Komatsu HYDRAULIC EXCAVATOR PC240LC-11 Shop Manual SEN06501-19 -PDF

Description

Komatsu HYDRAULIC EXCAVATOR PC240LC-11 Shop Manual SEN06501-19 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HYDRAULIC EXCAVATOR PC240LC-11 Shop Manual SEN06501-19 – PDF DOWNLOAD

Language : English
Pages :2792
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC240LC-11 Shop Manual SEN06501-19 – PDF DOWNLOAD

SERIAL NUMBERS 95001 and up

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC240LC-11 Shop Manual SEN06501-19 – PDF DOWNLOAD

SERIAL NUMBERS 95001 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: PC240LC-11 93
Working Range Drawings 95
Working Range: PC240LC-11 95
Specifications 96
Specifications: PC240LC-11 96
Weight Table 99
Weight Table: PC240LC-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 130
DEF Mixing Tube 130
SCR Assembly 130
DEF Tank 133
DEF Pump 135
DEF Injector 136
DEF Hose 137
DEF Tank Heating Valve 138
Boot-up System 139
Layout Drawing of Boot-up System 139
System Operating Lamp System 141
System Diagram of System Operating Lamp System 141
Function of Operation Lamp System 141
Battery Disconnect Switch 143
Function of Battery Disconnect Switch 143
Engine System 144
Layout Drawing of Engine System 144
Specifications of Engine System 145
Function of Engine System 145
Engine Control System 146
System Diagram of Engine Control 146
Function of Engine Control System 147
Auto-Deceleration System 149
System Diagram of Auto-Deceleration System 149
Function of Auto-Deceleration System 149
Operation of Auto-Deceleration System 150
Engine Automatic Warm-up System 151
System Diagram of Engine Automatic Warm-up System 151
Function of Engine Automatic Warm-up System 152
Overheat Prevention System 153
Overheat Prevention System Diagram 153
Function of Overheat Prevention System 154
Turbocharger Protection System 156
System Diagram of Turbocharger Protection System 156
Function of Turbocharger Protection System 157
Automatic Idle Stop System 158
System Diagram of Automatic Idle Stop System 158
Function of Automatic Idle Stop System 158
Component Parts of Engine System 161
VGT 161
EGR System 165
EGR Valve 167
EGR Cooler 169
KCCV System 170
KCCV Ventilator 172
KDPF 174
Cooling System 179
Layout Drawing of Cooling System 179
Specifications of Cooling System 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 203
KomVision Camera 207
KOMTRAX Terminal 207
Pump Controller 210
Resistor for PC-EPC Valve 214
CAN Terminating Resistor 214
Engine Controller 216
Fuel Control Dial 222
Hydraulic System 224
Layout Drawing of Hydraulic System 224
CLSS 230
Structure of CLSS 230
Operation of Unload Valve and LS Pressure 232
Pump Swash Plate Angle (Oil Flow) Control 233
Pressure Compensation Control 249
Engine and Pump Combined Control System 252
Engine and Pump Combined Control System Diagram 252
Function of Engine and Pump Combined Control System 253
Pump and Valve Control System 258
Pump and Valve Control System Diagram 258
Function of Pump and Valve Control System 259
Component Parts of Hydraulic System 261
Hydraulic Tank 261
Main Pump 263
Control Valve 287
Work Equipment System 350
Layout Drawing of Work Equipment System 350
Structure of Valve Control 355
One-Touch Power Maximizing System 357
System Diagram of One-Touch Power Maximizing System 357
Function of One-Touch Power Maximizing System 358
PPC Lock System 359
System Diagram of PPC Lock 359
Function of PPC Lock System 359
Work Equipment and Travel Automatic Lock System 360
System Diagram of Lock Lever Automatic Lock System 360
Function of Work Equipment and Travel Automatic Lock System 360
Operation of Lock Lever Automatic Lock System 361
Attachment Oil Flow Adjuster System 362
Attachment Oil Flow Adjuster System Diagram 362
Function of Attachment Oil Flow Adjuster System 363
Attachment Oil Flow Adjuster System 364
Tool Control System Diagram 364
Component Parts of Work Equipment System 366
Work Equipment and Swing PPC Valve 366
1st-Line Attachment PPC Valve (with EPC Valve) 372
2nd-Line Attachment PPC Valve 378
Solenoid Valve 380
Boom Anti-drop Valve 383
Arm Anti-Drop Valve 387
Attachment Circuit Selector Valve (For High Pressure) 391
Attachment Circuit Selector Valve (For Low Pressure) 393
1st-Line Attachment Variable Relief Valve 395
2nd-Line Attachment Variable Relief Valve 398
Attachment Bypass Solenoid Valve 401
Pilot Circuit Accumulator 403
Attachment Circuit Accumulator 404
Swing System 405
Layout Drawing of Swing System 405
Swing Control System Diagram 409
Function of Swing Control System 410
Component Parts of Swing System 413
Swing Motor 413
Swing Machinery 424
Swing Circle 425
Travel System 427
Layout Drawing of Travel System 427
System Diagram of Travel Control System 431
Function of Travel Control System 431
Component Parts of Travel System 433
Travel Motor 433
Final Drive 445
Travel PPC Valve 447
Center Swivel Joint 452
Undercarriage and Frame 454
Layout Drawing of Undercarriage 454
Specifications of Undercarriage 455
Work Equipment 456
Structure of Work Equipment 456
Function of Work Equipment 457
Work Equipment Clearance Adjustment Shim 458
Function of Work Equipment Clearance Adjustment Shim 458
Bucket Clearance Adjustment Shim 459
Function of Bucket Clearance Adjustment Shim 459
CAB Related Parts 460
ROPS CAB 460
Structure of ROPS CAB 460
Function of ROPS CAB 460
CAB Mount 461
Structure of CAB Mount 461
Function of CAB Mount 461
CAB Tipping Stopper 462
Structure of CAB Tipping Stopper 462
Function of CAB Tipping Stopper 462
20 Standard Value Table 463
Table of Contents 464
Standard Value Table for Engine 465
Standard Value Table for Engine: PC240LC-11 465
Standard Value Table for Machine 469
Standard Value Table for Machine: PC240LC-11 469
Machine Posture and Procedures to Measure Performance 482
Standard Value Table for Electricity 486
Standard Value Table for Electricity 486
30 Testing and Adjusting 497
Table of Contents 498
Precautions Before Work 501
Related Information on Testing and Adjusting 502
Tools for Testing and Adjusting 502
Sketch of Tools for Testing and Adjusting 509
Engine and Cooling System 511
Examine Engine Speed 511
How to Examine Engine Speed 511
Examine Boost Pressure 514
How to Examine Boost Pressure on Machine Monitor 514
How to Examine Boost Pressure by Testing Tool 515
Examine Exhaust Gas Color 516
How to Examine Exhaust Gas Color with the Handy Smoke Checker 516
How to Examine Exhaust Gas Color with Smoke Meter 517
Examine Mass Air Flow and Temperature Sensor 519
How to Examine Mass Air Flow and Temperature Sensor 519
Examine and Adjust Valve Clearance 521
Check Valve Clearance 521
Adjust Valve Clearance 522
Examine Compression Pressure 524
How to Examine Compression Pressure 524
Examine Blowby Pressure 529
How to Examine Blowby Pressure 529
Examine Engine Oil Pressure 531
How to Examine Engine Oil Pressure 531
Examine EGR Valve and VGT Oil Pressure 532
How to Examine EGR Valve and VGT Oil Pressure 532
Examine Fuel Pressure 534
How to Examine Fuel Pressure 535
Examine Fuel Discharge, Return and Leakage 540
How to Examine Fuel Discharge, Return, and Leakage 541
Bleed Air from Fuel System 547
How to Bleed Air from Fuel System 547
Examine Fuel Circuit for Leakage 548
How to Examine Fuel System for Leakage 548
Handle Cylinder Cut-out Mode Operation 550
Handle No-Injection Cranking Operation 551
Examine and Adjust Air Conditioner Compressor Belt Tension 552
How to Examine Air Conditioner Compressor Belt 552
How to Adjust Air Conditioner Compressor Belt 552
Examine Fan Belt and Alternator Belt 554
How to Examine Fan Belt and Alternator Belt 554
Examine Automatic Tensioner 555
How to Examine Automatic Tensioner 555
Write Correction for Ash in Soot Accumulation to Engine Controller 556
How to Write Correction for Ash in Soot Accumulation to Engine Controller 556
Examine SCR Related Functions 557
Examine DEF Pump Raised Pressure 560
Examine Injection Volume from DEF Injector 563
Examine DEF Line Heater Relay 1 567
Examine DEF Line Heater Relay 2 570
Examine DEF Pump Heater Relay 572
Examine DEF Tank Heater Valve 575
Examine SCR Denitration Efficiency 578
Clean DEF Tank 582
How to Clean DEF Tank 582
Clean DEF Pump 586
How to Clean DEF Pump 586
Bleed Air from Coolant Circuit of DEF Tank 593
How to Bleed Air from Coolant Circuit of DEF Tank 593
Power Train 595
Examine Swing Circle Bearing Clearance 595
How to Examine Swing Circle Bearing Clearance 595
Undercarriage and Frame 596
Examine and Adjust Track Tension 596
How to Examine Track Tension 596
How to Adjust Track Tension 596
Hydraulic System 598
Release Remained Pressure in Hydraulic Circuit 598
How to Release Remained Pressure in Hydraulic System 598
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 599
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 600
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 606
Examine Oil Pressure of Control Circuit 609
Examine Oil Pressure in Control Circuit 609
Examine and adjust oil pressure in pump PC control circuit 611
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 611
Examine PC-EPC Valve Outlet Pressure 612
How to Adjust Oil Pressure in Pump PC Control Circuit 613
Examine and Adjust Oil Pressure in Pump LS Control Circuit 615
Examine LS Differential Pressure with Machine Monitor 615
Examine LS Differential Pressure by Testing Tool 616
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 619
How to Examine LS-EPC Valve Outlet Pressure 620
Adjust LS Valve 621
Examine Outlet Pressure of Solenoid Valve 622
How to Examine Outlet Pressure of Solenoid Valve 622
Operating Condition of Solenoid Valve 623
Examine PPC Valve Outlet Pressure 626
Examine Outlet Pressure in PPC Valve 626
Examine Attachment Circuit Oil Pressure 628
How to Examine Attachment Circuit Oil Pressure 628
Adjust Play of Work Equipment and Swing PPC Valves 629
How to Adjust Play of Work Equipment and Swing PPC Valves 629
Examine Pump Swash Plate Sensor 630
How to Examine pump swash plate sensor 630
Examine Parts Which Cause Hydraulic Drift of Work Equipment 631
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 631
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 631
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 632
Examine Oil Leakage 633
How to Examine Oil Leakage from Boom Cylinder 633
How to Examine Oil Leakage from Arm Cylinder 633
How to Examine Oil Leakage from Bucket Cylinder 634
How to Examine Oil Leakage from Swing Motor 635
How to Examine Oil Leakage from Travel Motor 635
Bleed Air from Hydraulic System 636
How to Bleed Air from Hydraulic System 638
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 640
Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 640
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 644
Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 644
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 648
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 648
CAB Related Parts 655
Examine CAB Tipping Stopper 655
How to Examine Cab Tipping Stopper 655
How to Adjust Mirrors 656
Procedure to Adjust Machine Left Front Mirror (A) 656
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 657
Procedure to Adjust Machine Right Front Mirror (B) 658
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 659
Procedure to Adjust Machine Right Side Mirror (C) 660
Electrical System 662
Set and Operate Machine Monitor 662
Operator Mode 665
Function to Show Technician Identification Status Screen 666
Function to Show Operator Identification Input Screen 666
Examine Function by LCD (Liquid Crystal Display) 667
Examine Function of Service Meter 667
Usage Limitation and Maintenance Password Change Function 667
Service Mode 670
Operate Service Mode 670
How to See Pre-defined Monitoring Information 672
How to Examine Self-Define Monitor Information 678
Abnormality Record Menu 689
How to See Maintenance Record 693
Maintenance Mode Setting 695
Set Phone Number Entry 698
Default Menu 699
Diagnostic Tests Menu 711
Adjustment Menu 720
No-Injection Cranking Operation 751
KOMTRAX Settings Menu 752
Show Service Message 754
How to Start Up KOMTRAX Terminal 756
Adjust Rearview Camera Angle 761
How to Adjust Rearview Camera Angle 761
Adjust KomVision Camera Angle 764
How to Adjust KomVision Camera Angle 765
Adjust KomVision Related Function 769
Setting of KomVision (Main Setting) 769
Setting of KomVision (Camera Setting) 771
Setting of KomVision (Camera Calibration) 773
KomVision screen – Check 12 m visibility 786
Set Region of Bluetooth(R) Compatible Radio 789
Set Region of Bluetooth(R) Compatible Radio 789
Handle Voltage Circuit of Engine Controller 791
Handle Battery Disconnect Switch 792
Examine Diodes 793
Examine Diodes by Digital Tester 793
How to Examine Diodes by Analog Tester 793
Pm Clinic 794
Pm Clinic Service 794
Pm Clinic Check Sheet 795
40 Troubleshooting 807
Table of Contents 808
Precautions Before Work 818
Related Information to Troubleshooting 819
General Troubleshooting Points 819
Troubleshooting Points for Urea SCR System 820
Sequence of Events in Troubleshooting 834
Checks Before Troubleshooting 836
Inspection Procedure Before Troubleshooting 838
Walk-Around Check 838
Test in Accordance with Testing Procedure 840
Examine Fuel Level and Type 840
Examine for Impure Ingredient in Fuel 840
Examine Fuel Prefilter 841
Examine Water Separator, Drain Water and Sediment 841
How to Replace Fuel Prefilter Cartridge 842
Examine Fuel Main Filter 843
Examine Engine Oil Level (Oil Quantity in Oil Pan) 845
Examine Coolant Level (Reservoir Tank) 846
Examine Air Cleaner Clogging 846
Clean Outer Element 847
Replace Element 849
Examine Hydraulic Oil Level 850
Examine Hydraulic Oil Strainer 851
Examine Hydraulic Oil Filter 852
Examine Oil Level in Swing Machinery Case 853
Examine Oil Level in Damper Case 854
Examine Oil Level in Final Drive Case 854
Bleed Air from Fuel System 855
Bleed Air from Hydraulic System 855
How to Examine Electric Equipment 855
Preparation for Troubleshooting of Electrical System 863
Procedure for Troubleshooting 873
Symptom and Troubleshooting Numbers 876
Information Shown in Troubleshooting Table 880
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 882
Connector List and Layout 885
Connector Contact Connection Table 898
T-Branch Box and T-Branch Adapter Table 938
Fuse Location Table 944
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 946
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 950
Failure Code Table 952
Troubleshooting by Failure Code (Display of Code) 970
Failure Code [879AKA] 970
Failure Code [879AKB] 971
Failure Code [879BKA] 972
Failure Code [879BKB] 974
Failure Code [879CKA] 976
Failure Code [879CKB] 977
Failure Code [879DKZ] 978
Failure Code [879EMC] 980
Failure Code [879FMC] 981
Failure Code [879GKX] 982
Failure Code [989L00] 984
Failure Code [989M00] 985
Failure Code [989N00] 986
Failure Code [A1U0N3] 987
Failure Code [A1U0N4] 989
Failure Code [A900FR] 991
Failure Code [A900N6] 992
Failure Code [A900NY] 993
Failure Code [AA10NX] 994
Failure Code [AB00KE] 996
Failure Code [AQ10N3] 999
Failure Code [AS00N3]1001
Failure Code [AS00R2]1003
Failure Code [AS00R3]1004
Failure Code [AS00R4]1005
Failure Code [AS00R5]1006
Failure Code [AS00R6]1007
Failure Code [AS00ZK]1008
Failure Code [AS10KM]1009
Failure Code [AS10NR]1010
Failure Code [AS10NT]1011
Failure Code [B@BAZG]1012
Failure Code [B@BAZK]1013
Failure Code [B@BCNS]1015
Failure Code [B@BCQA]1016
Failure Code [B@BCZK]1018
Failure Code [B@HANS]1020
Failure Code [CA115]1021
Failure Code [CA122]1022
Failure Code [CA123]1024
Failure Code [CA131]1026
Failure Code [CA132]1028
Failure Code [CA144]1030
Failure Code [CA145]1032
Failure Code [CA153]1034
Failure Code [CA154]1037
Failure Code [CA187]1039
Failure Code [CA221]1041
Failure Code [CA222]1043
Failure Code [CA227]1045
Failure Code [CA234]1046
Failure Code [CA238]1047
Failure Code [CA239]1049
Failure Code [CA249]1051
Failure Code [CA256]1053
Failure Code [CA271]1055
Failure Code [CA272]1057
Failure Code [CA322]1059
Failure Code [CA323]1061
Failure Code [CA324]1063
Failure Code [CA325]1065
Failure Code [CA331]1067
Failure Code [CA332]1069
Failure Code [CA343]1071
Failure Code [CA351]1072
Failure Code [CA352]1073
Failure Code [CA356]1076
Failure Code [CA357]1078
Failure Code [CA386]1080
Failure Code [CA428]1081
Failure Code [CA429]1083
Failure Code [CA435]1085
Failure Code [CA441]1087
Failure Code [CA442]1089
Failure Code [CA449]1090
Failure Code [CA451]1091
Failure Code [CA452]1093
Failure Code [CA488]1095
Failure Code [CA515]1096
Failure Code [CA516]1098
Failure Code [CA553]1100
Failure Code [CA555]1101
Failure Code [CA556]1102
Failure Code [CA559]1103
Failure Code [CA595]1106
Failure Code [CA687]1107
Failure Code [CA689]1109
Failure Code [CA691]1112
Failure Code [CA692]1114
Failure Code [CA697]1116
Failure Code [CA698]1117
Failure Code [CA731]1118
Failure Code [CA778]1120
Failure Code [CA1117]1125
Failure Code [CA1664]1126
Failure Code [CA1669]1128
Failure Code [CA1673]1129
Failure Code [CA1677]1130
Failure Code [CA1678]1131
Failure Code [CA1682]1132
Failure Code [CA1683]1134
Failure Code [CA1684]1136
Failure Code [CA1686]1138
Failure Code [CA1691]1139
Failure Code [CA1694]1142
Failure Code [CA1695]1145
Failure Code [CA1696]1146
Failure Code [CA1712]1148
Failure Code [CA1713]1151
Failure Code [CA1714]1153
Failure Code [CA1715]1154
Failure Code [CA1776]1155
Failure Code [CA1777]1158
Failure Code [CA1843]1161
Failure Code [CA1844]1163
Failure Code [CA1879]1166
Failure Code [CA1881]1168
Failure Code [CA1883]1170
Failure Code [CA1885]1173
Failure Code [CA1887]1175
Failure Code [CA1921]1177
Failure Code [CA1922]1180
Failure Code [CA1942]1185
Failure Code [CA1993]1186
Failure Code [CA2185]1189
Failure Code [CA2186]1190
Failure Code [CA2249]1192
Failure Code [CA2271]1193
Failure Code [CA2272]1196
Failure Code [CA2288]1199
Failure Code [CA2311]1200
Failure Code [CA2349]1201
Failure Code [CA2353]1204
Failure Code [CA2357]1206
Failure Code [CA2381]1207
Failure Code [CA2382]1210
Failure Code [CA2383]1213
Failure Code [CA2386]1216
Failure Code [CA2387]1218
Troubleshooting Flowchart1222
Failure Code [CA2555]1223
Failure Code [CA2556]1226
Failure Code [CA2637]1229
Failure Code [CA2639]1231
Failure Code [CA2771]1234
Failure Code [CA2777]1240
Failure Code [CA2976]1243
Failure Code [CA3133]1245
Failure Code [CA3134]1248
Failure Code [CA3135]1250
Failure Code [CA3142]1253
Failure Code [CA3143]1254
Failure Code [CA3144]1255
Failure Code [CA3146]1257
Failure Code [CA3147]1258
Failure Code [CA3148]1259
Failure Code [CA3151]1261
Failure Code [CA3165]1267
Failure Code [CA3229]1269
Failure Code [CA3231]1271
Failure Code [CA3232]1273
Failure Code [CA3235]1277
Failure Code [CA3239]1279
Failure Code [CA3241]1282
Failure Code [CA3242]1285
Failure Code [CA3251]1288
Failure Code [CA3253]1290
Failure Code [CA3254]1293
Failure Code [CA3255]1296
Failure Code [CA3256]1300
Failure Code [CA3311]1302
Failure Code [CA3312]1304
Failure Code [CA3313]1307
Failure Code [CA3314]1308
Failure Code [CA3315]1309
Failure Code [CA3316]1311
Failure Code [CA3317]1312
Failure Code [CA3318]1313
Failure Code [CA3319]1315
Failure Code [CA3321]1316
Failure Code [CA3322]1318
Failure Code [CA3419]1320
Failure Code [CA3421]1322
Failure Code [CA3497]1324
Failure Code [CA3498]1325
Failure Code [CA3543]1326
Failure Code [CA3545]1333
Failure Code [CA3547]1335
Failure Code [CA3558]1336
Failure Code [CA3559]1338
Failure Code [CA3562]1340
Failure Code [CA3563]1342
Failure Code [CA3567]1345
Failure Code [CA3568]1348
Failure Code [CA3571]1352
Failure Code [CA3572]1354
Failure Code [CA3574]1356
Failure Code [CA3575]1358
Failure Code [CA3577]1360
Failure Code [CA3578]1362
Failure Code [CA3582]1364
Failure Code [CA3583]1370
Failure Code [CA3596]1372
Failure Code [CA3649]1374
Failure Code [CA3681]1376
Failure Code [CA3682]1381
Failure Code [CA3713]1387
Failure Code [CA3717]1390
Failure Code [CA3718]1391
Failure Code [CA3725]1392
Failure Code [CA3741]1395
Failure Code [CA3748]1396
Failure Code [CA3751]1398
Failure Code [CA3755]1400
Failure Code [CA3866]1402
Failure Code [CA3867]1406
Failure Code [CA3868]1409
Failure Code [CA3899]1413
Failure Code [CA3911]1415
Failure Code [CA3912]1419
Failure Code [CA3932]1421
Failure Code [CA3933]1423
Failure Code [CA3934]1425
Failure Code [CA3935]1428
Failure Code [CA3936]1430
Failure Code [CA4151]1432
Failure Code [CA4152]1436
Failure Code [CA4155]1440
Failure Code [CA4156]1442
Failure Code [CA4157]1445
Failure Code [CA4158]1447
Failure Code [CA4159]1448
Failure Code [CA4161]1449
Failure Code [CA4162]1452
Failure Code [CA4163]1455
Failure Code [CA4164]1456
Failure Code [CA4165]1458
Failure Code [CA4166]1460
Failure Code [CA4168]1461
Failure Code [CA4169]1464
Failure Code [CA4171]1466
Failure Code [CA4249]1469
Failure Code [CA4251]1471
Failure Code [CA4259]1473
Failure Code [CA4261]1476
Failure Code [CA4277]1479
Failure Code [CA4281]1483
Failure Code [CA4459]1486
Failure Code [CA4461]1488
Failure Code [CA4658]1491
Failure Code [CA4731]1495
Failure Code [CA4732]1496
Failure Code [CA4739]1497
Failure Code [CA4768]1498
Failure Code [CA4769]1500
Failure Code [CA4842]1503
Failure Code [CA4952]1507
Failure Code [CA5115]1509
Failure Code [CA5179]1512
Failure Code [CA5181]1514
Failure Code [CA5383]1516
Failure Code [D110KB]1518
Failure Code [D19JKZ]1520
Failure Code [D811MC]1523
Failure Code [D862KA]1524
Failure Code [D8ALKA]1525
Failure Code [D8ALKB]1527
Failure Code [D8AQKR]1529
Failure Code [DA20MC]1531
Failure Code [DA22KK]1532
Failure Code [DA25KP]1535
Failure Code [DA26KP]1538
Failure Code [DA29KQ]1541
Failure Code [DA2LKA]1543
Failure Code [DA2LKB]1545
Failure Code [DA2QKR]1547
Failure Code [DA2RKR]1550
Failure Code [DAF0KM]1551
Failure Code [DAF0MB]1552
Failure Code [DAF0MC]1553
Failure Code [DAF8KB]1554
Failure Code [DAF9KQ]1556
Failure Code [DAFGMC]1557
Failure Code [DAFLKA]1558
Failure Code [DAFLKB]1560
Failure Code [DAFQKR]1562
Failure Code [DAZ9KQ]1563
Failure Code [DAZQKR]1564
Failure Code [DB2QKR]1569
Failure Code [DB2RKR]1574
Failure Code [DBP0KM]1579
Failure Code [DBP0KT]1580
Failure Code [DBP5KB]1581
Failure Code [DBP5KY]1584
Failure Code [DBPQKR]1587
Failure Code [DDNRKA]1592
Failure Code [DDNRKY]1594
Failure Code [DDNS00]1596
Failure Code [DGH2KA]1598
Failure Code [DGH2KB]1600
Failure Code [DHA4KA]1602
Failure Code [DHAAMA]1604
Failure Code [DHACMA]1606
Failure Code [DHPAMA]1608
Failure Code [DHPBMA]1611
Failure Code [DHS3MA]1614
Failure Code [DHS4MA]1617
Failure Code [DHS8MA]1620
Failure Code [DHS9MA]1623
Failure Code [DHSAMA]1626
Failure Code [DHSBMA]1629
Failure Code [DHSCMA]1632
Failure Code [DHSDMA]1635
Failure Code [DHSFMA]1638
Failure Code [DHSGMA]1641
Failure Code [DHSHMA]1644
Failure Code [DHSJMA]1647
Failure Code [DHZAMA]1650
Failure Code [DHZCL8]1654
Failure Code [DKR0MA]1655
Failure Code [DKR1MA]1658
Failure Code [DKULKA]1661
Failure Code [DKULKB]1663
Failure Code [DKULKY]1665
Failure Code [DR10KA]1667
Failure Code [DR12KA]1670
Failure Code [DR20KA]1672
Failure Code [DR21KX]1674
Failure Code [DR30KA]1676
Failure Code [DR31KX]1678
Failure Code [DR40KA]1680
Failure Code [DUMBKA]1682
Failure Code [DUMBKB]1684
Failure Code [DV20KB]1686
Failure Code [DW43KA]1688
Failure Code [DW43KB]1690
Failure Code [DW43KY]1692
Failure Code [DW45KA]1694
Failure Code [DW45KB]1697
Failure Code [DW45KY]1700
Failure Code [DW4CKY]1702
Failure Code [DW91KA]1704
Failure Code [DW91KB]1706
Failure Code [DW91KY]1708
Failure Code [DWA2KA]1710
Failure Code [DWA2KB]1712
Failure Code [DWA2KY]1714
Failure Code [DWK0KA]1716
Failure Code [DWK0KB]1718
Failure Code [DWK0KY]1720
Failure Code [DWK2KA]1722
Failure Code [DWK2KB]1724
Failure Code [DWK2KY]1726
Failure Code [DWK8KA]1728
Failure Code [DWK8KB]1730
Failure Code [DWK8KY]1732
Failure Code [DWPUKA]1734
Failure Code [DWPUKB]1736
Failure Code [DWPUKY]1738
Failure Code [DXA8KA]1740
Failure Code [DXA8KB]1742
Failure Code [DXA9KA]1744
Failure Code [DXA9KB]1746
Failure Code [DXE0KA]1748
Failure Code [DXE0KB]1750
Failure Code [DXE4KA]1752
Failure Code [DXE4KB]1754
Failure Code [DXE4KY]1756
Failure Code [DXE5KA]1758
Failure Code [DXE5KB]1760
Failure Code [DXE6KA]1762
Failure Code [DXE6KB]1764
Failure Code [DXE7KA]1766
Failure Code [DXE7KB]1768
Failure Code [DXE7KY]1770
Failure Code [DXE8KA]1772
Failure Code [DXE8KB]1774
Failure Code [DXE8KY]1776
Failure Code [DXE9KA]1778
Failure Code [DXE9KB]1780
Failure Code [DXE9KY]1782
Failure Code [DXEAKA]1784
Failure Code [DXEAKB]1786
Failure Code [DXEAKY]1788
Failure Code [DXEKKA]1790
Failure Code [DXEKKB]1792
Failure Code [DXEKKY]1794
Failure Code [DXELKA]1796
Failure Code [DXELKB]1798
Failure Code [DXELKY]1800
Failure Code [DY20KA]1802
Failure Code [DY20MA]1804
Failure Code [DY2CKB]1806
Failure Code [DY2DKB]1809
Failure Code [DY2EKB]1811
Troubleshooting of Electrical System (E-Mode)1813
E-1 Engine Does Not Start (Engine Does Not Crank)1813
E-2 Manual Preheating System Does Not Operate1819
E-3 Automatic Preheating System Does Not Operate1822
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On1824
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1826
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow1829
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow1830
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation1831
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs1832
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs1833
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation1834
E-12 Fuel Level Monitor Comes On in Red While Engine Runs1835
E-13 Water Separator Monitor Comes On in Red While Engine Runs1836
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1837
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation1838
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation1839
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum1840
E-18 Display of Fuel Gauge is Different from Actual Fuel Level1842
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum1843
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature1844
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum1845
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature1847
E-23 Some Areas of Machine Monitor Screen are Not Shown1848
E-24 Function Switch Does Not Operate1849
E-25 Automatic Warm-up System Does Not Work (in Cold Weather)1850
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out1851
E-27 Auto-Decelerator is Not Operated or Canceled with Lever1852
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown1853
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed1854
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change1855
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change1856
E-32 Alarm Buzzer Cannot be Canceled1858
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position1859
E-34 Service Mode Cannot be Selected1860
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move1861
E-36 All Work Equipment, Swing and Travel Do Not Lock1864
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing1866
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate1869
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show1871
E-40 One-Touch Power Maximizing Function is Not Cancelled1874
E-41 Alarm Does Not Sound During Travel1875
E-42 Alarm Does Not Stop When Machine Stops1877
E-43 Horn Does Not Sound1878
E-44 Horn Does Not Stop1881
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out1883
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate1884
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated1886
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function1887
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function1888
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function1889
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function1890
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function1891
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function1892
E-54 “Swing” is Not Shown Correctly with Monitoring Function1893
E-55 “Travel” is Not Shown Correctly with Monitoring Function1894
E-56 Service is Not Shown Correctly with Monitoring Function1895
E-57 Attachment Hydraulic Circuit Cannot be Changed1897
E-58 KOMTRAX System Does Not Operate Correctly1898
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1899
Information Shown in Troubleshooting Table (H-Mode)1899
System Chart of Hydraulic and Mechanical Systems1900
Failure Mode and Cause Table1902
H-1 All Work Equipment, Swing and Travel Do Not Work1911
H-2 All Work Equipment, Swing and Travel Lack Speed and Power1912
H-3 Fine Control Performance or Response is Unsatisfactory1915
H-4 Unusual Noise is Heard from Around Hydraulic Pump1916
H-5 Engine Speed Drops Largely or Engine Stops1917
H-6 Speed or Power of Boom is Low1919
H-7 Arm Speed or Power is Low1923
H-8 Bucket Speed or Power is Low1928
H-9 Work Equipment Does Not Move in Single Operation1931
H-10 Hydraulic Drift of Boom is Large1932
H-11 Hydraulic Drift of Arm is Large1934
H-12 Hydraulic Drift of Bucket is Large1936
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves1937
H-14 Time Lag of Work Equipment is Large1938
H-15 One-Touch Power Maximizing Function Does Not Operate1939
H-16 Attachment Circuit Cannot be Changed1940
H-17 Oil Flow in Attachment Circuit Cannot be Changed1941
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower1942
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely1943
H-20 In Mixed Operation of Swing and Boom Raise, Boom Raise Speed is Low1944
H-21 Machine Does Not Travel Straight1945
H-22 Machine is Not Steered Correctly or Steering Power is Low1947
H-23 Travel Speed is Low1950
H-24 One of Tracks Does Not Run1952
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast1953
H-26 Upper Structure Does Not Swing to Right and Left1954
H-27 Upper Structure Swings Only to Right or Left1955
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions1956
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction1957
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)1958
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)1959
H-32 Shock is Large When Upper Structure Stops Swing Operation1960
H-33 There is Large Unusual Noise When It Stops Swing Operation1961
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)1962
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)1963
Troubleshooting of Engine (S-Mode)1964
Information Shown in Troubleshooting Table (S-Mode)1964
Engine Does Not Crank When Starting Switch is Turned to Start Position1965
Engine Cranks but No Exhaust Smoke Comes Out1966
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)1967
Engine Startability is Unsatisfactory1969
Engine Does Not Pick Up Smoothly1971
Engine Stops During Operation1973
Engine Does Not Rotate Smoothly1975
Engine Lacks Output (or Lacks Power)1976
KDPF Becomes Clogged in a Short Time1978
Engine Oil Consumption is Excessive1980
Engine Oil Becomes Dirty Quickly1981
Fuel Consumption is Excessive1982
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)1983
Engine Oil Pressure Drops1984
Fuel Mixes Into Engine Oil1986
Water Mixes Into Engine Oil (Milky)1987
Coolant Temperature Increases Too High (Overheat)1988
Unusual Noise is Heard1989
Vibration is Excessive1990
Air Cannot be Bled from Fuel Circuit1991
Active Regeneration is Done Frequently1992
Active Regeneration Continues Long1994
White Smoke is Exhausted During Active Regeneration1995
DEF Consumption is Excessive1996
There is an Unusual Smell (Irritating Odor)1998
Foreign Materials Enter DEF (DEF Increases)1999
50 Disassembly and Assembly2001
Table of Contents2002
Precautions Before Work2007
Related Information on Disassembly and Assembly2008
How to Read This Manual2008
Coating Materials List2009
Special Tool List2014
Sketches of Special Tools2026
Engine and Cooling System2032
Remove and Install Supply Pump Assembly2032
Remove Supply Pump Assembly2032
Install Supply Pump Assembly2035
Remove and Install Injector Assembly2039
How to Remove Injector Assembly2039
How to Install Injector Assembly2044
Remove and Install Cylinder Head Assembly2052
How to Remove Cylinder Head Assembly2053
How to Install Cylinder Head Assembly2062
Remove and Install EGR Valve Assembly2078
Remove EGR Valve Assembly2078
Install EGR Valve Assembly2079
Remove and Install EGR Cooler Assembly2082
How to Remove EGR Cooler Assembly2082
How to Install EGR Cooler Assembly2085
Remove and Install Starter Assembly2090
Remove Starting Motor Assembly2090
Install Starting Motor Assembly2092
Remove and Install Alternator Belt2094
Remove Alternator Belt2094
Install Alternator Belt2096
Remove and Install Radiator Assembly2098
How to Remove Radiator Assembly2098
How to Install Radiator Assembly2100
Remove and Install Hydraulic Oil Cooler Assembly2102
How to Remove Hydraulic Oil Cooler Assembly2102
How to Install Hydraulic Oil Cooler Assembly2105
Remove and Install Aftercooler Assembly2108
Remove Aftercooler Assembly2108
Install Aftercooler Assembly2109
Remove and Install Engine and Main Pump Assembly2111
Remove Engine and Main Pump Assembly2112
Install Engine and Main Pump Assembly2120
Remove and Install Engine Front Oil Seal2131
How to Remove Engine Front Oil Seal2131
How to Install Engine Front Oil Seal2134
Remove and Install Engine Rear Oil Seal2138
How to Remove Engine Rear Oil Seal2138
How to Install Engine Rear Oil Seal2139
Remove and Install Fuel Cooler Assembly2142
Remove Fuel Cooler Assembly2142
Install Fuel Cooler Assembly2143
Remove and Install Engine Hood Assembly2144
How to Remove Engine Hood Assembly2144
How to Install Engine Hood Assembly2146
Remove and Install Fuel Tank Assembly2152
Remove Fuel Tank Assembly2152
Install Fuel Tank Assembly2156
Remove and Install DEF Tank Assembly2162
How to Remove DEF Tank Assembly2162
How to Install DEF Tank Assembly2167
Remove and Install DEF Tank Sensor Flange Assembly2172
How to Remove DEF Tank Sensor Flange Assembly2172
How to Install DEF Tank Sensor Flange Assembly2177
Remove and Install DEF Tank Sensor2183
Remove DEF Tank Sensor2183
Install DEF Tank Sensor2183
Remove and Install DEF Tank Strainer2190
Remove DEF Tank Strainer2190
Install DEF Tank Strainer2190
Remove and Install DEF Tank Filler Port Filter2191
Remove DEF Tank Filler Port Filter2191
Install DEF Tank Filler Port Filter2193
Remove and Install KDPF Assembly2196
How to Remove KDPF Assembly2196
How to Install KDPF Assembly2198
Disassemble and Assemble KDPF Assembly2200
Disassemble KDPF Assembly2201
Assemble KDPF Assembly2204
Remove and Install SCR Assembly2209
How to Remove SCR Assembly2209
How to Install SCR Assembly2211
Remove and Install KDPF and SCR Assembly2213
How to Remove KDPF and SCR Assembly2213
Install KDPF and SCR Assembly2219
Remove and Install KDPF and SCR Assembly Bracket2225
Remove KDPF and SCR Assembly Bracket2225
Install KDPF and SCR Assembly Bracket2231
Remove and Install Bellows Pipe Assembly2238
How to Remove Bellows Pipe Assembly2238
How to Install Bellows Pipe Assembly2240
Remove and Install KCCV Assembly2244
Remove KCCV Assembly2244
Install KCCV Assembly2247
Remove and Install DEF Mixing Tube2251
Remove DEF Mixing Tube2251
Install DEF Mixing Tube2256
Remove and Install DEF Injector2261
Remove DEF Injector2261
Install DEF Injector2263
Remove and Install DEF Pump2265
Remove DEF Pump2265
Install DEF Pump2268
Remove and Install DEF Hose2271
Remove DEF Hose2271
Install DEF Hose2279
Remove and Install Air Cleaner Assembly2285
Remove Air Cleaner Assembly2285
Install Air Cleaner Assembly2286
Remove and Install Air Conditioner Compressor Assembly2289
Remove Air Conditioner Compressor Assembly2289
How to Install Air Conditioner Compressor Assembly2291
Remove and Install Air Conditioner Condenser Assembly2294
How to Remove Air Conditioner Condenser Assembly2294
How to Install Air Conditioner Condenser Assembly2295
Power Train2296
Remove and Install Travel Motor and Final Drive Assembly2296
Remove Travel Motor and Final Drive Assembly2296
Install Travel Motor and Final Drive Assembly2297
Disassemble and Assemble Final Drive Assembly2299
Disassemble Final Drive Assembly2299
Assemble Final Drive Assembly2303
Remove and Install Swing Motor and Swing Machinery Assembly2312
Remove Swing Motor and Swing Machinery Assembly2312
Install Swing Motor and Swing Machinery Assembly2315
Disassemble and Assemble Swing Machinery Assembly2318
Disassemble Swing Machinery Assembly2318
Assemble Swing Machinery Assembly2322
Remove and Install Swing Circle Assembly2329
Remove Swing Circle Assembly2329
Install Swing Circle Assembly2329
Undercarriage and Frame2331
Separate and Connect Track Assembly2331
Separate Track Assembly2331
Install Track Assembly2333
Remove and Install Sprocket2336
Remove Sprocket2336
Install Sprocket2336
Remove and Install Idler and Idler Cushion Assembly2338
Remove Idler and Idler Cushion Assembly2338
Install Idler and Idler Cushion Assembly2339
Disassemble and Assemble Idler Assembly2340
Disassemble Idler Assembly2340
Assemble Idler Assembly2341
Disassemble and Assemble Idler Cushion Assembly2345
Disassemble Idler Cushion Assembly2346
Assemble Idler Cushion Assembly2347
Disassemble and Assemble Track Roller Assembly2348
Disassemble Track Roller Assembly2349
Assemble Track Roller Assembly2350
Disassemble and Assemble Carrier Roller Assembly2352
Disassemble Carrier Roller Assembly2352
Assemble Carrier Roller Assembly2354
Remove and Install Revolving Frame Assembly2356
Remove Revolving Frame Assembly2356
Install Revolving Frame Assembly2358
Remove and Install Counterweight Assembly2361
Remove Counterweight Assembly2361
Install Counterweight Assembly2364
Hydraulic System2368
Remove and Install Center Swivel Joint Assembly2368
Remove Center Swivel Joint Assembly2368
Install Center Swivel Joint Assembly2370
Disassemble and Assemble Center Swivel Joint Assembly2373
Disassemble Center Swivel Joint Assembly2374
Assemble Center Swivel Joint Assembly2375
Remove and Install Hydraulic Tank Assembly2376
Remove Hydraulic Tank Assembly2376
How to Install Hydraulic Tank Assembly2379
Remove and Install Main Pump Assembly2383
Remove Main Pump Assembly2383
Install Main Pump Assembly2386
Remove and Install Control Valve Assembly2390
How to Remove Control Valve Assembly2390
How to Install Control Valve Assembly2397
Disassemble and Assemble Control Valve Assembly2405
Replace Pressure Compensation Valve Seal Ring2405
Assemble Control Valve Assembly2407
Disassemble and Assemble Work Equipment PPC Valve Assembly2411
Disassemble Work Equipment PPC Valve Assembly2411
How to Assemble Work Equipment PPC Valve Assembly2411
Disassemble and Assemble Travel PPC Valve Assembly2413
Disassemble Travel PPC Valve Assembly2413
How to Assemble Travel PPC Valve Assembly2414
Work Equipment2416
Remove and Install Work Equipment Assembly2416
Remove Work Equipment Assembly2416
Install Work Equipment Assembly2420
Remove and Install Boom Anti-drop Valve Assembly2426
Remove Boom Anti-drop Valve Assembly2426
Install Boom Anti-drop Valve Assembly2428
Remove and Install Arm Anti-Drop Valve Assembly2429
Remove Arm Anti-Drop Valve Assembly2429
Install Arm Anti-Drop Valve Assembly2431
Disassemble and Assemble Anti-Drop Valve Assembly2432
Disassemble Anti-Drop Valve Assembly2432
Assemble Anti-Drop Valve Assembly2432
Disassemble and Assemble Work Equipment Cylinder Assembly2433
How to Disassemble Work Equipment Cylinder Assembly2433
How to Assemble Work Equipment Cylinder Assembly2436
CAB Related Parts2442
Remove and Install Operator Cab Assembly2442
How to Remove Operator Cab Assembly2442
Install Operator CAB Assembly2448
Remove and Install Operator Cab Glass (Adhered Glass)2455
Remove Operator CAB Glass (Adhered Glass)2457
Install Operator CAB Glass (Adhered Glass)2457
Remove and Install Front Window Assembly2467
Remove Front Window Assembly2467
Install Front Window Assembly2470
Remove and Install Floor Frame Assembly2476
How to Remove Floor Frame Assembly2476
How to Install Floor Frame Assembly2483
Remove and Install Air Conditioner Unit Assembly2490
Remove Air Conditioner Unit Assembly2490
Install Air Conditioner Unit Assembly2496
Remove and Install Operator Seat2503
Remove Operator’s Seat2503
Install Operator’s Seat2505
How to Remove and Install Seat Belt2508
How to Remove Seat Belt2508
How to Install Seatbelt2509
Remove and Install Work Equipment Control Lever Assembly2510
How to Remove Work Equipment Control Lever Assembly2510
How to Install Work Equipment Control Lever Assembly2516
Remove and Install Front Wiper Assembly2525
Remove Front Wiper Assembly2525
Install Front Wiper Assembly2530
Electrical System2539
Remove and Install Engine Controller Assembly2539
Remove Engine Controller Assembly2539
Install Engine Controller Assembly2541
Remove and Install Pump Controller Assembly2542
Remove Pump Controller Assembly2542
Install Pump Controller Assembly2546
Remove and Install KomVision Controller Assembly2551
Remove KomVision Controller Assembly2551
Install KomVision Controller Assembly2552
Remove and Install Machine Monitor Assembly2554
Remove Machine Monitor Assembly2554
Install Machine Monitor Assembly2557
Remove and Install Pump Swash Plate Sensor2560
Remove Pump Swash Plate Sensor2560
Install Pump Swash Plate Sensor2561
Remove and Install Mass Air Flow and Temperature Sensor2562
How to Remove Mass Air Flow and Temperature Sensor2562
How to Install Mass Air Flow and Temperature Sensor2563
Remove and Install KCCV Crankcase Pressure Sensor2564
How to Remove KCCV Crankcase Pressure Sensor2564
How to Install KCCV Crankcase Pressure Sensor2565
Remove and Install SCR Temperature Sensor2567
Remove SCR Temperature Sensor2567
Install SCR Temperature Sensor2569
Remove and Install KOMTRAX Terminal Assembly2572
Remove KOMTRAX Terminal Assembly2572
Install KOMTRAX Terminal Assembly2575
Remove and Install KomVision Camera2578
Remove KomVision Camera2578
Install KomVision Camera2581
60 Maintenance Standard2585
Table of Contents2586
Engine and Cooling System2587
Maintenance Standard for Engine Mount2587
Maintenance Standard for Cooling System2588
Power Train2589
Maintenance Standard for Swing Circle2589
Maintenance Standard for Swing Machinery2590
Maintenance Standard for Final Drive2592
Maintenance Standard for Sprocket2594
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing2595
Undercarriage and Frame2596
Maintenance Standard for Track Frame and Idler Cushion2596
Maintenance Standard for Idler2598
Maintenance Standard for Track Roller2600
Maintenance Standard for Carrier Roller2601
Maintenance Standard for Track Shoes2602
Maintenance Standard for Triple Shoes2605
Maintenance Standard for Swamp Shoes2606
Maintenance Standard for Road Liner2607
Hydraulic System2608
Maintenance Standard for Hydraulic Tank2608
Maintenance Standard for Main Pump2609
Maintenance Standard for LS-EPC Valve2610
Maintenance Standard for PC-EPC Valve2611
Maintenance Standard for Swing Motor2612
Maintenance Standard for Travel Motor2615
Maintenance Standard for Control Valve2618
Maintenance Standard for Boom Anti-Drop Valve2628
Maintenance Standard for Arm Anti-Drop Valve2630
Maintenance Standard for Work Equipment and Swing PPC Valve2632
Maintenance Standard for Travel PPC Valve2635
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)2638
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve2639
Maintenance Standard for 2nd-Line Attachment PPC Valve2641
Maintenance Standard for Solenoid Valve2643
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure)2644
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)2645
Maintenance Standard for Center Swivel Joint2646
Work Equipment2647
Maintenance Standard for Work Equipment Linkage2647
Dimensions of Arm2652
Dimensions of Bucket2654
Maintenance Standard for Boom Cylinder2656
Maintenance Standard for Boom Cylinder (Large Diameter Piston)2657
Maintenance Standard for Arm Cylinder2658
Maintenance Standard for Bucket Cylinder2659
80 Appendix2661
Table of Contents2662
Precautions Before Work2664
Air Conditioner System2665
Precautions for Refrigerant2665
Air Conditioner Component2666
Specifications of Air Conditioner2668
Structure and Function of Refrigeration Cycle2669
Outline of Refrigeration Cycle2670
Component Parts of Air Conditioner System2672
Air Conditioner Unit2672
Configuration Diagram of Air Conditioner Unit2672
Function of Air Conditioner Unit2674
Component Parts of Air Conditioner Unit2676
Function of Evaporator as Air Conditioner Unit Component2677
Function of Heater Core as Air Conditioner Unit Component2677
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2677
Function of Servo Motor as Air Conditioner Unit Component2677
Structure of Expansion Valve as Air Conditioner Unit Component2678
Function of Expansion Valve as Air Conditioner Unit Component2678
Operate Expansion Valve as Air Conditioner Unit Component2678
Function of Dual Pressure Switch2679
Air Conditioner Controller2680
Structure of Air Conditioner Controller2680
Compressor2681
Structure of Compressor2681
Specifications of Compressor2681
Function of Compressor2681
Condenser2682
Structure of Condenser2682
Specifications of Condenser2682
Function of Condenser2682
Air Conditioner Related Sensors2684
Structure of Sunlight Sensor2684
Function of Sunlight Sensor2684
Structure of Outside Temperature Sensor2684
Function of Outside Air Temperature Sensor2684
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2686
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2688
System Diagram of Air Conditioner2690
Input and Output Signals of Air Conditioner Controller2691
Function of Air Conditioner Controller2692
Locations of Air Conditioner Parts and Layout of Connectors2693
Examine Air Leakage (Duct)2697
How to Examine Air Leakage (Duct)2697
Examine Air Conditioner with Self-Diagnosis Function2699
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2700
Examine Vent (Mode) Changeover2701
How to Examine Vent (Mode) Changeover2701
Examine Fresh/Recirc Air Changeover2703
How to Examine Fresh/Recirc Air Changeover2703
Examine Sunlight Sensor2704
How to Examine Sunlight Sensor2704
Examine Refrigerant (Dual) Pressure Switch2705
How to Examine Refrigerant (Dual) Pressure Switch2705
Examine Relay2706
How to Examine Relay2706
Air Conditioner Troubleshooting Chart 12707
Air Conditioner Troubleshooting Chart 22708
Information Shown in Troubleshooting Table2711
Failure Code [879AKA]2712
Failure Code [879AKB]2713
Failure Code [879BKA]2714
Failure Code [879BKB]2716
Failure Code [879CKA]2718
Failure Code [879CKB]2719
Failure Code [879DKZ]2720
Failure Code [879EMC]2722
Failure Code [879FMC]2723
Failure Code [879GKX]2724
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2726
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2728
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2731
A-4 Troubleshooting for Fresh/Recirc Air Changeover2733
Troubleshooting by Gauge Pressure2735
Connect Service Tool2738
How to Connect Service Tool2738
Precautions for Disconnection and Connection of Air Conditioner Piping2740
Handle Compressor Oil2742
Replace Desiccant2744
90 Circuit Diagrams2747
Table of Contents2748
Hydraulic Circuit Diagram2749
Symbols Used in Hydraulic Circuit Diagram2749
Hydraulic Circuit Diagram2753
Electrical Circuit Diagram2755
Symbols Used in Electric Circuit Diagram2755
Electrical Circuit Diagram (1/7)2759
Electrical Circuit Diagram (2/7)2761
Electrical Circuit Diagram (3/7)2763
Electrical Circuit Diagram (4/7)2765
Electrical Circuit Diagram (5/7)2767
Electrical Circuit Diagram (6/7)2769
Electrical Circuit Diagram (7/7)2771
INDEX2773

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24