Komatsu Hydraulic Excavator PC240LC-11 Shop Manual SEN06696-11 PDF

Description

Komatsu Hydraulic Excavator PC240LC-11 Shop Manual SEN06696-11 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Excavator PC240LC-11 Shop Manual SEN06696-11 – PDF DOWNLOAD

Language : English
Pages :2780
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Excavator PC240LC-11 Shop Manual SEN06696-11 – PDF DOWNLOAD

SERIAL NUMBERS 95321 and up

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC240LC-11 Shop Manual SEN06696-11 – PDF DOWNLOAD

SERIAL NUMBERS 95321 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 Isolator 143
Function of Battery Isolator 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 150
System Diagram of Auto-Deceleration System 150
Function of Auto-Deceleration System 150
Operation of Auto-Deceleration System 151
Engine Automatic Warm-up System 152
System Diagram of Engine Automatic Warm-up System 152
Function of Engine Automatic Warm-up System 153
Overheat Prevention System 154
Overheat Prevention System Diagram 154
Function of Overheat Prevention System 155
Turbocharger Protection System 157
System Diagram of Turbocharger Protection System 157
Function of Turbocharger Protection System 158
Automatic Idle Stop System 159
System Diagram of Automatic Idle Stop System 159
Function of Automatic Idle Stop System 159
Component Parts of Engine System 162
VGT 162
EGR System 166
EGR Valve 168
EGR Cooler 170
KCCV System 171
KCCV Ventilator 173
KDPF 175
Cooling System 180
Layout Drawing of Cooling System 180
Specifications of Cooling System 181
Control System 182
Layout Drawing of Control System 182
Machine Monitor System 185
System Diagram of Machine Monitor System 185
KomVision System 186
Layout Drawing of KomVision System 186
System Diagram of KomVision System 188
Function of KomVision System 188
KOMTRAX System 190
System Diagram of KOMTRAX System 190
Function of KOMTRAX System 190
Component Parts of Control System 191
Machine Monitor 191
KomVision Controller 204
KomVision Camera 208
KOMTRAX Terminal 209
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 288
Work Equipment System 351
Layout Drawing of Work Equipment System 351
Structure of Valve Control 356
One-Touch Power Maximizing System 358
System Diagram of One-Touch Power Maximizing System 358
Function of One-Touch Power Maximizing System 359
PPC Lock System 360
System Diagram of PPC Lock 360
Function of PPC Lock System 360
Work Equipment and Travel Automatic Lock System 361
System Diagram of Lock Lever Automatic Lock System 361
Function of Work Equipment and Travel Automatic Lock System 361
Operation of Lock Lever Automatic Lock System 362
Attachment Oil Flow Adjuster System 363
Attachment Oil Flow Adjuster System Diagram 363
Function of Attachment Oil Flow Adjuster System 364
Tool Control System 365
Tool Control System Diagram 365
Component Parts of Work Equipment System 367
Work Equipment and Swing PPC Valve 367
1st-Line Attachment PPC Valve (with EPC Valve) 373
2nd-Line Attachment PPC Valve 379
Solenoid Valve 381
Boom Anti-drop Valve 384
Arm Anti-Drop Valve 388
Attachment Circuit Selector Valve (For High Pressure) 392
Attachment Circuit Selector Valve (For Low Pressure) 394
Pilot Circuit Accumulator 397
Attachment Circuit Accumulator 398
Swing System 399
Layout Drawing of Swing System 399
Swing Control System Diagram 403
Function of Swing Control System 403
Component Parts of Swing System 407
Swing Motor 407
Swing Machinery 418
Swing Circle 419
Travel System 421
Layout Drawing of Travel System 421
System Diagram of Travel Control System 425
Function of Travel Control System 425
Component Parts of Travel System 427
Travel Motor 427
Final Drive 439
Travel PPC Valve 441
Center Swivel Joint 446
Undercarriage and Frame 448
Layout Drawing of Undercarriage 448
Specifications of Undercarriage 449
Work Equipment 450
Structure of Work Equipment 450
Function of Work Equipment 451
Work Equipment Clearance Adjustment Shim 452
Function of Work Equipment Clearance Adjustment Shim 452
Bucket Clearance Adjustment Shim 453
Function of Bucket Clearance Adjustment Shim 453
CAB Related Parts 454
ROPS CAB 454
Structure of ROPS CAB 454
Function of ROPS CAB 454
CAB Mount 455
Structure of CAB Mount 455
Function of CAB Mount 455
CAB Tipping Stopper 456
Structure of CAB Tipping Stopper 456
Function of CAB Tipping Stopper 456
20 Standard Value Table 457
Table of Contents 458
Standard Value Table for Engine 459
Standard Value Table for Engine: PC240LC-11 459
Standard Value Table for Machine 463
Standard Value Table for Machine: PC240LC-11 463
Machine Posture and Procedures to Measure Performance 476
Standard Value Table for Electricity 480
Standard Value Table for Electricity 480
30 Testing and Adjusting 491
Table of Contents 492
Precautions Before Work 495
Related Information on Testing and Adjusting 496
Tools for Testing and Adjusting 496
Sketch of Tools for Testing and Adjusting 503
Engine and Cooling System 505
Examine Engine Speed 505
How to Examine Engine Speed 505
Examine Boost Pressure 508
How to Examine Boost Pressure on Machine Monitor 508
How to Examine Boost Pressure by Testing Tool 509
Examine Exhaust Gas Color 510
How to Examine Exhaust Gas Color with the Handy Smoke Checker 510
How to Examine Exhaust Gas Color with Smoke Meter 511
Examine Mass Air Flow and Temperature Sensor 513
How to Examine Mass Air Flow and Temperature Sensor 513
Examine and Adjust Valve Clearance 515
Check Valve Clearance 515
Adjust Valve Clearance 516
Examine Compression Pressure 518
How to Examine Compression Pressure 518
Examine Blowby Pressure 523
How to Examine Blowby Pressure 523
Examine Engine Oil Pressure 525
How to Examine Engine Oil Pressure 525
Examine EGR Valve and VGT Oil Pressure 526
How to Examine EGR Valve and VGT Oil Pressure 526
Examine Fuel Pressure 528
How to Examine Fuel Pressure 529
Examine Fuel Discharge, Return and Leakage 534
How to Examine Fuel Discharge, Return, and Leakage 535
Bleed Air from Fuel System 541
How to Bleed Air from Fuel System 541
Examine Fuel Circuit for Leakage 542
How to Examine Fuel System for Leakage 542
Handle Cylinder Cut-out Mode Operation 544
Handle No-Injection Cranking Operation 545
Examine and Adjust Air Conditioner Compressor Belt Tension 546
How to Examine Air Conditioner Compressor Belt 546
How to Adjust Air Conditioner Compressor Belt 546
Examine Fan Belt and Alternator Belt 548
How to Examine Fan Belt and Alternator Belt 548
Examine Automatic Tensioner 549
How to Examine Automatic Tensioner 549
Write Correction for Ash in Soot Accumulation to Engine Controller 550
How to Write Correction for Ash in Soot Accumulation to Engine Controller 550
Examine SCR Related Functions 551
Examine DEF Pump Raised Pressure 554
Examine Injection Volume from DEF Injector 557
Examine DEF Line Heater Relay 1 560
Examine DEF Line Heater Relay 2 563
Examine DEF Pump Heater Relay 566
Examine DEF Tank Heater Valve 569
Examine SCR Denitration Efficiency 572
Clean DEF Tank 576
How to Clean DEF Tank 576
Clean DEF Pump 580
How to Clean DEF Pump 580
Bleed Air from Coolant Circuit of DEF Tank 587
How to Bleed Air from Coolant Circuit of DEF Tank 587
Power Train 589
Examine Swing Circle Bearing Clearance 589
How to Examine Swing Circle Bearing Clearance 589
Undercarriage and Frame 590
Examine and Adjust Track Tension 590
How to Examine Track Tension 590
How to Adjust Track Tension 590
Hydraulic System 592
Release Remained Pressure in Hydraulic Circuit 592
How to Release Remained Pressure in Hydraulic System 592
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 593
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 594
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 600
Examine Oil Pressure of Control Circuit 603
Examine Oil Pressure in Control Circuit 603
Examine and adjust oil pressure in pump PC control circuit 605
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 605
Examine PC-EPC Valve Outlet Pressure 606
How to Adjust Oil Pressure in Pump PC Control Circuit 607
Examine and Adjust Oil Pressure in Pump LS Control Circuit 609
Examine LS Differential Pressure with Machine Monitor 609
Examine LS Differential Pressure by Testing Tool 610
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 613
How to Examine LS-EPC Valve Outlet Pressure 614
Adjust LS Valve 615
Examine Outlet Pressure of Solenoid Valve 616
How to Examine Outlet Pressure of Solenoid Valve 616
Operating Condition of Solenoid Valve 617
Examine PPC Valve Outlet Pressure 620
Examine Outlet Pressure in PPC Valve 620
Adjust Play of Work Equipment and Swing PPC Valves 622
How to Adjust Play of Work Equipment and Swing PPC Valves 622
Examine Pump Swash Plate Sensor 623
How to Examine pump swash plate sensor 623
Examine Parts Which Cause Hydraulic Drift of Work Equipment 624
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 624
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 624
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 625
Examine Oil Leakage 626
How to Examine Oil Leakage from Boom Cylinder 626
How to Examine Oil Leakage from Arm Cylinder 626
How to Examine Oil Leakage from Bucket Cylinder 627
How to Examine Oil Leakage from Swing Motor 628
How to Examine Oil Leakage from Travel Motor 628
Bleed Air from Hydraulic System 629
How to Bleed Air from Hydraulic System 631
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 633
Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 633
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 637
Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 637
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 641
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 641
CAB Related Parts 648
Examine CAB Tipping Stopper 648
How to Examine Cab Tipping Stopper 648
How to Adjust Mirrors 649
Procedure to Adjust Machine Left Front Mirror (A) 649
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 650
Procedure to Adjust Machine Right Front Mirror (B) 651
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 652
Procedure to Adjust Machine Right Side Mirror (C) 653
Electrical System 655
Set and Operate Machine Monitor 655
Operator Mode 658
Function to Show Technician Identification Status Screen 659
Function to Show Operator Identification Input Screen 659
Examine Function by LCD (Liquid Crystal Display) 660
Examine Function of Service Meter 660
Usage Limitation and Maintenance Password Change Function 660
Service Mode 663
How to Operate Service Mode 663
How to See Pre-defined Monitoring Information 665
How to Examine Self-Define Monitor Information 672
Abnormality Record Menu 682
How to See Maintenance Record 687
Maintenance Mode Setting 689
Set Phone Number Entry 692
Default Menu 693
Diagnostic Tests Menu 705
Adjustment Menu 714
No-Injection Cranking Operation 732
KOMTRAX Settings Menu 733
Show Service Message 735
How to Start Up KOMTRAX Terminal 737
Adjust Rearview Camera Angle 742
How to Adjust Rearview Camera Angle 742
Adjust KomVision Camera Angle 745
How to Adjust KomVision Camera Angle 746
Adjust KomVision Related Function 750
Setting of KomVision (Main Setting) 750
Setting of KomVision (Camera Setting) 752
Setting of KomVision (Camera Calibration) 754
KomVision screen – Check 12 m visibility 767
Set Region of Bluetooth(R) Compatible Radio 770
Set Region of Bluetooth(R) Compatible Radio 770
Handle Voltage Circuit of Engine Controller 772
Handle Battery Isolator Switch 773
Examine Diodes 774
Examine Diodes by Digital Tester 774
How to Examine Diodes by Analog Tester 774
Pm Clinic 775
Pm Clinic Service 775
Pm Clinic Check Sheet 776
40 Troubleshooting 789
Table of Contents 790
Precautions Before Work 800
Related Information to Troubleshooting 801
General Troubleshooting Points 801
Troubleshooting Points for Urea SCR System 802
Sequence of Events in Troubleshooting 816
Checks Before Troubleshooting 818
Inspection Procedure Before Troubleshooting 820
Walk-Around Check 820
Test in Accordance with Testing Procedure 822
Examine Fuel Level and Type 822
Examine for Impure Ingredient in Fuel 822
Examine Fuel Prefilter 823
Examine Water Separator, Drain Water and Sediment 823
How to Replace Fuel Prefilter Cartridge 824
Examine Fuel Main Filter 825
Examine Engine Oil Level (Oil Quantity in Oil Pan) 827
Examine Coolant Level (Reservoir Tank) 828
Examine Air Cleaner Clogging 828
Clean Outer Element 829
Replace Element 831
Examine Hydraulic Oil Level 832
Examine Hydraulic Oil Strainer 833
Examine Hydraulic Oil Filter 834
Examine Oil Level in Swing Machinery Case 835
Examine Oil Level in Damper Case 836
Examine Oil Level in Final Drive Case 836
Bleed Air from Fuel System 837
Bleed Air from Hydraulic System 837
How to Examine Electric Equipment 837
Preparation for Troubleshooting of Electrical System 845
Procedure for Troubleshooting 855
Symptom and Troubleshooting Numbers 858
Information Shown in Troubleshooting Table 862
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 864
Connector List and Layout 867
Connector Contact Connection Table 880
T-Branch Box and T-Branch Adapter Table 920
Fuse Location Table 926
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 929
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 933
Failure Code Table 935
Troubleshooting by Failure Code (Display of Code) 953
Failure Code [6AZ0ZG] 953
Failure Code [879AKA] 955
Failure Code [879AKB] 956
Failure Code [879BKA] 957
Failure Code [879BKB] 959
Failure Code [879CKA] 961
Failure Code [879CKB] 962
Failure Code [879DKZ] 963
Failure Code [879EMC] 965
Failure Code [879FMC] 966
Failure Code [879GKX] 967
Failure Code [989L00] 969
Failure Code [989M00] 970
Failure Code [989N00] 971
Failure Code [A1U0N3] 972
Failure Code [A1U0N4] 974
Failure Code [A900FR] 976
Failure Code [A900N6] 977
Failure Code [A900NY] 978
Failure Code [AA10NX] 979
Failure Code [AB00KE] 981
Failure Code [AQ10N3] 984
Failure Code [AS00N3] 986
Failure Code [AS00R2] 988
Failure Code [AS00R3] 989
Failure Code [AS00R4] 990
Failure Code [AS00R5] 991
Failure Code [AS00R6] 992
Failure Code [AS00ZK] 993
Failure Code [AS10KM] 994
Failure Code [AS10NR] 995
Failure Code [AS10NT] 996
Failure Code [B@BAZG] 997
Failure Code [B@BAZK] 998
Failure Code [B@BCNS]1000
Failure Code [B@BCQA]1001
Failure Code [B@BCZK]1003
Failure Code [B@HANS]1005
Failure Code [CA115]1006
Failure Code [CA122]1007
Failure Code [CA123]1009
Failure Code [CA131]1011
Failure Code [CA132]1013
Failure Code [CA144]1015
Failure Code [CA145]1017
Failure Code [CA153]1019
Failure Code [CA154]1022
Failure Code [CA187]1024
Failure Code [CA221]1026
Failure Code [CA222]1028
Failure Code [CA227]1030
Failure Code [CA234]1031
Failure Code [CA238]1032
Failure Code [CA239]1034
Failure Code [CA249]1036
Failure Code [CA256]1038
Failure Code [CA271]1040
Failure Code [CA272]1042
Failure Code [CA322]1044
Failure Code [CA323]1046
Failure Code [CA324]1048
Failure Code [CA325]1050
Failure Code [CA331]1052
Failure Code [CA332]1054
Failure Code [CA343]1056
Failure Code [CA351]1057
Failure Code [CA352]1058
Failure Code [CA356]1061
Failure Code [CA357]1063
Failure Code [CA386]1065
Failure Code [CA428]1066
Failure Code [CA429]1068
Failure Code [CA435]1070
Failure Code [CA441]1072
Failure Code [CA442]1075
Failure Code [CA449]1076
Failure Code [CA451]1077
Failure Code [CA452]1079
Failure Code [CA488]1081
Failure Code [CA515]1082
Failure Code [CA516]1084
Failure Code [CA553]1086
Failure Code [CA555]1087
Failure Code [CA556]1088
Failure Code [CA559]1089
Failure Code [CA595]1092
Failure Code [CA687]1093
Failure Code [CA689]1095
Failure Code [CA691]1098
Failure Code [CA692]1100
Failure Code [CA697]1102
Failure Code [CA698]1103
Failure Code [CA731]1104
Failure Code [CA778]1106
Failure Code [CA1117]1111
Failure Code [CA1664]1112
Failure Code [CA1669]1114
Failure Code [CA1673]1115
Failure Code [CA1677]1116
Failure Code [CA1678]1117
Failure Code [CA1682]1118
Failure Code [CA1683]1120
Failure Code [CA1684]1122
Failure Code [CA1686]1124
Failure Code [CA1691]1125
Failure Code [CA1694]1128
Failure Code [CA1695]1131
Failure Code [CA1696]1132
Failure Code [CA1712]1134
Failure Code [CA1713]1137
Failure Code [CA1714]1139
Failure Code [CA1715]1140
Failure Code [CA1776]1141
Failure Code [CA1777]1144
Failure Code [CA1843]1147
Failure Code [CA1844]1149
Failure Code [CA1879]1152
Failure Code [CA1881]1154
Failure Code [CA1883]1156
Failure Code [CA1885]1159
Failure Code [CA1887]1161
Failure Code [CA1921]1163
Failure Code [CA1922]1166
Failure Code [CA1942]1171
Failure Code [CA1993]1172
Failure Code [CA2185]1175
Failure Code [CA2186]1176
Failure Code [CA2249]1178
Failure Code [CA2271]1179
Failure Code [CA2272]1182
Failure Code [CA2288]1185
Failure Code [CA2311]1186
Failure Code [CA2349]1187
Failure Code [CA2353]1190
Failure Code [CA2357]1192
Failure Code [CA2381]1193
Failure Code [CA2382]1196
Failure Code [CA2383]1199
Failure Code [CA2386]1202
Failure Code [CA2387]1204
Troubleshooting Flowchart1208
Failure Code [CA2555]1209
Failure Code [CA2556]1212
Failure Code [CA2637]1215
Failure Code [CA2639]1217
Failure Code [CA2771]1220
Failure Code [CA2777]1226
Failure Code [CA2976]1229
Failure Code [CA3133]1231
Failure Code [CA3134]1234
Failure Code [CA3135]1236
Failure Code [CA3142]1239
Failure Code [CA3143]1240
Failure Code [CA3144]1241
Failure Code [CA3146]1243
Failure Code [CA3147]1244
Failure Code [CA3148]1245
Failure Code [CA3151]1247
Failure Code [CA3165]1253
Failure Code [CA3229]1255
Failure Code [CA3231]1257
Failure Code [CA3232]1259
Failure Code [CA3235]1263
Failure Code [CA3239]1265
Failure Code [CA3241]1268
Failure Code [CA3242]1271
Failure Code [CA3251]1274
Failure Code [CA3253]1276
Failure Code [CA3254]1279
Failure Code [CA3255]1282
Failure Code [CA3256]1286
Failure Code [CA3311]1288
Failure Code [CA3312]1290
Failure Code [CA3313]1293
Failure Code [CA3314]1294
Failure Code [CA3315]1295
Failure Code [CA3316]1297
Failure Code [CA3317]1298
Failure Code [CA3318]1299
Failure Code [CA3319]1301
Failure Code [CA3321]1302
Failure Code [CA3322]1304
Failure Code [CA3419]1306
Failure Code [CA3421]1308
Failure Code [CA3497]1310
Failure Code [CA3498]1311
Failure Code [CA3543]1312
Failure Code [CA3545]1319
Failure Code [CA3547]1321
Failure Code [CA3558]1322
Failure Code [CA3559]1324
Failure Code [CA3562]1326
Failure Code [CA3563]1328
Failure Code [CA3567]1331
Failure Code [CA3568]1334
Failure Code [CA3571]1338
Failure Code [CA3572]1340
Failure Code [CA3574]1342
Failure Code [CA3575]1344
Failure Code [CA3577]1346
Failure Code [CA3578]1348
Failure Code [CA3582]1350
Failure Code [CA3583]1356
Failure Code [CA3596]1358
Failure Code [CA3649]1360
Failure Code [CA3681]1362
Failure Code [CA3682]1367
Failure Code [CA3713]1372
Failure Code [CA3717]1375
Failure Code [CA3718]1376
Failure Code [CA3725]1377
Failure Code [CA3741]1380
Failure Code [CA3748]1381
Failure Code [CA3751]1383
Failure Code [CA3755]1385
Failure Code [CA3866]1387
Failure Code [CA3867]1391
Failure Code [CA3868]1394
Failure Code [CA3899]1398
Failure Code [CA3911]1400
Failure Code [CA3912]1404
Failure Code [CA3932]1406
Failure Code [CA3933]1408
Failure Code [CA3934]1410
Failure Code [CA3935]1413
Failure Code [CA3936]1415
Failure Code [CA4151]1417
Failure Code [CA4152]1421
Failure Code [CA4155]1425
Failure Code [CA4156]1428
Failure Code [CA4157]1431
Failure Code [CA4158]1433
Failure Code [CA4159]1434
Failure Code [CA4161]1435
Failure Code [CA4162]1438
Failure Code [CA4163]1441
Failure Code [CA4164]1442
Failure Code [CA4165]1444
Failure Code [CA4166]1446
Failure Code [CA4168]1447
Failure Code [CA4169]1450
Failure Code [CA4171]1452
Failure Code [CA4249]1455
Failure Code [CA4251]1457
Failure Code [CA4259]1459
Failure Code [CA4261]1462
Failure Code [CA4277]1465
Failure Code [CA4281]1469
Failure Code [CA4459]1472
Failure Code [CA4461]1475
Failure Code [CA4658]1478
Failure Code [CA4731]1482
Failure Code [CA4732]1483
Failure Code [CA4739]1484
Failure Code [CA4768]1485
Failure Code [CA4769]1487
Failure Code [CA4842]1490
Failure Code [CA4952]1494
Failure Code [CA5115]1496
Failure Code [CA5179]1499
Failure Code [CA5181]1501
Failure Code [CA5383]1503
Failure Code [D110KB]1505
Failure Code [D19JKZ]1507
Failure Code [D811MC]1510
Failure Code [D862KA]1511
Failure Code [D8ALKA]1512
Failure Code [D8ALKB]1514
Failure Code [D8AQKR]1516
Failure Code [DA20MC]1518
Failure Code [DA22KK]1519
Failure Code [DA25KP]1522
Failure Code [DA26KP]1525
Failure Code [DA29KQ]1527
Failure Code [DA2LKA]1529
Failure Code [DA2LKB]1531
Failure Code [DA2QKR]1533
Failure Code [DA2RKR]1536
Failure Code [DAF0KM]1537
Failure Code [DAF0MB]1538
Failure Code [DAF0MC]1539
Failure Code [DAF8KB]1540
Failure Code [DAF9KQ]1542
Failure Code [DAFGMC]1543
Failure Code [DAFLKA]1544
Failure Code [DAFLKB]1546
Failure Code [DAFQKR]1548
Failure Code [DAZ9KQ]1549
Failure Code [DAZQKR]1550
Failure Code [DB2QKR]1555
Failure Code [DB2RKR]1560
Failure Code [DBP0KM]1565
Failure Code [DBP0KT]1566
Failure Code [DBP5KB]1567
Failure Code [DBP5KY]1570
Failure Code [DBPQKR]1572
Failure Code [DDNRKA]1577
Failure Code [DDNRKY]1579
Failure Code [DDNS00]1581
Failure Code [DGH2KA]1583
Failure Code [DGH2KB]1585
Failure Code [DHA4KA]1587
Failure Code [DHAAMA]1589
Failure Code [DHACMA]1591
Failure Code [DHPAMA]1593
Failure Code [DHPBMA]1596
Failure Code [DHS3MA]1599
Failure Code [DHS4MA]1602
Failure Code [DHS8MA]1605
Failure Code [DHS9MA]1608
Failure Code [DHSAMA]1611
Failure Code [DHSBMA]1614
Failure Code [DHSCMA]1617
Failure Code [DHSDMA]1620
Failure Code [DHSFMA]1623
Failure Code [DHSGMA]1626
Failure Code [DHSHMA]1629
Failure Code [DHSJMA]1632
Failure Code [DHZAMA]1635
Failure Code [DHZCL8]1639
Failure Code [DKR0MA]1640
Failure Code [DKR1MA]1643
Failure Code [DKULKA]1646
Failure Code [DKULKB]1648
Failure Code [DKULKY]1650
Failure Code [DR10KA]1652
Failure Code [DR12KA]1655
Failure Code [DR20KA]1657
Failure Code [DR21KX]1659
Failure Code [DR30KA]1661
Failure Code [DR31KX]1663
Failure Code [DR40KA]1665
Failure Code [DUMBKA]1667
Failure Code [DUMBKB]1669
Failure Code [DV20KB]1671
Failure Code [DW43KA]1673
Failure Code [DW43KB]1675
Failure Code [DW43KY]1677
Failure Code [DW45KA]1679
Failure Code [DW45KB]1682
Failure Code [DW45KY]1685
Failure Code [DW4CKY]1687
Failure Code [DW91KA]1689
Failure Code [DW91KB]1691
Failure Code [DW91KY]1693
Failure Code [DWA2KA]1695
Failure Code [DWA2KB]1697
Failure Code [DWA2KY]1699
Failure Code [DWK0KA]1701
Failure Code [DWK0KB]1703
Failure Code [DWK0KY]1705
Failure Code [DWK2KA]1707
Failure Code [DWK2KB]1709
Failure Code [DWK2KY]1711
Failure Code [DWK8KA]1713
Failure Code [DWK8KB]1715
Failure Code [DWK8KY]1717
Failure Code [DWPUKA]1719
Failure Code [DWPUKB]1721
Failure Code [DWPUKY]1723
Failure Code [DXA8KA]1725
Failure Code [DXA8KB]1727
Failure Code [DXA9KA]1729
Failure Code [DXA9KB]1731
Failure Code [DXE0KA]1733
Failure Code [DXE0KB]1735
Failure Code [DXE4KA]1737
Failure Code [DXE4KB]1739
Failure Code [DXE4KY]1741
Failure Code [DXE5KA]1743
Failure Code [DXE5KB]1745
Failure Code [DXE6KA]1747
Failure Code [DXE6KB]1749
Failure Code [DXE7KA]1751
Failure Code [DXE7KB]1753
Failure Code [DXE7KY]1755
Failure Code [DXE8KA]1757
Failure Code [DXE8KB]1759
Failure Code [DXE8KY]1761
Failure Code [DXE9KA]1763
Failure Code [DXE9KB]1765
Failure Code [DXE9KY]1767
Failure Code [DXEAKA]1769
Failure Code [DXEAKB]1771
Failure Code [DXEAKY]1773
Failure Code [DXEKKA]1775
Failure Code [DXEKKB]1777
Failure Code [DXEKKY]1779
Failure Code [DXELKA]1781
Failure Code [DXELKB]1783
Failure Code [DXELKY]1785
Failure Code [DY20KA]1787
Failure Code [DY20MA]1789
Failure Code [DY2CKB]1791
Failure Code [DY2DKB]1794
Failure Code [DY2EKB]1796
Troubleshooting of Electrical System (E-Mode)1798
E-1 Engine Does Not Start (Engine Does Not Crank)1798
E-2 Manual Preheating System Does Not Operate1804
E-3 Automatic Preheating System Does Not Operate1807
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On1809
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1811
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow1814
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow1815
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation1816
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs1817
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs1818
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation1819
E-12 Fuel Level Monitor Comes On in Red While Engine Runs1820
E-13 Water Separator Monitor Comes On in Red While Engine Runs1821
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1822
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation1823
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation1824
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum1825
E-18 Display of Fuel Gauge is Different from Actual Fuel Level1827
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum1828
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature1829
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum1830
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature1832
E-23 Some Areas of Machine Monitor Screen are Not Shown1833
E-24 Function Switch Does Not Operate1834
E-25 Automatic Warm-up System Does Not Work (in Cold Weather)1835
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out1836
E-27 Auto-Decelerator is Not Operated or Canceled with Lever1837
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown1838
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed1839
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change1840
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change1841
E-32 Alarm Buzzer Cannot be Canceled1843
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position1844
E-34 Service Mode Cannot be Selected1845
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move1846
E-36 All Work Equipment, Swing and Travel Do Not Lock1849
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing1851
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate1854
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show1856
E-40 One-Touch Power Maximizing Function is Not Cancelled1859
E-41 Alarm Does Not Sound During Travel1860
E-42 Alarm Does Not Stop When Machine Stops1862
E-43 Horn Does Not Sound1863
E-44 Horn Does Not Stop1866
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out1868
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate1869
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated1871
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function1872
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function1873
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function1874
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function1875
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function1876
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function1877
E-54 “Swing” is Not Shown Correctly with Monitoring Function1878
E-55 “Travel” is Not Shown Correctly with Monitoring Function1879
E-56 Service is Not Shown Correctly with Monitoring Function1880
E-57 Attachment Hydraulic Circuit Cannot be Changed1882
E-58 KOMTRAX System Does Not Operate Correctly1883
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1884
Information Shown in Troubleshooting Table (H-Mode)1884
System Chart of Hydraulic and Mechanical Systems1885
Failure Mode and Cause Table1887
H-1 All Work Equipment, Swing and Travel Do Not Work1896
H-2 All Work Equipment, Swing and Travel Lack Speed and Power1897
H-3 Fine Control Performance or Response is Unsatisfactory1900
H-4 Unusual Noise is Heard from Around Hydraulic Pump1901
H-5 Engine Speed Drops Largely or Engine Stops1902
H-6 Speed or Power of Boom is Low1904
H-7 Arm Speed or Power is Low1908
H-8 Bucket Speed or Power is Low1913
H-9 Work Equipment Does Not Move in Single Operation1916
H-10 Hydraulic Drift of Boom is Large1917
H-11 Hydraulic Drift of Arm is Large1919
H-12 Hydraulic Drift of Bucket is Large1921
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves1922
H-14 Time Lag of Work Equipment is Large1923
H-15 One-Touch Power Maximizing Function Does Not Operate1924
H-16 Attachment Circuit Cannot be Changed1925
H-17 Oil Flow in Attachment Circuit Cannot be Changed1926
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower1927
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely1928
H-20 In Mixed Operation of Swing and Boom Raise, Boom Raise Speed is Low1929
H-21 Machine Does Not Travel Straight1930
H-22 Machine is Not Steered Correctly or Steering Power is Low1932
H-23 Travel Speed is Low1935
H-24 One of Tracks Does Not Run1937
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast1938
H-26 Upper Structure Does Not Swing to Right and Left1939
H-27 Upper Structure Swings Only to Right or Left1940
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions1941
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction1942
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)1943
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)1944
H-32 Shock is Large When Upper Structure Stops Swing Operation1945
H-33 There is Large Unusual Noise When It Stops Swing Operation1946
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)1947
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)1948
Troubleshooting of Engine (S-Mode)1949
Information Shown in Troubleshooting Table (S-Mode)1949
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position1950
S-2 Engine Cranks but No Exhaust Smoke Comes Out1951
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)1952
S-4 Engine Startability is Unsatisfactory1954
S-5 Engine Does Not Pick Up Smoothly1956
S-6 Engine Stops During Operation1958
S-7 Engine Runs Rough or is Not Stable1960
S-8 Engine Lacks Power1961
S-9 KDPF Becomes Clogged in a Short Time1963
S-10 Engine Oil Consumption is Excessive1965
S-11 Oil Becomes Dirty Quickly1966
S-12 Fuel Consumption is Excessive1967
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant1968
S-14 Oil Pressure Drops1969
S-15 Fuel Mixes Into Engine Oil1971
S-16 Water Mixes Into Engine Oil (Milky)1972
S-17 Coolant Temperature Increases Too High (Overheating)1973
S-18 Unusual Noise is Heard1974
S-19 Vibration is Excessive1975
S-20 Air Cannot be Bled from Fuel Circuit1976
S-21 Active Regeneration is Done Frequently1977
S-22 Active Regeneration Continues Long1979
S-23 White Smoke is Exhausted During Active Regeneration1980
S-24 DEF Consumption is Excessive1981
S-25 There is Unusual Smell (Irritating Odor)1983
S-26 Foreign Materials Enter DEF (DEF Increases)1984
50 Disassembly and Assembly1985
Table of Contents1986
Precautions Before Work1991
Related Information on Disassembly and Assembly1992
How to Read This Manual1992
Coating Materials List1993
Special Tool List1998
Sketches of Special Tools2010
Engine and Cooling System2016
Remove and Install Supply Pump Assembly2016
Remove Supply Pump Assembly2016
Install Supply Pump Assembly2019
Remove and Install Injector Assembly2023
How to Remove Injector Assembly2023
How to Install Injector Assembly2028
Remove and Install Cylinder Head Assembly2036
How to Remove Cylinder Head Assembly2037
How to Install Cylinder Head Assembly2046
Remove and Install EGR Valve Assembly2062
Remove EGR Valve Assembly2062
Install EGR Valve Assembly2063
Remove and Install EGR Cooler Assembly2066
How to Remove EGR Cooler Assembly2066
How to Install EGR Cooler Assembly2069
Remove and Install Starter Assembly2074
Remove Starting Motor Assembly2074
Install Starting Motor Assembly2076
Remove and Install Alternator Belt2078
Remove Alternator Belt2078
Install Alternator Belt2080
Remove and Install Radiator Assembly2082
How to Remove Radiator Assembly2082
How to Install Radiator Assembly2084
Remove and Install Hydraulic Oil Cooler Assembly2086
How to Remove Hydraulic Oil Cooler Assembly2086
How to Install Hydraulic Oil Cooler Assembly2089
Remove and Install Aftercooler Assembly2092
Remove Aftercooler Assembly2092
Install Aftercooler Assembly2093
Remove and Install Engine and Main Pump Assembly2095
Remove Engine and Main Pump Assembly2096
Install Engine and Main Pump Assembly2104
Remove and Install Engine Front Oil Seal2115
How to Remove Engine Front Oil Seal2115
How to Install Engine Front Oil Seal2118
Remove and Install Engine Rear Oil Seal2122
How to Remove Engine Rear Oil Seal2122
How to Install Engine Rear Oil Seal2123
Remove and Install Fuel Cooler Assembly2126
Remove Fuel Cooler Assembly2126
Install Fuel Cooler Assembly2127
Remove and Install Engine Hood Assembly2128
How to Remove Engine Hood Assembly2128
How to Install Engine Hood Assembly2130
Remove and Install Fuel Tank Assembly2136
Remove Fuel Tank Assembly2136
Install Fuel Tank Assembly2140
Remove and Install DEF Tank Assembly2146
How to Remove DEF Tank Assembly2146
How to Install DEF Tank Assembly2151
Remove and Install DEF Tank Sensor Flange Assembly2156
How to Remove DEF Tank Sensor Flange Assembly2156
How to Install DEF Tank Sensor Flange Assembly2161
Remove and Install DEF Tank Sensor2167
Remove DEF Tank Sensor2167
Install DEF Tank Sensor2167
Remove and Install DEF Tank Strainer2174
Remove DEF Tank Strainer2174
Install DEF Tank Strainer2174
Remove and Install DEF Tank Filler Port Filter2175
Remove DEF Tank Filler Port Filter2175
Install DEF Tank Filler Port Filter2177
Remove and Install KDPF Assembly2180
How to Remove KDPF Assembly2180
How to Install KDPF Assembly2182
Disassemble and Assemble KDPF Assembly2184
Disassemble KDPF Assembly2185
Assemble KDPF Assembly2188
Remove and Install SCR Assembly2193
How to Remove SCR Assembly2193
How to Install SCR Assembly2195
Remove and Install KDPF and SCR Assembly2197
How to Remove KDPF and SCR Assembly2197
Install KDPF and SCR Assembly2203
Remove and Install KDPF and SCR Assembly Bracket2209
Remove KDPF and SCR Assembly Bracket2209
Install KDPF and SCR Assembly Bracket2215
Remove and Install Bellows Pipe Assembly2222
How to Remove Bellows Pipe Assembly2222
How to Install Bellows Pipe Assembly2224
Remove and Install KCCV Assembly2228
Remove KCCV Assembly2228
Install KCCV Assembly2231
Remove and Install DEF Mixing Tube2235
Remove DEF Mixing Tube2235
Install DEF Mixing Tube2240
Remove and Install DEF Injector2245
Remove DEF Injector2245
Install DEF Injector2247
Remove and Install DEF Pump2249
Remove DEF Pump2249
Install DEF Pump2252
Remove and Install DEF Hose2255
Remove DEF Hose2255
Install DEF Hose2263
Remove and Install Air Cleaner Assembly2269
Remove Air Cleaner Assembly2269
Install Air Cleaner Assembly2270
Remove and Install Air Conditioner Compressor Assembly2273
Remove Air Conditioner Compressor Assembly2273
How to Install Air Conditioner Compressor Assembly2275
Remove and Install Air Conditioner Condenser Assembly2278
How to Remove Air Conditioner Condenser Assembly2278
How to Install Air Conditioner Condenser Assembly2279
Power Train2280
Remove and Install Travel Motor and Final Drive Assembly2280
Remove Travel Motor and Final Drive Assembly2280
Install Travel Motor and Final Drive Assembly2281
Disassemble and Assemble Final Drive Assembly2283
Disassemble Final Drive Assembly2283
Assemble Final Drive Assembly2287
Remove and Install Swing Motor and Swing Machinery Assembly2296
Remove Swing Motor and Swing Machinery Assembly2296
Install Swing Motor and Swing Machinery Assembly2299
Disassemble and Assemble Swing Machinery Assembly2302
Disassemble Swing Machinery Assembly2302
Assemble Swing Machinery Assembly2306
Remove and Install Swing Circle Assembly2313
Remove Swing Circle Assembly2313
Install Swing Circle Assembly2313
Undercarriage and Frame2315
Separate and Connect Track Assembly2315
Separate Track Assembly2315
Install Track Assembly2317
Remove and Install Sprocket2320
Remove Sprocket2320
Install Sprocket2320
Remove and Install Idler and Idler Cushion Assembly2322
Remove Idler and Idler Cushion Assembly2322
Install Idler and Idler Cushion Assembly2323
Disassemble and Assemble Idler Assembly2324
Disassemble Idler Assembly2324
Assemble Idler Assembly2325
Disassemble and Assemble Idler Cushion Assembly2329
Disassemble Idler Cushion Assembly2330
Assemble Idler Cushion Assembly2331
Disassemble and Assemble Track Roller Assembly2332
Disassemble Track Roller Assembly2333
Assemble Track Roller Assembly2334
Disassemble and Assemble Carrier Roller Assembly2336
Disassemble Carrier Roller Assembly2336
Assemble Carrier Roller Assembly2338
Remove and Install Revolving Frame Assembly2340
Remove Revolving Frame Assembly2340
Install Revolving Frame Assembly2342
Remove and Install Counterweight Assembly2345
Remove Counterweight Assembly2345
Install Counterweight Assembly2348
Hydraulic System2352
Remove and Install Center Swivel Joint Assembly2352
Remove Center Swivel Joint Assembly2352
Install Center Swivel Joint Assembly2354
Disassemble and Assemble Center Swivel Joint Assembly2357
Disassemble Center Swivel Joint Assembly2358
Assemble Center Swivel Joint Assembly2359
Remove and Install Hydraulic Tank Assembly2360
Remove Hydraulic Tank Assembly2360
How to Install Hydraulic Tank Assembly2363
Remove and Install Main Pump Assembly2367
Remove Main Pump Assembly2367
Install Main Pump Assembly2370
Remove and Install Control Valve Assembly2374
How to Remove Control Valve Assembly2374
How to Install Control Valve Assembly2381
Disassemble and Assemble Control Valve Assembly2389
Replace Pressure Compensation Valve Seal Ring2389
Assemble Control Valve Assembly2391
Disassemble and Assemble Work Equipment PPC Valve Assembly2395
Disassemble Work Equipment PPC Valve Assembly2395
How to Assemble Work Equipment PPC Valve Assembly2395
Disassemble and Assemble Travel PPC Valve Assembly2397
Disassemble Travel PPC Valve Assembly2397
How to Assemble Travel PPC Valve Assembly2398
Work Equipment2400
Remove and Install Work Equipment Assembly2400
Remove Work Equipment Assembly2400
Install Work Equipment Assembly2404
Remove and Install Boom Anti-drop Valve Assembly2410
Remove Boom Anti-drop Valve Assembly2410
Install Boom Anti-drop Valve Assembly2412
Remove and Install Arm Anti-Drop Valve Assembly2413
Remove Arm Anti-Drop Valve Assembly2413
Install Arm Anti-Drop Valve Assembly2415
Disassemble and Assemble Anti-Drop Valve Assembly2416
Disassemble Anti-Drop Valve Assembly2416
Assemble Anti-Drop Valve Assembly2416
Disassemble and Assemble Work Equipment Cylinder Assembly2417
How to Disassemble Work Equipment Cylinder Assembly2417
How to Assemble Work Equipment Cylinder Assembly2420
CAB Related Parts2426
Remove and Install Operator Cab Assembly2426
How to Remove Operator Cab Assembly2426
Install Operator CAB Assembly2432
Remove and Install Operator Cab Glass (Adhered Glass)2439
Remove Operator CAB Glass (Adhered Glass)2441
Install Operator CAB Glass (Adhered Glass)2441
Remove and Install Front Window Assembly2451
Remove Front Window Assembly2451
Install Front Window Assembly2454
Remove and Install Floor Frame Assembly2460
How to Remove Floor Frame Assembly2460
How to Install Floor Frame Assembly2467
Remove and Install Air Conditioner Unit Assembly2474
Remove Air Conditioner Unit Assembly2474
Install Air Conditioner Unit Assembly2480
Remove and Install Operator Seat2487
Remove Operator’s Seat2487
Install Operator’s Seat2489
How to Remove and Install Seat Belt2492
How to Remove Seat Belt2492
How to Install Seatbelt2493
Remove and Install Work Equipment Control Lever Assembly2494
How to Remove Work Equipment Control Lever Assembly2494
How to Install Work Equipment Control Lever Assembly2500
Remove and Install Front Wiper Assembly2509
Remove Front Wiper Assembly2509
Install Front Wiper Assembly2514
Electrical System2523
Remove and Install Engine Controller Assembly2523
Remove Engine Controller Assembly2523
Install Engine Controller Assembly2525
Remove and Install Pump Controller Assembly2526
Remove Pump Controller Assembly2526
Install Pump Controller Assembly2530
Remove and Install KomVision Controller Assembly2535
Remove KomVision Controller Assembly2535
Install KomVision Controller Assembly2536
Remove and Install Machine Monitor Assembly2538
Remove Machine Monitor Assembly2538
Install Machine Monitor Assembly2541
Remove and Install Pump Swash Plate Sensor2544
Remove Pump Swash Plate Sensor2544
Install Pump Swash Plate Sensor2545
Remove and Install Mass Air Flow and Temperature Sensor2546
How to Remove Mass Air Flow and Temperature Sensor2546
How to Install Mass Air Flow and Temperature Sensor2547
Remove and Install KCCV Crankcase Pressure Sensor2548
How to Remove KCCV Crankcase Pressure Sensor2548
How to Install KCCV Crankcase Pressure Sensor2549
Remove and Install SCR Temperature Sensor2551
Remove SCR Temperature Sensor2551
Install SCR Temperature Sensor2553
Remove and Install KomVision Camera2556
Remove KomVision Camera2556
Install KomVision Camera2559
Remove and Install KOMTRAX Terminal Assembly2562
Remove KOMTRAX Terminal Assembly2562
Install KOMTRAX Terminal Assembly2565
60 Maintenance Standard2569
Table of Contents2570
Engine and Cooling System2571
Maintenance Standard for Engine Mount2571
Maintenance Standard for Cooling System2572
Power Train2573
Maintenance Standard for Swing Circle2573
Maintenance Standard for Swing Machinery2574
Maintenance Standard for Final Drive2576
Maintenance Standard for Sprocket2578
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing2579
Undercarriage and Frame2580
Maintenance Standard for Track Frame and Idler Cushion2580
Maintenance Standard for Idler2582
Maintenance Standard for Track Roller2584
Maintenance Standard for Carrier Roller2585
Maintenance Standard for Track Shoes2586
Maintenance Standard for Triple Shoes2589
Maintenance Standard for Swamp Shoes2590
Maintenance Standard for Road Liner2591
Hydraulic System2592
Maintenance Standard for Hydraulic Tank2592
Maintenance Standard for Main Pump2593
Maintenance Standard for LS-EPC Valve2594
Maintenance Standard for PC-EPC Valve2595
Maintenance Standard for Swing Motor2596
Maintenance Standard for Travel Motor2599
Maintenance Standard for Control Valve2602
Maintenance Standard for Boom Anti-Drop Valve2612
Maintenance Standard for Arm Anti-Drop Valve2614
Maintenance Standard for Work Equipment and Swing PPC Valve2616
Maintenance Standard for Travel PPC Valve2619
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)2622
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve2623
Maintenance Standard for 2nd-Line Attachment PPC Valve2625
Maintenance Standard for Solenoid Valve2627
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure)2628
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)2629
Maintenance Standard for Center Swivel Joint2630
Work Equipment2631
Maintenance Standard for Work Equipment Linkage2631
Dimensions of Arm2636
Dimensions of Bucket2638
Maintenance Standard for Boom Cylinder2640
Maintenance Standard for Boom Cylinder (Large Diameter Piston)2641
Maintenance Standard for Arm Cylinder2642
Maintenance Standard for Bucket Cylinder2643
80 Appendix2645
Table of Contents2646
Precautions Before Work2648
Air Conditioner System2649
Precautions for Refrigerant2649
Air Conditioner Component2650
Specifications of Air Conditioner2652
Structure and Function of Refrigeration Cycle2653
Outline of Refrigeration Cycle2654
Component Parts of Air Conditioner System2656
Air Conditioner Unit2656
Configuration Diagram of Air Conditioner Unit2656
Function of Air Conditioner Unit2658
Component Parts of Air Conditioner Unit2660
Function of Evaporator as Air Conditioner Unit Component2661
Function of Heater Core as Air Conditioner Unit Component2661
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2661
Function of Servo Motor as Air Conditioner Unit Component2661
Structure of Expansion Valve as Air Conditioner Unit Component2662
Function of Expansion Valve as Air Conditioner Unit Component2662
Operate Expansion Valve as Air Conditioner Unit Component2662
Function of Dual Pressure Switch2663
Air Conditioner Controller2664
Structure of Air Conditioner Controller2664
Compressor2665
Structure of Compressor2665
Specifications of Compressor2665
Function of Compressor2665
Condenser2666
Structure of Condenser2666
Specifications of Condenser2666
Function of Condenser2666
Air Conditioner Related Sensors2668
Structure of Sunlight Sensor2668
Function of Sunlight Sensor2668
Structure of Outside Temperature Sensor2668
Function of Outside Air Temperature Sensor2668
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2670
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2672
System Diagram of Air Conditioner2674
Input and Output Signals of Air Conditioner Controller2675
Function of Air Conditioner Controller2676
Locations of Air Conditioner Parts and Layout of Connectors2677
Examine Air Leakage (Duct)2681
How to Examine Air Leakage (Duct)2681
Examine Air Conditioner with Self-Diagnosis Function2683
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2684
Examine Vent (Mode) Changeover2685
How to Examine Vent (Mode) Changeover2685
Examine Fresh/Recirc Air Changeover2687
How to Examine Fresh/Recirc Air Changeover2687
Examine Sunlight Sensor2688
How to Examine Sunlight Sensor2688
Examine Refrigerant (Dual) Pressure Switch2689
How to Examine Refrigerant (Dual) Pressure Switch2689
Examine Relay2690
How to Examine Relay2690
Air Conditioner Troubleshooting Chart 12691
Air Conditioner Troubleshooting Chart 22692
Information Shown in Troubleshooting Table2695
Failure Code [879AKA]2696
Failure Code [879AKB]2697
Failure Code [879BKA]2698
Failure Code [879BKB]2700
Failure Code [879CKA]2702
Failure Code [879CKB]2703
Failure Code [879DKZ]2704
Failure Code [879EMC]2706
Failure Code [879FMC]2707
Failure Code [879GKX]2708
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2710
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2712
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2715
A-4 Troubleshooting for Fresh/Recirc Air Changeover2717
Troubleshooting by Gauge Pressure2719
Connect Service Tool2722
How to Connect Service Tool2722
Precautions for Disconnection and Connection of Air Conditioner Piping2724
Handle Compressor Oil2726
Replace Desiccant2728
90 Circuit Diagrams2731
Table of Contents2732
Hydraulic Circuit Diagram2733
Symbols Used in Hydraulic Circuit Diagram2733
Hydraulic Circuit Diagram2737
Electrical Circuit Diagram2739
Symbols Used in Electric Circuit Diagram2739
Electrical Circuit Diagram (1/9)2743
Electrical Circuit Diagram (2/9)2745
Electrical Circuit Diagram (3/9)2747
Electrical Circuit Diagram (4/9)2749
Electrical Circuit Diagram (5/9)2751
Electrical Circuit Diagram (6/9)2753
Electrical Circuit Diagram (7/9)2755
Electrical Circuit Diagram (8/9)2757
Electrical Circuit Diagram (9/9)2759
INDEX2761

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24