645
Failure Code [DHS9MA]1648
Failure Code [DHSAMA]1651
Failure Code [DHSBMA]1654
Failure Code [DHSCMA]1657
Failure Code [DHSDMA]1660
Failure Code [DHSFMA]1663
Failure Code [DHSGMA]1666
Failure Code [DHSHMA]1669
Failure Code [DHSJMA]1672
Failure Code [DHX1MA]1675
Failure Code [DHZAMA]1677
Failure Code [DHZCL8]1681
Failure Code [DKR0MA]1682
Failure Code [DKR1MA]1685
Failure Code [DKULKA]1688
Failure Code [DKULKB]1690
Failure Code [DKULKY]1692
Failure Code [DLM5KA]1694
Failure Code [DLM5MB]1696
Failure Code [DR10KA]1698
Failure Code [DR12KA]1701
Failure Code [DR20KA]1703
Failure Code [DR21KX]1705
Failure Code [DR30KA]1707
Failure Code [DR31KX]1709
Failure Code [DR40KA]1711
Failure Code [DUMBKA]1713
Failure Code [DUMBKB]1715
Failure Code [DV20KB]1717
Failure Code [DW43KA]1719
Failure Code [DW43KB]1721
Failure Code [DW43KY]1723
Failure Code [DW45KA]1725
Failure Code [DW45KB]1728
Failure Code [DW45KY]1731
Failure Code [DW4CKY]1733
Failure Code [DW91KA]1735
Failure Code [DW91KB]1737
Failure Code [DW91KY]1739
Failure Code [DWA2KA]1741
Failure Code [DWA2KB]1743
Failure Code [DWA2KY]1745
Failure Code [DWK0KA]1747
Failure Code [DWK0KB]1749
Failure Code [DWK0KY]1751
Failure Code [DWK2KA]1753
Failure Code [DWK2KB]1755
Failure Code [DWK2KY]1757
Failure Code [DWK8KA]1759
Failure Code [DWK8KB]1761
Failure Code [DWK8KY]1763
Failure Code [DWN5KA]1765
Failure Code [DWN5KB]1767
Failure Code [DWN5KY]1769
Failure Code [DWPUKA]1771
Failure Code [DWPUKB]1773
Failure Code [DWPUKY]1775
Failure Code [DXA8KA]1777
Failure Code [DXA8KB]1779
Failure Code [DXA9KA]1781
Failure Code [DXA9KB]1783
Failure Code [DXE0KA]1785
Failure Code [DXE0KB]1787
Failure Code [DXE4KA]1789
Failure Code [DXE4KB]1791
Failure Code [DXE4KY]1793
Failure Code [DXE5KA]1795
Failure Code [DXE5KB]1797
Failure Code [DXE6KA]1799
Failure Code [DXE6KB]1801
Failure Code [DXE7KA]1803
Failure Code [DXE7KB]1805
Failure Code [DXE7KY]1807
Failure Code [DXE8KA]1809
Failure Code [DXE8KB]1811
Failure Code [DXE8KY]1813
Failure Code [DXE9KA]1815
Failure Code [DXE9KB]1817
Failure Code [DXE9KY]1819
Failure Code [DXEAKA]1821
Failure Code [DXEAKB]1823
Failure Code [DXEAKY]1825
Failure Code [DXEKKA]1827
Failure Code [DXEKKB]1829
Failure Code [DXEKKY]1831
Failure Code [DXELKA]1833
Failure Code [DXELKB]1835
Failure Code [DXELKY]1837
Failure Code [DY20KA]1839
Failure Code [DY20MA]1841
Failure Code [DY2CKB]1843
Failure Code [DY2DKB]1846
Failure Code [DY2EKB]1848
Troubleshooting of Electrical System (E-Mode)1850
E-1 Engine Does Not Start (Engine Does Not Crank)1850
E-2 Manual Preheating System Does Not Operate1856
E-3 Automatic Preheating System Does Not Operate1859
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On1861
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1863
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow1866
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow1867
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation1868
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs1869
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs1870
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation1871
E-12 Fuel Level Monitor Comes On in Red While Engine Runs1872
E-13 Water Separator Monitor Comes On in Red While Engine Runs1873
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1874
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation1875
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation1876
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum1877
E-18 Display of Fuel Gauge is Different from Actual Fuel Level1879
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum1880
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature1881
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum1882
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature1884
E-23 Some Areas of Machine Monitor Screen are Not Shown1885
E-24 Function Switch Does Not Operate1886
E-25 Automatic Warm-up System Does Not Work (in Cold Weather)1887
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out1888
E-27 Auto-Decelerator is Not Operated or Canceled with Lever1889
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown1890
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed1891
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change1892
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change1893
E-32 Alarm Buzzer Cannot be Canceled1895
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position1896
E-34 Service Mode Cannot be Selected1897
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move1898
E-36 All Work Equipment, Swing and Travel Do Not Lock1901
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing1903
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate1906
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show1908
E-40 One-Touch Power Maximizing Function is Not Cancelled1911
E-41 Alarm Does Not Sound During Travel1912
E-42 Alarm Does Not Stop When Machine Stops1914
E-43 Horn Does Not Sound1915
E-44 Horn Does Not Stop1918
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out1920
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate1921
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated1923
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function1924
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function1925
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function1926
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function1927
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function1928
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function1929
E-54 “Swing” is Not Shown Correctly with Monitoring Function1930
E-55 “Travel” is Not Shown Correctly with Monitoring Function1931
E-56 Service is Not Shown Correctly with Monitoring Function1932
E-57 Attachment Hydraulic Circuit Cannot be Changed1934
E-58 KOMTRAX System Does Not Operate Correctly1935
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1936
Information Shown in Troubleshooting Table (H-Mode)1936
System Chart of Hydraulic and Mechanical Systems1937
Failure Mode and Cause Table1939
H-1 All Work Equipment, Swing and Travel Do Not Work1948
H-2 All Work Equipment, Swing and Travel Lack Speed and Power1949
H-3 Fine Control Performance or Response is Unsatisfactory1952
H-4 Unusual Noise is Heard from Around Hydraulic Pump1953
H-5 Engine Speed Drops Largely or Engine Stops1954
H-6 Speed or Power of Boom is Low1956
H-7 Arm Speed or Power is Low1960
H-8 Bucket Speed or Power is Low1965
H-9 Work Equipment Does Not Move in Single Operation1968
H-10 Hydraulic Drift of Boom is Large1969
H-11 Hydraulic Drift of Arm is Large1971
H-12 Hydraulic Drift of Bucket is Large1973
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves1974
H-14 Time Lag of Work Equipment is Large1975
H-15 One-Touch Power Maximizing Function Does Not Operate1976
H-16 Attachment Circuit Cannot be Changed1977
H-17 Oil Flow in Attachment Circuit Cannot be Changed1978
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower1979
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely1980
H-20 In Mixed Operation of Swing and Boom Raise, Boom Raise Speed is Low1981
H-21 Machine Does Not Travel Straight1982
H-22 Machine is Not Steered Correctly or Steering Power is Low1984
H-23 Travel Speed is Low1987
H-24 One of Tracks Does Not Run1989
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast1990
H-26 Upper Structure Does Not Swing to Right and Left1991
H-27 Upper Structure Swings Only to Right or Left1992
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions1993
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction1994
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)1995
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)1996
H-32 Shock is Large When Upper Structure Stops Swing Operation1997
H-33 There is Large Unusual Noise When It Stops Swing Operation1998
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)1999
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)2000
H-36 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)2001
H-37 Unusual Noise is Heard from Around Fan2002
Troubleshooting of Engine (S-Mode)2003
Information Shown in Troubleshooting Table (S-Mode)2003
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position2004
S-2 Engine Cranks but No Exhaust Smoke Comes Out2005
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)2006
S-4 Engine Startability is Unsatisfactory2008
S-5 Engine Does Not Pick Up Smoothly2010
S-6 Engine Stops During Operation2012
S-7 Engine Runs Rough or is Not Stable2014
S-8 Engine Lacks Power2015
S-9 KDPF Becomes Clogged in a Short Time2017
S-10 Engine Oil Consumption is Excessive2019
S-11 Oil Becomes Dirty Quickly2020
S-12 Fuel Consumption is Excessive2021
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant2022
S-14 Oil Pressure Drops2023
S-15 Fuel Mixes Into Engine Oil2025
S-16 Water Mixes Into Engine Oil (Milky)2026
S-17 Coolant Temperature Increases Too High (Overheating)2027
S-18 Unusual Noise is Heard2028
S-19 Vibration is Excessive2029
S-20 Air Cannot be Bled from Fuel Circuit2030
S-21 Active Regeneration is Done Frequently2031
S-22 Active Regeneration Continues Long2033
S-23 White Smoke is Exhausted During Active Regeneration2034
S-24 DEF Consumption is Excessive2035
S-25 There is Unusual Smell (Irritating Odor)2037
S-26 Foreign Materials Enter DEF (DEF Increases)2038
50 Disassembly and Assembly2039
Table of Contents2040
Precautions Before Work2045
Related Information on Disassembly and Assembly2046
How to Read This Manual2046
Coating Materials List2047
Special Tool List2052
Sketches of Special Tools2064
Engine and Cooling System2070
Remove and Install Supply Pump Assembly2070
Remove Supply Pump Assembly2070
Install Supply Pump Assembly2073
Remove and Install Injector Assembly2076
How to Remove Injector Assembly2076
How to Install Injector Assembly2081
Remove and Install Cylinder Head Assembly2089
How to Remove Cylinder Head Assembly2090
How to Install Cylinder Head Assembly2099
Remove and Install EGR Valve Assembly2115
Remove EGR Valve Assembly2115
Install EGR Valve Assembly2116
Remove and Install EGR Cooler Assembly2118
How to Remove EGR Cooler Assembly2118
How to Install EGR Cooler Assembly2122
Remove and Install Starter Assembly2127
Remove Starting Motor Assembly2127
Install Starting Motor Assembly2128
Remove and Install Alternator Belt2131
Remove Alternator Belt2131
Install Alternator Belt2133
Remove and Install Radiator Assembly2136
How to Remove Radiator Assembly2136
How to Install Radiator Assembly2138
Remove and Install Hydraulic Oil Cooler Assembly2141
How to Remove Hydraulic Oil Cooler Assembly2141
How to Install Hydraulic Oil Cooler Assembly2144
Remove and Install Aftercooler Assembly2147
Remove Aftercooler Assembly2147
Install Aftercooler Assembly2149
Remove and Install Fan Clutch Assembly2151
How to Remove Fan Clutch Assembly2151
How to Install Fan Clutch Assembly2156
Remove and Install Fan2160
Remove Fan2160
Install Fan2160
Remove and Install Engine and Main Pump Assembly2161
Remove Engine and Main Pump Assembly2161
Install Engine and Main Pump Assembly2170
Remove and Install Engine Front Oil Seal2182
How to Remove Engine Front Oil Seal2182
How to Install Engine Front Oil Seal2185
Remove and Install Engine Rear Oil Seal2189
How to Remove Engine Rear Oil Seal2189
How to Install Engine Rear Oil Seal2190
Remove and Install Fuel Cooler Assembly2193
Remove Fuel Cooler Assembly2193
Install Fuel Cooler Assembly2193
Remove and Install Engine Hood Assembly2195
How to Remove Engine Hood Assembly2195
How to Install Engine Hood Assembly2197
Remove and Install Fuel Tank Assembly2202
Remove Fuel Tank Assembly2202
Install Fuel Tank Assembly2206
Remove and Install DEF Tank Assembly2212
How to Remove DEF Tank Assembly2212
How to Install DEF Tank Assembly2217
Remove and Install DEF Tank Sensor Flange Assembly2223
How to Remove DEF Tank Sensor Flange Assembly2223
How to Install DEF Tank Sensor Flange Assembly2229
Remove and Install DEF Tank Sensor2235
Remove DEF Tank Sensor2235
Install DEF Tank Sensor2235
Remove and Install DEF Tank Strainer2242
Remove DEF Tank Strainer2242
Install DEF Tank Strainer2242
Remove and Install DEF Tank Filler Port Filter2243
Remove DEF Tank Filler Port Filter2243
Install DEF Tank Filler Port Filter2245
Remove and Install KDPF Assembly2248
How to Remove KDPF Assembly2248
How to Install KDPF Assembly2250
Disassemble and Assemble KDPF Assembly2252
Disassemble KDPF Assembly2253
Assemble KDPF Assembly2256
Remove and Install SCR Assembly2261
How to Remove SCR Assembly2261
How to Install SCR Assembly2263
Remove and Install KDPF and SCR Assembly2265
How to Remove KDPF and SCR Assembly2265
Install KDPF and SCR Assembly2272
Remove and Install KDPF and SCR Assembly Bracket2278
Remove KDPF and SCR Assembly Bracket2278
Install KDPF and SCR Assembly Bracket2285
Remove and Install Bellows Pipe Assembly2292
How to Remove Bellows Pipe Assembly2292
How to Install Bellows Pipe Assembly2294
Remove and Install KCCV Assembly2298
Remove KCCV Assembly2298
Install KCCV Assembly2300
Remove and Install DEF Mixing Tube2305
Remove DEF Mixing Tube2305
Install DEF Mixing Tube2311
Remove and Install DEF Injector2317
Remove DEF Injector2317
Install DEF Injector2320
Remove and Install DEF Pump2323
Remove DEF Pump2323
Install DEF Pump2326
Remove and Install DEF Hose2329
Remove DEF Hose2329
Install DEF Hose2337
Remove and Install Air Cleaner Assembly2343
Remove Air Cleaner Assembly2343
Install Air Cleaner Assembly2344
Remove and Install Air Conditioner Compressor Assembly2346
Remove Air Conditioner Compressor Assembly2346
How to Install Air Conditioner Compressor Assembly2348
Remove and Install Air Conditioner Condenser Assembly2351
How to Remove Air Conditioner Condenser Assembly2351
How to Install Air Conditioner Condenser Assembly2352
Power Train2353
Remove and Install Travel Motor and Final Drive Assembly2353
Remove Travel Motor and Final Drive Assembly2353
Install Travel Motor and Final Drive Assembly2354
Disassemble and Assemble Final Drive Assembly2356
Disassemble Final Drive Assembly2356
Assemble Final Drive Assembly2360
Remove and Install Swing Motor and Swing Machinery Assembly2369
Remove Swing Motor and Swing Machinery Assembly2369
Install Swing Motor and Swing Machinery Assembly2371
Disassemble and Assemble Swing Machinery Assembly2375
Disassemble Swing Machinery Assembly2375
Assemble Swing Machinery Assembly2379
Remove and Install Swing Circle Assembly2386
Remove Swing Circle Assembly2386
Install Swing Circle Assembly2386
Undercarriage and Frame2388
Separate and Connect Track Assembly2388
Separate Track Assembly2388
Install Track Assembly2390
Remove and Install Sprocket2393
Remove Sprocket2393
Install Sprocket2393
Remove and Install Idler and Idler Cushion Assembly2395
Remove Idler and Idler Cushion Assembly2395
Install Idler and Idler Cushion Assembly2396
Disassemble and Assemble Idler Assembly2397
Disassemble Idler Assembly2397
Assemble Idler Assembly2398
Disassemble and Assemble Idler Cushion Assembly2402
Disassemble Idler Cushion Assembly2403
Assemble Idler Cushion Assembly2403
Disassemble and Assemble Track Roller Assembly2405
Disassemble Track Roller Assembly2406
Assemble Track Roller Assembly2407
Disassemble and Assemble Carrier Roller Assembly2409
Disassemble Carrier Roller Assembly2409
Assemble Carrier Roller Assembly2411
Remove and Install Revolving Frame Assembly2413
Remove Revolving Frame Assembly2413
Install Revolving Frame Assembly2415
Remove and Install Counterweight Assembly2418
Remove Counterweight Assembly2418
Install Counterweight Assembly2421
Hydraulic System2425
Remove and Install Center Swivel Joint Assembly2425
Remove Center Swivel Joint Assembly2425
Install Center Swivel Joint Assembly2427
Disassemble and Assemble Center Swivel Joint Assembly2430
Disassemble Center Swivel Joint Assembly2430
Assemble Center Swivel Joint Assembly2431
Remove and Install Hydraulic Tank Assembly2433
Remove Hydraulic Tank Assembly2433
How to Install Hydraulic Tank Assembly2436
Remove and Install Main Pump Assembly2440
Remove Main Pump Assembly2440
Install Main Pump Assembly2443
Remove and Install Control Valve Assembly2447
How to Remove Control Valve Assembly2447
How to Install Control Valve Assembly2454
Disassemble and Assemble Control Valve Assembly2462
Replace Pressure Compensation Valve Seal Ring2462
Assemble Control Valve Assembly2464
Disassemble and Assemble Work Equipment PPC Valve Assembly2468
Disassemble Work Equipment PPC Valve Assembly2468
How to Assemble Work Equipment PPC Valve Assembly2468
Disassemble and Assemble Travel PPC Valve Assembly2470
Disassemble Travel PPC Valve Assembly2470
How to Assemble Travel PPC Valve Assembly2471
Work Equipment2473
Remove and Install Work Equipment Assembly2473
Remove Work Equipment Assembly2473
Install Work Equipment Assembly2477
Remove and Install Boom Anti-drop Valve Assembly2482
Remove Boom Anti-drop Valve Assembly2482
Install Boom Anti-drop Valve Assembly2484
Remove and Install Arm Anti-Drop Valve Assembly2485
Remove Arm Anti-Drop Valve Assembly2485
Install Arm Anti-Drop Valve Assembly2487
Disassemble and Assemble Anti-Drop Valve Assembly2488
Disassemble Anti-Drop Valve Assembly2488
Assemble Anti-Drop Valve Assembly2488
Disassemble and Assemble Work Equipment Cylinder Assembly2489
How to Disassemble Work Equipment Cylinder Assembly2489
How to Assemble Work Equipment Cylinder Assembly2492
CAB Related Parts2498
Remove and Install Operator Cab Assembly2498
How to Remove Operator Cab Assembly2498
Install Operator CAB Assembly2506
Remove and Install Operator Cab Glass (Adhered Glass)2513
Remove Operator CAB Glass (Adhered Glass)2515
Install Operator CAB Glass (Adhered Glass)2515
Remove and Install Front Window Assembly2525
Remove Front Window Assembly2525
Install Front Window Assembly2528
Remove and Install Floor Frame Assembly2534
How to Remove Floor Frame Assembly2534
How to Install Floor Frame Assembly2541
Remove and Install Air Conditioner Unit Assembly2548
Remove Air Conditioner Unit Assembly2548
Install Air Conditioner Unit Assembly2554
Remove and Install Operator Seat2561
Remove Operator’s Seat2561
Install Operator’s Seat2563
How to Remove and Install Seat Belt2566
How to Remove Seat Belt2566
How to Install Seatbelt2567
Remove and Install Work Equipment Control Lever Assembly2568
How to Remove Work Equipment Control Lever Assembly2568
How to Install Work Equipment Control Lever Assembly2574
Remove and Install Front Wiper Assembly2583
Remove Front Wiper Assembly2583
Install Front Wiper Assembly2588
Electrical System2597
Remove and Install Engine Controller Assembly2597
Remove Engine Controller Assembly2597
Install Engine Controller Assembly2599
Remove and Install Pump Controller Assembly2600
Remove Pump Controller Assembly2600
Install Pump Controller Assembly2604
Remove and Install KomVision Controller Assembly2609
Remove KomVision Controller Assembly2609
Install KomVision Controller Assembly2610
Remove and Install Machine Monitor Assembly2612
Remove Machine Monitor Assembly2612
Install Machine Monitor Assembly2615
Remove and Install Pump Swash Plate Sensor2619
Remove Pump Swash Plate Sensor2619
Install Pump Swash Plate Sensor2620
Remove and Install Mass Air Flow and Temperature Sensor2621
How to Remove Mass Air Flow and Temperature Sensor2621
How to Install Mass Air Flow and Temperature Sensor2621
Remove and Install KCCV Crankcase Pressure Sensor2623
How to Remove KCCV Crankcase Pressure Sensor2623
How to Install KCCV Crankcase Pressure Sensor2624
Remove and Install SCR Temperature Sensor2625
Remove SCR Temperature Sensor2625
Install SCR Temperature Sensor2627
Remove and Install KomVision Camera2630
Remove KomVision Camera2630
Install KomVision Camera2633
Remove and Install KOMTRAX Terminal Assembly2636
Remove KOMTRAX Terminal Assembly2636
Install KOMTRAX Terminal Assembly2639
60 Maintenance Standard2643
Table of Contents2644
Engine and Cooling System2645
Maintenance Standard for Engine Mount2645
Maintenance Standard for Cooling System2646
Power Train2648
Maintenance Standard for Swing Circle2648
Maintenance Standard for Swing Machinery2649
Maintenance Standard for Final Drive2651
Maintenance Standard for Sprocket2653
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing2654
Undercarriage and Frame2655
Maintenance Standard for Track Frame and Idler Cushion2655
Maintenance Standard for Idler2657
Maintenance Standard for Track Roller2659
Maintenance Standard for Carrier Roller2660
Maintenance Standard for Track Shoes2661
Maintenance Standard for Triple Shoes2664
Maintenance Standard for Swamp Shoes2665
Maintenance Standard for Road Liner2666
Hydraulic System2667
Maintenance Standard for Hydraulic Tank2667
Maintenance Standard for Main Pump2668
Maintenance Standard for LS-EPC Valve2669
Maintenance Standard for PC-EPC Valve2670
Maintenance Standard for Swing Motor2671
Maintenance Standard for Travel Motor2674
Maintenance Standard for Control Valve2677
Maintenance Standard for Boom Anti-Drop Valve2687
Maintenance Standard for Arm Anti-Drop Valve2689
Maintenance Standard for Work Equipment and Swing PPC Valve2691
Maintenance Standard for Travel PPC Valve2694
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)2697
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve2698
Maintenance Standard for 2nd-Line Attachment PPC Valve2700
Maintenance Standard for Solenoid Valve2702
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure)2703
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)2704
Maintenance Standard for Center Swivel Joint2705
Work Equipment2706
Maintenance Standard for Work Equipment Linkage2706
Dimensions of Arm2711
Dimensions of Bucket2713
Maintenance Standard for Boom Cylinder (Large Diameter Piston)2715
Maintenance Standard for Arm Cylinder2716
Maintenance Standard for Bucket Cylinder2717
80 Appendix2719
Table of Contents2720
Precautions Before Work2722
Air Conditioner System2723
Precautions for Refrigerant2723
Air Conditioner Component2724
Specifications of Air Conditioner2726
Structure and Function of Refrigeration Cycle2727
Outline of Refrigeration Cycle2728
Component Parts of Air Conditioner System2730
Air Conditioner Unit2730
Configuration Diagram of Air Conditioner Unit2730
Function of Air Conditioner Unit2732
Component Parts of Air Conditioner Unit2734
Function of Evaporator as Air Conditioner Unit Component2735
Function of Heater Core as Air Conditioner Unit Component2735
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2735
Function of Servo Motor as Air Conditioner Unit Component2735
Structure of Expansion Valve as Air Conditioner Unit Component2736
Function of Expansion Valve as Air Conditioner Unit Component2736
Operate Expansion Valve as Air Conditioner Unit Component2736
Function of Dual Pressure Switch2737
Air Conditioner Controller2738
Structure of Air Conditioner Controller2738
Compressor2739
Structure of Compressor2739
Specifications of Compressor2739
Function of Compressor2739
Condenser2740
Structure of Condenser2740
Specifications of Condenser2740
Function of Condenser2740
Air Conditioner Related Sensors2742
Structure of Sunlight Sensor2742
Function of Sunlight Sensor2742
Structure of Outside Temperature Sensor2742
Function of Outside Air Temperature Sensor2742
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2744
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2746
System Diagram of Air Conditioner2748
Input and Output Signals of Air Conditioner Controller2749
Function of Air Conditioner Controller2750
Locations of Air Conditioner Parts and Layout of Connectors2751
Examine Air Leakage (Duct)2755
How to Examine Air Leakage (Duct)2755
Examine Air Conditioner with Self-Diagnosis Function2757
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2758
Examine Vent (Mode) Changeover2759
How to Examine Vent (Mode) Changeover2759
Examine Fresh/Recirc Air Changeover2761
How to Examine Fresh/Recirc Air Changeover2761
Examine Sunlight Sensor2762
How to Examine Sunlight Sensor2762
Examine Refrigerant (Dual) Pressure Switch2763
How to Examine Refrigerant (Dual) Pressure Switch2763
Examine Relay2764
How to Examine Relay2764
Air Conditioner Troubleshooting Chart 12765
Air Conditioner Troubleshooting Chart 22766
Information Shown in Troubleshooting Table2769
Failure Code [879AKA]2770
Failure Code [879AKB]2771
Failure Code [879BKA]2772
Failure Code [879BKB]2774
Failure Code [879CKA]2776
Failure Code [879CKB]2777
Failure Code [879DKZ]2778
Failure Code [879EMC]2780
Failure Code [879FMC]2781
Failure Code [879GKX]2782
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2784
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2786
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2789
A-4 Troubleshooting for Fresh/Recirc Air Changeover2791
Troubleshooting by Gauge Pressure2793
Connect Service Tool2796
How to Connect Service Tool2796
Precautions for Disconnection and Connection of Air Conditioner Piping2798
Handle Compressor Oil2800
Replace Desiccant2802
90 Circuit Diagrams2805
Table of Contents2806
Hydraulic Circuit Diagram2807
Symbols Used in Hydraulic Circuit Diagram2807
Hydraulic Circuit Diagram2811
Electrical Circuit Diagram2813
Symbols Used in Electric Circuit Diagram2813
Electrical Circuit Diagram (1/8)2817
Electrical Circuit Diagram (2/8)2819
Electrical Circuit Diagram (3/8)2821
Electrical Circuit Diagram (4/8)2823
Electrical Circuit Diagram (5/8)2825
Electrical Circuit Diagram (6/8)2827
Electrical Circuit Diagram (7/8)2829
Electrical Circuit Diagram (8/8)2831
INDEX2833

IMAGES PREVIEW OF THE MANUAL:

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