Komatsu Hydraulic Excavator PC290LC-11 Shop Manual SEN06507-20 PDF

Description

Komatsu Hydraulic Excavator PC290LC-11 Shop Manual SEN06507-20 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Excavator PC290LC-11 Shop Manual SEN06507-20 – PDF DOWNLOAD

Language : English
Pages :2784
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Excavator PC290LC-11 Shop Manual SEN06507-20 – PDF DOWNLOAD

SERIAL NUMBERS 35001 and up

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC290LC-11 Shop Manual SEN06507-20 – PDF DOWNLOAD

SERIAL NUMBERS 35001 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: PC290LC-11 93
Working Range Drawings 95
Working Range: PC290LC-11 95
Specifications 96
Specifications: PC290LC-11 96
Weight Table 99
Weight Table: PC290LC-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 131
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 166
EGR Valve 168
EGR Cooler 170
KCCV System 172
KCCV Ventilator 174
KDPF 176
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 216
Engine Controller 217
Fuel Control Dial 224
Hydraulic System 226
Layout Drawing of Hydraulic System 226
CLSS 232
Structure of CLSS 232
Operation of Unload Valve and LS Pressure 234
Pump Swash Plate Angle (Oil Flow) Control 235
Pressure Compensation Control 251
Engine and Pump Combined Control System 254
Engine and Pump Combined Control System Diagram 254
Function of Engine and Pump Combined Control System 255
Pump and Valve Control System 260
Pump and Valve Control System Diagram 260
Function of Pump and Valve Control System 261
Component Parts of Hydraulic System 263
Hydraulic Tank 263
Main Pump 265
Control Valve 290
Work Equipment System 352
Layout Drawing of Work Equipment System 352
Structure of Valve Control 357
One-Touch Power Maximizing System 359
System Diagram of One-Touch Power Maximizing System 359
Function of One-Touch Power Maximizing System 360
PPC Lock System 361
System Diagram of PPC Lock 361
Function of PPC Lock System 361
Work Equipment and Travel Automatic Lock System 362
System Diagram of Lock Lever Automatic Lock System 362
Function of Work Equipment and Travel Automatic Lock System 362
Operation of Lock Lever Automatic Lock System 363
Attachment Oil Flow Adjuster System 364
Attachment Oil Flow Adjuster System Diagram 364
Function of Attachment Oil Flow Adjuster System 365
Tool Control System 366
Tool Control System Diagram 366
Component Parts of Work Equipment System 368
Work Equipment and Swing PPC Valve 368
1st-Line Attachment PPC Valve (with EPC Valve) 375
2nd-Line Attachment PPC Valve 382
Solenoid Valve 384
Boom Anti-drop Valve 387
Arm Anti-Drop Valve 391
Attachment Circuit Selector Valve (For High Pressure) 396
Attachment Circuit Selector Valve (For Low Pressure) 398
1st-Line Attachment Variable Relief Valve 399
2nd-Line Attachment Variable Relief Valve 402
Operation of Attachment Bypass Solenoid Valve 405
Pilot Circuit Accumulator 408
Attachment Circuit Accumulator 409
Swing System 410
Layout Drawing of Swing System 410
Swing Control System Diagram 414
Function of Swing Control System 414
Component Parts of Swing System 418
Swing Motor 418
Swing Machinery 429
Swing Circle 431
Travel System 432
Layout Drawing of Travel System 432
System Diagram of Travel Control System 436
Function of Travel Control System 436
Component Parts of Travel System 438
Travel Motor 438
Final Drive 450
Travel PPC Valve 453
Center Swivel Joint 457
Undercarriage and Frame 459
Layout Drawing of Undercarriage 459
Specifications of Undercarriage 460
Work Equipment 461
Structure of Work Equipment 461
Function of Work Equipment 462
Work Equipment Clearance Adjustment Shim 463
Function of Work Equipment Clearance Adjustment Shim 463
Bucket Clearance Adjustment Shim 464
Function of Bucket Clearance Adjustment Shim 464
CAB Related Parts 465
ROPS CAB 465
Structure of ROPS CAB 465
Function of ROPS CAB 465
CAB Mount 466
Structure of CAB Mount 466
Function of CAB Mount 466
CAB Tipping Stopper 467
Structure of CAB Tipping Stopper 467
Function of CAB Tipping Stopper 467
20 Standard Value Table 469
Table of Contents 470
Standard Value Table for Engine 471
Standard Value Table for Engine: PC290LC-11 471
Standard Value Table for Machine 475
Standard Value Table for Machine: PC290LC-11 475
Machine Posture and Procedures to Measure Performance 488
Standard Value Table for Electricity 492
Standard Value Table for Electricity 492
30 Testing and Adjusting 503
Table of Contents 504
Precautions Before Work 507
Related Information on Testing and Adjusting 508
Tools for Testing and Adjusting 508
Sketch of Tools for Testing and Adjusting 515
Engine and Cooling System 517
Examine Engine Speed 517
How to Examine Engine Speed 517
Examine Boost Pressure 520
How to Examine Boost Pressure on Machine Monitor 520
How to Examine Boost Pressure by Testing Tool 521
Examine Exhaust Gas Color 522
How to Examine Exhaust Gas Color with the Handy Smoke Checker 522
How to Examine Exhaust Gas Color with Smoke Meter 523
Examine Mass Air Flow and Temperature Sensor 525
How to Examine Mass Air Flow and Temperature Sensor 525
Examine and Adjust Valve Clearance 527
Check Valve Clearance 527
Adjust Valve Clearance 528
Examine Compression Pressure 530
How to Examine Compression Pressure 530
Examine Blowby Pressure 535
How to Examine Blowby Pressure 535
Examine Engine Oil Pressure 537
How to Examine Engine Oil Pressure 537
Examine EGR Valve and VGT Oil Pressure 538
How to Examine EGR Valve and VGT Oil Pressure 538
Examine Fuel Pressure 540
How to Examine Fuel Pressure 541
Examine Fuel Discharge, Return and Leakage 546
How to Examine Fuel Discharge, Return, and Leakage 547
Bleed Air from Fuel System 553
How to Bleed Air from Fuel System 553
Examine Fuel Circuit for Leakage 554
How to Examine Fuel System for Leakage 554
Handle Cylinder Cut-out Mode Operation 556
Handle No-Injection Cranking Operation 557
Examine and Adjust Air Conditioner Compressor Belt Tension 558
How to Examine Air Conditioner Compressor Belt 558
How to Adjust Air Conditioner Compressor Belt 558
Examine Fan Belt and Alternator Belt 560
How to Examine Fan Belt and Alternator Belt 560
Examine Automatic Tensioner 561
How to Examine Automatic Tensioner 561
Write Correction for Ash in Soot Accumulation to Engine Controller 562
How to Write Correction for Ash in Soot Accumulation to Engine Controller 562
Examine SCR Related Functions 563
Examine DEF Pump Raised Pressure 566
Examine Injection Volume from DEF Injector 569
Examine DEF Line Heater Relay 1 573
Examine DEF Line Heater Relay 2 576
Examine DEF Pump Heater Relay 578
Examine DEF Tank Heater Valve 581
Examine SCR Denitration Efficiency 584
Clean DEF Tank 588
How to Clean DEF Tank 588
Bleed Air from Coolant Circuit of DEF Tank 592
How to Bleed Air from Coolant Circuit of DEF Tank 592
Clean DEF Pump 594
How to Clean DEF Pump 594
Power Train 600
Examine Swing Circle Bearing Clearance 600
How to Examine Swing Circle Bearing Clearance 600
Undercarriage and Frame 601
Examine and Adjust Track Tension 601
How to Examine Track Tension 601
How to Adjust Track Tension 601
Hydraulic System 603
Release Remained Pressure in Hydraulic Circuit 603
How to Release Remained Pressure in Hydraulic System 603
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 604
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 605
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 611
Examine Oil Pressure of Control Circuit 614
Examine Oil Pressure in Control Circuit 614
Examine and adjust oil pressure in pump PC control circuit 616
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 616
Examine PC-EPC Valve Outlet Pressure 617
How to Adjust Oil Pressure in Pump PC Control Circuit 618
Examine and Adjust Oil Pressure in Pump LS Control Circuit 620
Examine LS Differential Pressure with Machine Monitor 620
Examine LS Differential Pressure by Testing Tool 621
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 624
How to Examine LS-EPC Valve Outlet Pressure 625
Adjust LS Valve 626
Examine Outlet Pressure of Solenoid Valve 627
How to Examine Outlet Pressure of Solenoid Valve 627
Operating Condition of Solenoid Valve 628
Examine PPC Valve Outlet Pressure 631
Examine Outlet Pressure in PPC Valve 631
Examine Attachment Circuit Oil Pressure 633
How to Examine Attachment Circuit Oil Pressure 633
Adjust Play of Work Equipment and Swing PPC Valves 634
How to Adjust Play of Work Equipment and Swing PPC Valves 634
Examine Pump Swash Plate Sensor 635
How to Examine pump swash plate sensor 635
Examine Parts Which Cause Hydraulic Drift of Work Equipment 636
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 636
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 636
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 637
Examine Oil Leakage 638
How to Examine Oil Leakage from Boom Cylinder 638
How to Examine Oil Leakage from Arm Cylinder 638
How to Examine Oil Leakage from Bucket Cylinder 639
How to Examine Oil Leakage from Swing Motor 640
How to Examine Oil Leakage from Travel Motor 640
Bleed Air from Hydraulic System 641
How to Bleed Air from Hydraulic System 643
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 645
Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 645
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 649
Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 649
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 653
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 653
CAB Related Parts 660
Examine CAB Tipping Stopper 660
How to Examine Cab Tipping Stopper 660
How to Adjust Mirrors 661
Procedure to Adjust Machine Left Front Mirror (A) 661
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 662
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 663
Procedure to Adjust Machine Right Side Mirror (C) 664
Electrical System 666
Set and Operate Machine Monitor 666
Operator Mode 669
Function to Show Technician Identification Status Screen 670
Function to Show Operator Identification Input Screen 670
Examine Function by LCD (Liquid Crystal Display) 671
Examine Function of Service Meter 671
Usage Limitation and Maintenance Password Change Function 671
Service Mode 674
Operate Service Mode 674
How to See Pre-defined Monitoring Information 676
How to Examine Self-Define Monitor Information 682
Abnormality Record Menu 693
How to See Maintenance Record 697
Maintenance Mode Setting 698
Set Phone Number Entry 702
Default Menu 703
Diagnostic Tests Menu 715
Adjustment Menu 724
No-Injection Cranking Operation 754
KOMTRAX Settings Menu 755
Show Service Message 757
How to Start Up KOMTRAX Terminal 759
Adjust Rearview Camera Angle 764
How to Adjust Rearview Camera Angle 764
Adjust KomVision Camera Angle 767
How to Adjust KomVision Camera Angle 768
Adjust KomVision Related Function 772
Setting of KomVision (Main Setting) 772
Setting of KomVision (Camera Setting) 774
Setting of KomVision (Camera Calibration) 776
KomVision screen – Check 12 m visibility 789
Set Region of Bluetooth(R) Compatible Radio 792
Set Region of Bluetooth(R) Compatible Radio 792
Handle Voltage Circuit of Engine Controller 794
Handle Battery Disconnect Switch 795
Examine Diodes 796
Examine Diodes by Digital Tester 796
How to Examine Diodes by Analog Tester 796
Pm Clinic 797
Pm Clinic Service 797
Pm Clinic Check Sheet 798
40 Troubleshooting 811
Table of Contents 812
Precautions Before Work 822
Related Information to Troubleshooting 823
General Troubleshooting Points 823
Troubleshooting Points for Urea SCR System 824
Sequence of Events in Troubleshooting 838
Checks Before Troubleshooting 840
Inspection Procedure Before Troubleshooting 842
Walk-Around Check 842
Test in Accordance with Testing Procedure 844
Examine Fuel Level and Type 844
Examine for Impure Ingredient in Fuel 844
Examine Fuel Prefilter 845
Examine Water Separator, Drain Water and Sediment 845
How to Replace Fuel Prefilter Cartridge 846
Examine Fuel Main Filter 847
Examine Engine Oil Level (Oil Quantity in Oil Pan) 849
Examine Coolant Level (Reservoir Tank) 850
Examine Air Cleaner Clogging 850
Clean Outer Element 851
Replace Element 853
Examine Hydraulic Oil Level 854
Examine Hydraulic Oil Strainer 855
Examine Hydraulic Oil Filter 856
Examine Oil Level in Swing Machinery Case 857
Examine Oil Level in Damper Case 858
Examine Oil Level in Final Drive Case 858
Bleed Air from Fuel System 859
Bleed Air from Hydraulic System 859
How to Examine Electric Equipment 859
Preparation for Troubleshooting of Electrical System 867
Procedure for Troubleshooting 877
Symptom and Troubleshooting Numbers 880
Information Shown in Troubleshooting Table 884
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 886
Connector List and Layout 889
Connector Contact Connection Table 902
T-Branch Box and T-Branch Adapter Table 942
Fuse Location Table 948
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 950
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 954
Failure Code Table 956
Troubleshooting by Failure Code (Display of Code) 974
Failure Code [879AKA] 974
Failure Code [879AKB] 975
Failure Code [879BKA] 976
Failure Code [879BKB] 978
Failure Code [879CKA] 980
Failure Code [879CKB] 981
Failure Code [879DKZ] 982
Failure Code [879EMC] 984
Failure Code [879FMC] 985
Failure Code [879GKX] 986
Failure Code [989L00] 988
Failure Code [989M00] 989
Failure Code [989N00] 990
Failure Code [A1U0N3] 991
Failure Code [A1U0N4] 993
Failure Code [A900FR] 995
Failure Code [A900N6] 996
Failure Code [A900NY] 997
Failure Code [AA10NX] 998
Failure Code [AB00KE]1000
Failure Code [AQ10N3]1003
Failure Code [AS00N3]1005
Failure Code [AS00R2]1007
Failure Code [AS00R3]1008
Failure Code [AS00R4]1009
Failure Code [AS00R5]1010
Failure Code [AS00R6]1011
Failure Code [AS00ZK]1012
Failure Code [AS10KM]1013
Failure Code [AS10NR]1014
Failure Code [AS10NT]1015
Failure Code [B@BAZG]1016
Failure Code [B@BAZK]1017
Failure Code [B@BCNS]1019
Failure Code [B@BCQA]1020
Failure Code [B@BCZK]1022
Failure Code [B@HANS]1024
Failure Code [CA115]1025
Failure Code [CA122]1026
Failure Code [CA123]1028
Failure Code [CA131]1030
Failure Code [CA132]1032
Failure Code [CA144]1034
Failure Code [CA145]1036
Failure Code [CA153]1038
Failure Code [CA154]1041
Failure Code [CA187]1043
Failure Code [CA221]1045
Failure Code [CA222]1047
Failure Code [CA227]1049
Failure Code [CA234]1050
Failure Code [CA238]1051
Failure Code [CA239]1053
Failure Code [CA249]1055
Failure Code [CA256]1057
Failure Code [CA271]1059
Failure Code [CA272]1061
Failure Code [CA322]1063
Failure Code [CA323]1065
Failure Code [CA324]1067
Failure Code [CA325]1069
Failure Code [CA331]1071
Failure Code [CA332]1073
Failure Code [CA343]1075
Failure Code [CA351]1076
Failure Code [CA352]1077
Failure Code [CA356]1080
Failure Code [CA357]1082
Failure Code [CA386]1084
Failure Code [CA428]1085
Failure Code [CA429]1087
Failure Code [CA435]1089
Failure Code [CA441]1091
Failure Code [CA442]1093
Failure Code [CA449]1094
Failure Code [CA451]1095
Failure Code [CA452]1097
Failure Code [CA488]1099
Failure Code [CA515]1100
Failure Code [CA516]1102
Failure Code [CA553]1104
Failure Code [CA555]1105
Failure Code [CA556]1106
Failure Code [CA559]1107
Failure Code [CA595]1110
Failure Code [CA687]1111
Failure Code [CA689]1113
Failure Code [CA691]1116
Failure Code [CA692]1118
Failure Code [CA697]1120
Failure Code [CA698]1121
Failure Code [CA731]1122
Failure Code [CA778]1124
Failure Code [CA1117]1129
Failure Code [CA1664]1130
Failure Code [CA1669]1132
Failure Code [CA1673]1133
Failure Code [CA1677]1134
Failure Code [CA1678]1135
Failure Code [CA1682]1136
Failure Code [CA1683]1138
Failure Code [CA1684]1140
Failure Code [CA1686]1142
Failure Code [CA1691]1143
Failure Code [CA1694]1146
Failure Code [CA1695]1149
Failure Code [CA1696]1150
Failure Code [CA1712]1152
Failure Code [CA1713]1155
Failure Code [CA1714]1157
Failure Code [CA1715]1158
Failure Code [CA1776]1159
Failure Code [CA1777]1162
Failure Code [CA1843]1165
Failure Code [CA1844]1167
Failure Code [CA1879]1170
Failure Code [CA1881]1172
Failure Code [CA1883]1174
Failure Code [CA1885]1177
Failure Code [CA1887]1179
Failure Code [CA1921]1181
Failure Code [CA1922]1184
Failure Code [CA1942]1189
Failure Code [CA1993]1190
Failure Code [CA2185]1193
Failure Code [CA2186]1194
Failure Code [CA2249]1196
Failure Code [CA2271]1197
Failure Code [CA2272]1200
Failure Code [CA2288]1203
Failure Code [CA2311]1204
Failure Code [CA2349]1205
Failure Code [CA2353]1208
Failure Code [CA2357]1210
Failure Code [CA2381]1211
Failure Code [CA2382]1214
Failure Code [CA2383]1217
Failure Code [CA2386]1220
Failure Code [CA2387]1222
Troubleshooting Flowchart1226
Failure Code [CA2555]1227
Failure Code [CA2556]1230
Failure Code [CA2637]1233
Failure Code [CA2639]1235
Failure Code [CA2771]1238
Failure Code [CA2777]1244
Failure Code [CA2976]1247
Failure Code [CA3133]1249
Failure Code [CA3134]1252
Failure Code [CA3135]1254
Failure Code [CA3142]1257
Failure Code [CA3143]1258
Failure Code [CA3144]1259
Failure Code [CA3146]1261
Failure Code [CA3147]1262
Failure Code [CA3148]1263
Failure Code [CA3151]1265
Failure Code [CA3165]1271
Failure Code [CA3229]1273
Failure Code [CA3231]1275
Failure Code [CA3232]1277
Failure Code [CA3235]1281
Failure Code [CA3239]1283
Failure Code [CA3241]1286
Failure Code [CA3242]1289
Failure Code [CA3251]1292
Failure Code [CA3253]1294
Failure Code [CA3254]1297
Failure Code [CA3255]1300
Failure Code [CA3256]1304
Failure Code [CA3311]1306
Failure Code [CA3312]1308
Failure Code [CA3313]1311
Failure Code [CA3314]1312
Failure Code [CA3315]1313
Failure Code [CA3316]1315
Failure Code [CA3317]1316
Failure Code [CA3318]1317
Failure Code [CA3319]1319
Failure Code [CA3321]1320
Failure Code [CA3322]1322
Failure Code [CA3419]1324
Failure Code [CA3421]1326
Failure Code [CA3497]1328
Failure Code [CA3498]1329
Failure Code [CA3543]1330
Failure Code [CA3545]1337
Failure Code [CA3547]1339
Failure Code [CA3558]1340
Failure Code [CA3559]1342
Failure Code [CA3562]1344
Failure Code [CA3563]1346
Failure Code [CA3567]1349
Failure Code [CA3568]1352
Failure Code [CA3571]1356
Failure Code [CA3572]1358
Failure Code [CA3574]1360
Failure Code [CA3575]1362
Failure Code [CA3577]1363
Failure Code [CA3578]1365
Failure Code [CA3582]1367
Failure Code [CA3583]1373
Failure Code [CA3596]1375
Failure Code [CA3649]1377
Failure Code [CA3681]1379
Failure Code [CA3682]1384
Failure Code [CA3713]1390
Failure Code [CA3717]1393
Failure Code [CA3718]1394
Failure Code [CA3725]1395
Failure Code [CA3741]1398
Failure Code [CA3748]1399
Failure Code [CA3751]1401
Failure Code [CA3755]1403
Failure Code [CA3866]1405
Failure Code [CA3867]1409
Failure Code [CA3868]1412
Failure Code [CA3899]1416
Failure Code [CA3911]1418
Failure Code [CA3912]1422
Failure Code [CA3932]1424
Failure Code [CA3933]1426
Failure Code [CA3934]1428
Failure Code [CA3935]1431
Failure Code [CA3936]1433
Failure Code [CA4151]1435
Failure Code [CA4152]1439
Failure Code [CA4155]1443
Failure Code [CA4156]1445
Failure Code [CA4157]1448
Failure Code [CA4158]1450
Failure Code [CA4159]1451
Failure Code [CA4161]1452
Failure Code [CA4162]1455
Failure Code [CA4163]1458
Failure Code [CA4164]1459
Failure Code [CA4165]1461
Failure Code [CA4166]1463
Failure Code [CA4168]1464
Failure Code [CA4169]1467
Failure Code [CA4171]1469
Failure Code [CA4249]1472
Failure Code [CA4251]1474
Failure Code [CA4259]1476
Failure Code [CA4261]1479
Failure Code [CA4277]1482
Failure Code [CA4281]1486
Failure Code [CA4459]1489
Failure Code [CA4461]1491
Failure Code [CA4658]1494
Failure Code [CA4731]1498
Failure Code [CA4732]1499
Failure Code [CA4739]1500
Failure Code [CA4768]1501
Failure Code [CA4769]1503
Failure Code [CA4842]1506
Failure Code [CA4952]1510
Failure Code [CA5115]1512
Failure Code [CA5179]1515
Failure Code [CA5181]1517
Failure Code [CA5383]1519
Failure Code [D110KB]1521
Failure Code [D19JKZ]1523
Failure Code [D811MC]1526
Failure Code [D862KA]1527
Failure Code [D8ALKA]1528
Failure Code [D8ALKB]1530
Failure Code [D8AQKR]1532
Failure Code [DA20MC]1534
Failure Code [DA22KK]1535
Failure Code [DA25KP]1538
Failure Code [DA26KP]1541
Failure Code [DA29KQ]1544
Failure Code [DA2LKA]1546
Failure Code [DA2LKB]1548
Failure Code [DA2QKR]1550
Failure Code [DA2RKR]1553
Failure Code [DAF0KM]1554
Failure Code [DAF0MB]1555
Failure Code [DAF0MC]1556
Failure Code [DAF8KB]1557
Failure Code [DAF9KQ]1559
Failure Code [DAFGMC]1560
Failure Code [DAFLKA]1561
Failure Code [DAFLKB]1563
Failure Code [DAFQKR]1565
Failure Code [DAZ9KQ]1566
Failure Code [DAZQKR]1567
Failure Code [DB2QKR]1572
Failure Code [DB2RKR]1577
Failure Code [DBP0KM]1582
Failure Code [DBP0KT]1583
Failure Code [DBP5KB]1584
Failure Code [DBP5KY]1587
Failure Code [DBPQKR]1590
Failure Code [DDNRKA]1595
Failure Code [DDNRKY]1597
Failure Code [DDNS00]1599
Failure Code [DGH2KA]1601
Failure Code [DGH2KB]1603
Failure Code [DHA4KA]1605
Failure Code [DHAAMA]1607
Failure Code [DHACMA]1609
Failure Code [DHPAMA]1611
Failure Code [DHPBMA]1614
Failure Code [DHS3MA]1617
Failure Code [DHS4MA]1620
Failure Code [DHS8MA]1623
Failure Code [DHS9MA]1626
Failure Code [DHSAMA]1629
Failure Code [DHSBMA]1632
Failure Code [DHSCMA]1635
Failure Code [DHSDMA]1638
Failure Code [DHSFMA]1641
Failure Code [DHSGMA]1644
Failure Code [DHSHMA]1647
Failure Code [DHSJMA]1650
Failure Code [DHZAMA]1653
Failure Code [DHZCL8]1657
Failure Code [DKR0MA]1658
Failure Code [DKR1MA]1661
Failure Code [DKULKA]1664
Failure Code [DKULKB]1666
Failure Code [DKULKY]1668
Failure Code [DR10KA]1670
Failure Code [DR12KA]1673
Failure Code [DR20KA]1675
Failure Code [DR21KX]1677
Failure Code [DR30KA]1679
Failure Code [DR31KX]1681
Failure Code [DR40KA]1683
Failure Code [DUMBKA]1685
Failure Code [DUMBKB]1687
Failure Code [DV20KB]1689
Failure Code [DW43KA]1691
Failure Code [DW43KB]1693
Failure Code [DW43KY]1695
Failure Code [DW45KA]1697
Failure Code [DW45KB]1700
Failure Code [DW45KY]1703
Failure Code [DW4CKY]1705
Failure Code [DW91KA]1707
Failure Code [DW91KB]1709
Failure Code [DW91KY]1711
Failure Code [DWA2KA]1713
Failure Code [DWA2KB]1715
Failure Code [DWA2KY]1717
Failure Code [DWK0KA]1719
Failure Code [DWK0KB]1721
Failure Code [DWK0KY]1723
Failure Code [DWK2KA]1725
Failure Code [DWK2KB]1727
Failure Code [DWK2KY]1729
Failure Code [DWK8KA]1731
Failure Code [DWK8KB]1733
Failure Code [DWK8KY]1735
Failure Code [DXA8KA]1737
Failure Code [DXA8KB]1739
Failure Code [DXA9KA]1741
Failure Code [DXA9KB]1743
Failure Code [DXE0KA]1745
Failure Code [DXE0KB]1747
Failure Code [DXE4KA]1749
Failure Code [DXE4KB]1751
Failure Code [DXE4KY]1753
Failure Code [DXE5KA]1755
Failure Code [DXE5KB]1757
Failure Code [DXE6KA]1759
Failure Code [DXE6KB]1761
Failure Code [DXE7KA]1763
Failure Code [DXE7KB]1765
Failure Code [DXE7KY]1767
Failure Code [DXE8KA]1769
Failure Code [DXE8KB]1771
Failure Code [DXE8KY]1773
Failure Code [DXE9KA]1775
Failure Code [DXE9KB]1777
Failure Code [DXE9KY]1779
Failure Code [DXEAKA]1781
Failure Code [DXEAKB]1783
Failure Code [DXEAKY]1785
Failure Code [DXEKKA]1787
Failure Code [DXEKKB]1789
Failure Code [DXEKKY]1791
Failure Code [DXELKA]1793
Failure Code [DXELKB]1795
Failure Code [DXELKY]1797
Failure Code [DY20KA]1799
Failure Code [DY20MA]1801
Failure Code [DY2CKB]1803
Failure Code [DY2DKB]1806
Failure Code [DY2EKB]1808
Troubleshooting of Electrical System (E-Mode)1810
E-1 Engine Does Not Start (Engine Does Not Crank)1810
E-2 Manual Preheating System Does Not Operate1816
E-3 Automatic Preheating System Does Not Operate1819
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On1821
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1823
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow1826
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow1827
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation1828
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs1829
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs1830
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation1831
E-12 Fuel Level Monitor Comes On in Red While Engine Runs1832
E-13 Water Separator Monitor Comes On in Red While Engine Runs1833
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1834
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation1835
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation1836
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum1837
E-18 Display of Fuel Gauge is Different from Actual Fuel Level1839
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum1840
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature1841
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum1842
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature1844
E-23 Some Areas of Machine Monitor Screen are Not Shown1845
E-24 Function Switch Does Not Operate1846
E-25 Automatic Warm-up System Does Not Work (in Cold Weather)1847
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out1848
E-27 Auto-Decelerator is Not Operated or Canceled with Lever1849
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown1850
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed1851
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change1852
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change1853
E-32 Alarm Buzzer Cannot be Canceled1855
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position1856
E-34 Service Mode Cannot be Selected1857
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move1858
E-36 All Work Equipment, Swing and Travel Do Not Lock1861
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing1863
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate1866
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show1868
E-40 One-Touch Power Maximizing Function is Not Cancelled1871
E-41 Alarm Does Not Sound During Travel1872
E-42 Alarm Does Not Stop When Machine Stops1874
E-43 Horn Does Not Sound1875
E-44 Horn Does Not Stop1878
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out1880
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate1881
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated1883
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function1884
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function1885
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function1886
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function1887
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function1888
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function1889
E-54 “Swing” is Not Shown Correctly with Monitoring Function1890
E-55 “Travel” is Not Shown Correctly with Monitoring Function1891
E-56 Service is Not Shown Correctly with Monitoring Function1892
E-57 Attachment Hydraulic Circuit Cannot be Changed1894
E-58 KOMTRAX System Does Not Operate Correctly1895
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1896
Information Shown in Troubleshooting Table (H-Mode)1896
System Chart of Hydraulic and Mechanical Systems1897
Failure Mode and Cause Table1899
H-1 All Work Equipment, Swing and Travel Do Not Work1908
H-2 All Work Equipment, Swing and Travel Lack Speed and Power1909
H-3 Fine Control Performance or Response is Unsatisfactory1912
H-4 Unusual Noise is Heard from Around Hydraulic Pump1913
H-5 Engine Speed Drops Largely or Engine Stops1914
H-6 Speed or Power of Boom is Low1916
H-7 Arm Speed or Power is Low1920
H-8 Bucket Speed or Power is Low1925
H-9 Work Equipment Does Not Move in Single Operation1928
H-10 Hydraulic Drift of Boom is Large1929
H-11 Hydraulic Drift of Arm is Large1931
H-12 Hydraulic Drift of Bucket is Large1933
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves1934
H-14 Time Lag of Work Equipment is Large1935
H-15 One-Touch Power Maximizing Function Does Not Operate1936
H-16 Attachment Circuit Cannot be Changed1937
H-17 Oil Flow in Attachment Circuit Cannot be Changed1938
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower1939
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely1940
H-20 In Mixed Operation of Swing and Boom Raise, Boom Raise Speed is Low1941
H-21 Machine Does Not Travel Straight1942
H-22 Machine is Not Steered Correctly or Steering Power is Low1944
H-23 Travel Speed is Low1947
H-24 One of Tracks Does Not Run1949
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast1950
H-26 Upper Structure Does Not Swing to Right and Left1951
H-27 Upper Structure Swings Only to Right or Left1952
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions1953
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction1954
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)1955
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)1956
H-32 Shock is Large When Upper Structure Stops Swing Operation1957
H-33 There is Large Unusual Noise When It Stops Swing Operation1958
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)1959
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)1960
Troubleshooting of Engine (S-Mode)1961
Information Shown in Troubleshooting Table (S-Mode)1961
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position1962
S-2 Engine Cranks but No Exhaust Smoke Comes Out1963
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)1964
S-4 Engine Startability is Unsatisfactory1966
S-5 Engine Does Not Pick Up Smoothly1968
S-6 Engine Stops During Operation1970
S-7 Engine Runs Rough or is Not Stable1972
S-8 Engine Lacks Power1973
S-9 KDPF Becomes Clogged in a Short Time1975
S-10 Engine Oil Consumption is Excessive1977
S-11 Oil Becomes Dirty Quickly1978
S-12 Fuel Consumption is Excessive1979
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant1980
S-14 Oil Pressure Drops1981
S-15 Fuel Mixes Into Engine Oil1983
S-16 Water Mixes Into Engine Oil (Milky)1984
S-17 Coolant Temperature Increases Too High (Overheating)1985
S-18 Unusual Noise is Heard1986
S-19 Vibration is Excessive1987
S-20 Air Cannot be Bled from Fuel Circuit1988
S-21 Active Regeneration is Done Frequently1989
S-22 Active Regeneration Continues Long1991
S-23 White Smoke is Exhausted During Active Regeneration1992
S-24 DEF Consumption is Excessive1993
S-25 There is Unusual Smell (Irritating Odor)1995
S-26 Foreign Materials Enter DEF (DEF Increases)1996
50 Disassembly and Assembly1997
Table of Contents1998
Precautions Before Work2003
Related Information on Disassembly and Assembly2004
How to Read This Manual2004
Coating Materials List2005
Special Tool List2010
Sketches of Special Tools2022
Engine and Cooling System2028
Remove and Install Supply Pump Assembly2028
Remove Supply Pump Assembly2028
Install Supply Pump Assembly2031
Remove and Install Injector Assembly2035
How to Remove Injector Assembly2035
How to Install Injector Assembly2040
Remove and Install Cylinder Head Assembly2048
How to Remove Cylinder Head Assembly2049
How to Install Cylinder Head Assembly2058
Remove and Install EGR Valve Assembly2074
Remove EGR Valve Assembly2074
Install EGR Valve Assembly2075
Remove and Install EGR Cooler Assembly2078
How to Remove EGR Cooler Assembly2078
How to Install EGR Cooler Assembly2081
Remove and Install Starter Assembly2086
Remove Starting Motor Assembly2086
Install Starting Motor Assembly2088
Remove and Install Alternator Belt2090
Remove Alternator Belt2090
Install Alternator Belt2092
Remove and Install Radiator Assembly2094
How to Remove Radiator Assembly2094
How to Install Radiator Assembly2096
Remove and Install Hydraulic Oil Cooler Assembly2098
How to Remove Hydraulic Oil Cooler Assembly2098
How to Install Hydraulic Oil Cooler Assembly2101
Remove and Install Aftercooler Assembly2104
Remove Aftercooler Assembly2104
Install Aftercooler Assembly2105
Remove and Install Engine and Main Pump Assembly2107
Remove Engine and Main Pump Assembly2108
Install Engine and Main Pump Assembly2116
Remove and Install Engine Front Oil Seal2127
How to Remove Engine Front Oil Seal2127
How to Install Engine Front Oil Seal2130
Remove and Install Engine Rear Oil Seal2134
How to Remove Engine Rear Oil Seal2134
How to Install Engine Rear Oil Seal2135
Remove and Install Fuel Cooler Assembly2138
Remove Fuel Cooler Assembly2138
Install Fuel Cooler Assembly2139
Remove and Install Engine Hood Assembly2140
How to Remove Engine Hood Assembly2140
How to Install Engine Hood Assembly2142
Remove and Install Fuel Tank Assembly2148
Remove Fuel Tank Assembly2148
Install Fuel Tank Assembly2152
Remove and Install DEF Tank Assembly2158
How to Remove DEF Tank Assembly2158
How to Install DEF Tank Assembly2163
Remove and Install DEF Tank Sensor Flange Assembly2169
How to Remove DEF Tank Sensor Flange Assembly2169
How to Install DEF Tank Sensor Flange Assembly2174
Remove and Install DEF Tank Sensor2180
Remove DEF Tank Sensor2180
Install DEF Tank Sensor2180
Remove and Install DEF Tank Strainer2187
Remove DEF Tank Strainer2187
Install DEF Tank Strainer2187
Remove and Install DEF Tank Filler Port Filter2188
Remove DEF Tank Filler Port Filter2188
Install DEF Tank Filler Port Filter2190
Remove and Install KDPF Assembly2193
How to Remove KDPF Assembly2193
How to Install KDPF Assembly2195
Disassemble and Assemble KDPF Assembly2197
Disassemble KDPF Assembly2198
Assemble KDPF Assembly2201
Remove and Install SCR Assembly2206
How to Remove SCR Assembly2206
How to Install SCR Assembly2208
Remove and Install KDPF and SCR Assembly2210
How to Remove KDPF and SCR Assembly2210
Install KDPF and SCR Assembly2216
Remove and Install KDPF and SCR Assembly Bracket2222
Remove KDPF and SCR Assembly Bracket2222
Install KDPF and SCR Assembly Bracket2229
Remove and Install Bellows Pipe Assembly2237
How to Remove Bellows Pipe Assembly2237
How to Install Bellows Pipe Assembly2239
Remove and Install KCCV Assembly2243
Remove KCCV Assembly2243
Install KCCV Assembly2245
Remove and Install DEF Mixing Tube2250
Remove DEF Mixing Tube2250
Install DEF Mixing Tube2255
Remove and Install DEF Injector2260
Remove DEF Injector2260
Install DEF Injector2262
Remove and Install DEF Pump2264
Remove DEF Pump2264
Install DEF Pump2266
Remove and Install DEF Hose2269
Remove DEF Hose2269
Install DEF Hose2277
Remove and Install Air Cleaner Assembly2283
Remove Air Cleaner Assembly2283
Install Air Cleaner Assembly2284
Remove and Install Air Conditioner Compressor Assembly2286
Remove Air Conditioner Compressor Assembly2286
How to Install Air Conditioner Compressor Assembly2288
Remove and Install Air Conditioner Condenser Assembly2291
How to Remove Air Conditioner Condenser Assembly2291
How to Install Air Conditioner Condenser Assembly2292
Power Train2293
Remove and Install Travel Motor and Final Drive Assembly2293
Remove Travel Motor and Final Drive Assembly2293
Install Travel Motor and Final Drive Assembly2294
Disassemble and Assemble Final Drive Assembly2295
Disassemble Final Drive Assembly2295
Assemble Final Drive Assembly2299
Remove and Install Swing Motor and Swing Machinery Assembly2308
Remove Swing Motor and Swing Machinery Assembly2308
Install Swing Motor and Swing Machinery Assembly2310
Disassemble and Assemble Swing Machinery Assembly2314
Disassemble Swing Machinery Assembly2314
Assemble Swing Machinery Assembly2318
Remove and Install Swing Circle Assembly2325
Remove Swing Circle Assembly2325
Install Swing Circle Assembly2325
Undercarriage and Frame2327
Separate and Connect Track Assembly2327
Separate Track Assembly2327
Install Track Assembly2329
Remove and Install Sprocket2332
Remove Sprocket2332
Install Sprocket2332
Remove and Install Idler and Idler Cushion Assembly2334
Remove Idler and Idler Cushion Assembly2334
Install Idler and Idler Cushion Assembly2335
Disassemble and Assemble Idler Assembly2336
Disassemble Idler Assembly2336
Assemble Idler Assembly2337
Disassemble and Assemble Idler Cushion Assembly2341
Disassemble Idler Cushion Assembly2342
Assemble Idler Cushion Assembly2343
Disassemble and Assemble Track Roller Assembly2344
Disassemble Track Roller Assembly2345
Assemble Track Roller Assembly2346
Disassemble and Assemble Carrier Roller Assembly2348
Disassemble Carrier Roller Assembly2348
Assemble Carrier Roller Assembly2349
Remove and Install Revolving Frame Assembly2352
Remove Revolving Frame Assembly2352
Install Revolving Frame Assembly2354
Remove and Install Counterweight Assembly2356
Remove Counterweight Assembly2356
Install Counterweight Assembly2359
Hydraulic System2363
Remove and Install Center Swivel Joint Assembly2363
Remove Center Swivel Joint Assembly2363
Install Center Swivel Joint Assembly2365
Disassemble and Assemble Center Swivel Joint Assembly2368
Disassemble Center Swivel Joint Assembly2369
Assemble Center Swivel Joint Assembly2370
Remove and Install Hydraulic Tank Assembly2371
Remove Hydraulic Tank Assembly2371
How to Install Hydraulic Tank Assembly2374
Remove and Install Main Pump Assembly2378
Remove Main Pump Assembly2378
Install Main Pump Assembly2381
Remove and Install Control Valve Assembly2385
How to Remove Control Valve Assembly2385
How to Install Control Valve Assembly2390
Disassemble and Assemble Control Valve Assembly2397
Replace Pressure Compensation Valve Seal Ring2397
Assemble Control Valve Assembly2399
Disassemble and Assemble Work Equipment PPC Valve Assembly2403
Disassemble Work Equipment PPC Valve Assembly2403
How to Assemble Work Equipment PPC Valve Assembly2403
Disassemble and Assemble Travel PPC Valve Assembly2405
Disassemble Travel PPC Valve Assembly2405
How to Assemble Travel PPC Valve Assembly2406
Work Equipment2408
Remove and Install Work Equipment Assembly2408
Remove Work Equipment Assembly2408
Install Work Equipment Assembly2412
Remove and Install Boom Anti-drop Valve Assembly2418
Remove Boom Anti-drop Valve Assembly2418
Install Boom Anti-drop Valve Assembly2420
Remove and Install Arm Anti-Drop Valve Assembly2421
Remove Arm Anti-Drop Valve Assembly2421
Install Arm Anti-Drop Valve Assembly2423
Disassemble and Assemble Anti-Drop Valve Assembly2424
Disassemble Anti-Drop Valve Assembly2424
Assemble Anti-Drop Valve Assembly2424
Disassemble and Assemble Work Equipment Cylinder Assembly2425
How to Disassemble Work Equipment Cylinder Assembly2425
How to Assemble Work Equipment Cylinder Assembly2428
CAB Related Parts2434
Remove and Install Operator Cab Assembly2434
How to Remove Operator Cab Assembly2434
Install Operator CAB Assembly2440
Remove and Install Operator Cab Glass (Adhered Glass)2447
Remove Operator CAB Glass (Adhered Glass)2449
Install Operator CAB Glass (Adhered Glass)2449
Remove and Install Front Window Assembly2459
Remove Front Window Assembly2459
Install Front Window Assembly2462
Remove and Install Floor Frame Assembly2468
How to Remove Floor Frame Assembly2468
How to Install Floor Frame Assembly2475
Remove and Install Air Conditioner Unit Assembly2482
Remove Air Conditioner Unit Assembly2482
Install Air Conditioner Unit Assembly2488
Remove and Install Operator Seat2495
Remove Operator’s Seat2495
Install Operator’s Seat2497
How to Remove and Install Seat Belt2500
How to Remove Seat Belt2500
How to Install Seatbelt2501
Remove and Install Work Equipment Control Lever Assembly2502
How to Remove Work Equipment Control Lever Assembly2502
How to Install Work Equipment Control Lever Assembly2508
Remove and Install Front Wiper Assembly2517
Remove Front Wiper Assembly2517
Install Front Wiper Assembly2522
Electrical System2531
Remove and Install Engine Controller Assembly2531
Remove Engine Controller Assembly2531
Install Engine Controller Assembly2532
Remove and Install Pump Controller Assembly2534
Remove Pump Controller Assembly2534
Install Pump Controller Assembly2538
Remove and Install KomVision Controller Assembly2543
Remove KomVision Controller Assembly2543
Install KomVision Controller Assembly2544
Remove and Install Machine Monitor Assembly2546
Remove Machine Monitor Assembly2546
Install Machine Monitor Assembly2549
Remove and Install Pump Swash Plate Sensor2553
Remove Pump Swash Plate Sensor2553
Install Pump Swash Plate Sensor2554
Remove and Install Mass Air Flow and Temperature Sensor2555
How to Remove Mass Air Flow and Temperature Sensor2555
How to Install Mass Air Flow and Temperature Sensor2555
Remove and Install KCCV Crankcase Pressure Sensor2557
How to Remove KCCV Crankcase Pressure Sensor2557
How to Install KCCV Crankcase Pressure Sensor2558
Remove and Install SCR Temperature Sensor2560
Remove SCR Temperature Sensor2560
Install SCR Temperature Sensor2562
Remove and Install KomVision Camera2565
Remove KomVision Camera2565
Install KomVision Camera2568
Remove and Install KOMTRAX Terminal Assembly2571
Remove KOMTRAX Terminal Assembly2571
Install KOMTRAX Terminal Assembly2574
60 Maintenance Standard2577
Table of Contents2578
Engine and Cooling System2579
Maintenance Standard for Engine Mount2579
Maintenance Standard for Cooling System2580
Power Train2581
Maintenance Standard for Swing Circle2581
Maintenance Standard for Swing Machinery2582
Maintenance Standard for Final Drive2584
Maintenance Standard for Sprocket2586
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing2587
Undercarriage and Frame2588
Maintenance Standard for Track Frame and Idler Cushion2588
Maintenance Standard for Idler2590
Maintenance Standard for Track Roller2592
Maintenance Standard for Carrier Roller2594
Maintenance Standard for Track Shoes2595
Maintenance Standard for Triple Shoes2598
Hydraulic System2599
Maintenance Standard for Hydraulic Tank2599
Maintenance Standard for Main Pump2600
Maintenance Standard for LS-EPC Valve2601
Maintenance Standard for PC-EPC Valve2602
Maintenance Standard for Swing Motor2603
Maintenance Standard for Travel Motor2606
Maintenance Standard for Control Valve2609
Maintenance Standard for Boom Anti-Drop Valve2619
Maintenance Standard for Arm Anti-Drop Valve2621
Maintenance Standard for Work Equipment and Swing PPC Valve2623
Maintenance Standard for Travel PPC Valve2626
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)2629
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve2630
Maintenance Standard for 2nd-Line Attachment PPC Valve2632
Maintenance Standard for Solenoid Valve2634
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure)2635
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)2636
Maintenance Standard for Center Swivel Joint2637
Work Equipment2638
Maintenance Standard for Work Equipment Linkage2638
Dimensions of Arm2643
Dimensions of Bucket2645
Maintenance Standard for Boom Cylinder2647
Maintenance Standard for Arm Cylinder2648
Maintenance Standard for Bucket Cylinder2649
80 Appendix2651
Table of Contents2652
Precautions Before Work2654
Air Conditioner System2655
Precautions for Refrigerant2655
Air Conditioner Component2656
Specifications of Air Conditioner2658
Structure and Function of Refrigeration Cycle2659
Outline of Refrigeration Cycle2660
Component Parts of Air Conditioner System2662
Air Conditioner Unit2662
Configuration Diagram of Air Conditioner Unit2662
Function of Air Conditioner Unit2664
Component Parts of Air Conditioner Unit2666
Function of Evaporator as Air Conditioner Unit Component2667
Function of Heater Core as Air Conditioner Unit Component2667
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2667
Function of Servo Motor as Air Conditioner Unit Component2667
Structure of Expansion Valve as Air Conditioner Unit Component2668
Function of Expansion Valve as Air Conditioner Unit Component2668
Operate Expansion Valve as Air Conditioner Unit Component2668
Function of Dual Pressure Switch2669
Air Conditioner Controller2670
Structure of Air Conditioner Controller2670
Compressor2671
Structure of Compressor2671
Specifications of Compressor2671
Function of Compressor2671
Condenser2672
Structure of Condenser2672
Specifications of Condenser2672
Function of Condenser2672
Air Conditioner Related Sensors2674
Structure of Sunlight Sensor2674
Function of Sunlight Sensor2674
Structure of Outside Temperature Sensor2674
Function of Outside Air Temperature Sensor2674
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2676
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2678
System Diagram of Air Conditioner2680
Input and Output Signals of Air Conditioner Controller2681
Function of Air Conditioner Controller2682
Locations of Air Conditioner Parts and Layout of Connectors2683
Examine Air Leakage (Duct)2687
How to Examine Air Leakage (Duct)2687
Examine Air Conditioner with Self-Diagnosis Function2689
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2690
Examine Vent (Mode) Changeover2691
How to Examine Vent (Mode) Changeover2691
Examine Fresh/Recirc Air Changeover2693
How to Examine Fresh/Recirc Air Changeover2693
Examine Sunlight Sensor2694
How to Examine Sunlight Sensor2694
Examine Refrigerant (Dual) Pressure Switch2695
How to Examine Refrigerant (Dual) Pressure Switch2695
Examine Relay2696
How to Examine Relay2696
Air Conditioner Troubleshooting Chart 12697
Air Conditioner Troubleshooting Chart 22698
Information Shown in Troubleshooting Table2701
Failure Code [879AKA]2702
Failure Code [879AKB]2703
Failure Code [879BKA]2704
Failure Code [879BKB]2706
Failure Code [879CKA]2708
Failure Code [879CKB]2709
Failure Code [879DKZ]2710
Failure Code [879EMC]2712
Failure Code [879FMC]2713
Failure Code [879GKX]2714
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2716
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2718
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2721
A-4 Troubleshooting for Fresh/Recirc Air Changeover2723
Troubleshooting by Gauge Pressure2725
Connect Service Tool2728
How to Connect Service Tool2728
Precautions for Disconnection and Connection of Air Conditioner Piping2730
Handle Compressor Oil2732
Replace Desiccant2734
90 Circuit Diagrams2737
Table of Contents2738
Hydraulic Circuit Diagram2739
Symbols Used in Hydraulic Circuit Diagram2739
Hydraulic Circuit Diagram (1/2)2743
Hydraulic Circuit Diagram (2/2)2745
Electrical Circuit Diagram2747
Symbols Used in Electric Circuit Diagram2747
Electrical Circuit Diagram (1/7)2751
Electrical Circuit Diagram (2/7)2753
Electrical Circuit Diagram (3/7)2755
Electrical Circuit Diagram (4/7)2757
Electrical Circuit Diagram (5/7)2759
Electrical Circuit Diagram (6/7)2761
Electrical Circuit Diagram (7/7)2763
Index2765

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24