Komatsu Hydraulic Excavator PC290LC-11 Shop Manual SEN06759-11 – PDF

Description

Komatsu Hydraulic Excavator PC290LC-11 Shop Manual SEN06759-11 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Excavator PC290LC-11 Shop Manual SEN06759-11 – PDF DOWNLOAD

Language : English
Pages :2754
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Excavator PC290LC-11 Shop Manual SEN06759-11 – PDF DOWNLOAD

SERIAL NUMBERS 35151 and up

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC290LC-11 Shop Manual SEN06759-11 – PDF DOWNLOAD

SERIAL NUMBERS 35151 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 for Disposing of Waste Materials 37
Procedures for Exhaust Gas Regulations 38
Precautions for DEF 39
General Character and Precautions for Handling 39
Precautions for Adding 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
How to Disconnect and Connect Deutsch Connector 64
How to Disconnect and Connect Slide Lock Type Connector 65
How to Disconnect and Connect Connector with Lock to Pull 67
How to Disconnect and Connect Connector with Lock to Push 68
How to 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 Specifications 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 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
Attachment Bypass Solenoid Valve 396
Pilot Circuit Accumulator 398
Attachment Circuit Accumulator 399
Swing System 400
Layout Drawing of Swing System 400
Swing Control System Diagram 404
Function of Swing Control System 404
Component Parts of Swing System 408
Swing Motor 408
Swing Machinery 419
Swing Circle 420
Travel System 422
Layout Drawing of Travel System 422
System Diagram of Travel Control System 426
Function of Travel Control System 426
Component Parts of Travel System 428
Travel Motor 428
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: PC290LC-11 459
Standard Value Table for Machine 463
Standard Value Table for Machine: PC290LC-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
How to Examine Valve Clearance 515
How to 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
Bleed Air from Coolant Circuit of DEF Tank 580
How to Bleed Air from Coolant Circuit of DEF Tank 580
Clean DEF Pump 582
How to Clean DEF Pump 582
Power Train 588
Examine Swing Circle Bearing Clearance 588
How to Examine Swing Circle Bearing Clearance 588
Undercarriage and Frame 589
Examine and Adjust Track Tension 589
How to Examine Track Tension 589
How to Adjust Track Tension 589
Hydraulic System 591
Release Remained Pressure in Hydraulic Circuit 591
How to Release Remained Pressure in Hydraulic System 591
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 592
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 593
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 599
Examine Oil Pressure of Control Circuit 602
How to Examine Oil Pressure in Control Circuit 602
Examine and adjust oil pressure in pump PC control circuit 604
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 604
Examine PC-EPC Valve Outlet Pressure 605
How to Adjust Oil Pressure in Pump PC Control Circuit 606
Examine and Adjust Oil Pressure in Pump LS Control Circuit 608
How to Examine LS Differential Pressure with Machine Monitor 608
How to Examine LS Differential Pressure by Testing Tool 609
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 612
How to Examine LS-EPC Valve Outlet Pressure 613
How to Adjust LS Valve 614
Examine Outlet Pressure of Solenoid Valve 615
How to Examine Outlet Pressure of Solenoid Valve 615
Operating Condition of Solenoid Valve 616
Examine PPC Valve Outlet Pressure 619
How to Examine Outlet Pressure in PPC Valve 619
Adjust Play of Work Equipment and Swing PPC Valves 621
How to Adjust Play of Work Equipment and Swing PPC Valves 621
Examine Pump Swash Plate Sensor 622
How to Examine pump swash plate sensor 622
Examine Parts Which Cause Hydraulic Drift of Work Equipment 623
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 623
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 623
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 624
Examine Oil Leakage 625
How to Examine Oil Leakage from Boom Cylinder 625
How to Examine Oil Leakage from Arm Cylinder 625
How to Examine Oil Leakage from Bucket Cylinder 626
How to Examine Oil Leakage from Swing Motor 627
How to Examine Oil Leakage from Travel Motor 627
Bleed Air from Hydraulic System 628
How to Bleed Air from Hydraulic System 630
CAB Related Parts 632
Examine CAB Tipping Stopper 632
How to Examine Cab Tipping Stopper 632
How to Adjust Mirrors 633
Procedure to Adjust Machine Left Front Mirror (A) 633
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 634
Procedure to Adjust Machine Right Front Mirror (B) 635
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 636
Procedure to Adjust Machine Right Side Mirror (C) 637
Electrical System 639
Set and Operate Machine Monitor 639
Operator Mode 642
Function to Show Technician Identification Status Screen 643
Function to Show Operator Identification Input Screen 643
Examine Function by LCD (Liquid Crystal Display) 644
Examine Function of Service Meter 644
Usage Limitation and Maintenance Password Change Function 644
Service Mode 647
How to Operate Service Mode 647
How to See Pre-defined Monitoring Information 649
How to Examine Self-Define Monitor Information 656
Abnormality Record Menu 666
How to See Maintenance Record 671
Maintenance Mode Setting 672
How to Set Phone Number Entry 676
Default Menu 677
Diagnostic Tests Menu 689
Adjustment Menu 698
No-Injection Cranking Operation 715
KOMTRAX Settings Menu 716
How to Show Service Message 719
How to Start Up KOMTRAX Terminal 721
Adjust Rearview Camera Angle 726
How to Adjust Rearview Camera Angle 726
Adjust KomVision Camera Angle 729
How to Adjust KomVision Camera Angle 730
Adjust KomVision Related Function 734
Setting of KomVision (Main Setting) 734
Setting of KomVision (Camera Setting) 736
Setting of KomVision (Camera Calibration) 738
KomVision screen – Check 12 m visibility 751
Set Region of Bluetooth(R) Compatible Radio 754
How to Set Region of Bluetooth(R) Compatible Radio 754
Handle Voltage Circuit of Engine Controller 756
Handle Battery Isolator Switch 757
Examine Diodes 758
How to Examine Diodes by Digital Tester 758
How to Examine Diodes by Analog Tester 758
Pm Clinic 759
Pm Clinic Service 759
Pm Clinic Check Sheet 760
40 Troubleshooting 773
Table of Contents 774
Precautions Before Work 784
Related Information to Troubleshooting 785
General Troubleshooting Points 785
Troubleshooting Points for Urea SCR System 786
Sequence of Events in Troubleshooting 800
Checks Before Troubleshooting 802
Inspection Procedure Before Troubleshooting 804
Walk-Around Check 804
Test in Accordance with Testing Procedure 806
Examine Fuel Level and Type 806
Examine for Impure Ingredient in Fuel 806
Examine Fuel Prefilter 807
Examine Water Separator, Drain Water and Sediment 807
How to Replace Fuel Prefilter Cartridge 808
Examine Fuel Main Filter 809
Examine Engine Oil Level (Oil Quantity in Oil Pan) 811
Examine Coolant Level (Reservoir Tank) 812
Examine Air Cleaner Clogging 812
Clean Outer Element 813
Replace Element 815
Examine Hydraulic Oil Level 816
Examine Hydraulic Oil Strainer 817
Examine Hydraulic Oil Filter 818
Examine Oil Level in Swing Machinery Case 819
Examine Oil Level in Damper Case 820
Examine Oil Level in Final Drive Case 820
Bleed Air from Fuel System 821
Bleed Air from Hydraulic System 821
How to Examine Electric Equipment 821
Preparation for Troubleshooting of Electrical System 829
Procedure for Troubleshooting 839
Symptom and Troubleshooting Numbers 842
Information Shown in Troubleshooting Table 846
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 848
Connector List and Layout 851
Connector Contact Connection Table 864
T-Branch Box and T-Branch Adapter Table 904
Fuse Location Table 910
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 913
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 917
Failure Code Table 919
Troubleshooting by Failure Code (Display of Code) 937
Failure Code [6AZ0ZG] 937
Failure Code [879AKA] 939
Failure Code [879AKB] 940
Failure Code [879BKA] 941
Failure Code [879BKB] 943
Failure Code [879CKA] 945
Failure Code [879CKB] 946
Failure Code [879DKZ] 947
Failure Code [879EMC] 949
Failure Code [879FMC] 950
Failure Code [879GKX] 951
Failure Code [989L00] 953
Failure Code [989M00] 954
Failure Code [989N00] 955
Failure Code [A1U0N3] 956
Failure Code [A1U0N4] 958
Failure Code [A900FR] 960
Failure Code [A900N6] 961
Failure Code [A900NY] 962
Failure Code [AA10NX] 963
Failure Code [AB00KE] 965
Failure Code [AQ10N3] 968
Failure Code [AS00N3] 970
Failure Code [AS00R2] 972
Failure Code [AS00R3] 973
Failure Code [AS00R4] 974
Failure Code [AS00R5] 975
Failure Code [AS00R6] 976
Failure Code [AS00ZK] 977
Failure Code [AS10KM] 978
Failure Code [AS10NR] 979
Failure Code [AS10NT] 980
Failure Code [B@BAZG] 981
Failure Code [B@BAZK] 982
Failure Code [B@BCNS] 984
Failure Code [B@BCQA] 985
Failure Code [B@BCZK] 987
Failure Code [B@HANS] 989
Failure Code [CA115] 990
Failure Code [CA122] 991
Failure Code [CA123] 993
Failure Code [CA131] 995
Failure Code [CA132] 997
Failure Code [CA144] 999
Failure Code [CA145]1001
Failure Code [CA153]1003
Failure Code [CA154]1006
Failure Code [CA187]1008
Failure Code [CA221]1010
Failure Code [CA222]1012
Failure Code [CA227]1014
Failure Code [CA234]1015
Failure Code [CA238]1016
Failure Code [CA239]1018
Failure Code [CA249]1020
Failure Code [CA256]1022
Failure Code [CA271]1024
Failure Code [CA272]1026
Failure Code [CA322]1028
Failure Code [CA323]1030
Failure Code [CA324]1032
Failure Code [CA325]1034
Failure Code [CA331]1036
Failure Code [CA332]1038
Failure Code [CA343]1040
Failure Code [CA351]1041
Failure Code [CA352]1042
Failure Code [CA356]1045
Failure Code [CA357]1047
Failure Code [CA386]1049
Failure Code [CA428]1050
Failure Code [CA429]1052
Failure Code [CA435]1054
Failure Code [CA441]1056
Failure Code [CA442]1059
Failure Code [CA449]1060
Failure Code [CA451]1061
Failure Code [CA452]1063
Failure Code [CA488]1065
Failure Code [CA515]1066
Failure Code [CA516]1068
Failure Code [CA553]1070
Failure Code [CA555]1071
Failure Code [CA556]1072
Failure Code [CA559]1073
Failure Code [CA595]1076
Failure Code [CA687]1077
Failure Code [CA689]1079
Failure Code [CA691]1082
Failure Code [CA692]1084
Failure Code [CA697]1086
Failure Code [CA698]1087
Failure Code [CA731]1088
Failure Code [CA778]1090
Failure Code [CA1117]1095
Failure Code [CA1664]1096
Failure Code [CA1669]1098
Failure Code [CA1673]1099
Failure Code [CA1677]1100
Failure Code [CA1678]1101
Failure Code [CA1682]1102
Failure Code [CA1683]1104
Failure Code [CA1684]1106
Failure Code [CA1686]1108
Failure Code [CA1691]1109
Failure Code [CA1694]1112
Failure Code [CA1695]1115
Failure Code [CA1696]1116
Failure Code [CA1712]1118
Failure Code [CA1713]1121
Failure Code [CA1714]1123
Failure Code [CA1715]1124
Failure Code [CA1776]1125
Failure Code [CA1777]1128
Failure Code [CA1843]1131
Failure Code [CA1844]1133
Failure Code [CA1879]1136
Failure Code [CA1881]1138
Failure Code [CA1883]1140
Failure Code [CA1885]1143
Failure Code [CA1887]1145
Failure Code [CA1921]1147
Failure Code [CA1922]1150
Failure Code [CA1942]1155
Failure Code [CA1993]1156
Failure Code [CA2185]1159
Failure Code [CA2186]1160
Failure Code [CA2249]1162
Failure Code [CA2271]1163
Failure Code [CA2272]1166
Failure Code [CA2288]1169
Failure Code [CA2311]1170
Failure Code [CA2349]1171
Failure Code [CA2353]1174
Failure Code [CA2357]1176
Failure Code [CA2381]1177
Failure Code [CA2382]1180
Failure Code [CA2383]1183
Failure Code [CA2386]1186
Failure Code [CA2387]1188
Troubleshooting Flowchart1192
Failure Code [CA2555]1193
Failure Code [CA2556]1196
Failure Code [CA2637]1199
Failure Code [CA2639]1201
Failure Code [CA2771]1204
Failure Code [CA2777]1210
Failure Code [CA2976]1213
Failure Code [CA3133]1215
Failure Code [CA3134]1218
Failure Code [CA3135]1220
Failure Code [CA3142]1223
Failure Code [CA3143]1224
Failure Code [CA3144]1225
Failure Code [CA3146]1227
Failure Code [CA3147]1228
Failure Code [CA3148]1229
Failure Code [CA3151]1231
Failure Code [CA3165]1237
Failure Code [CA3229]1239
Failure Code [CA3231]1241
Failure Code [CA3232]1243
Failure Code [CA3235]1247
Failure Code [CA3239]1249
Failure Code [CA3241]1252
Failure Code [CA3242]1255
Failure Code [CA3251]1258
Failure Code [CA3253]1260
Failure Code [CA3254]1263
Failure Code [CA3255]1266
Failure Code [CA3256]1270
Failure Code [CA3311]1272
Failure Code [CA3312]1274
Failure Code [CA3313]1277
Failure Code [CA3314]1278
Failure Code [CA3315]1279
Failure Code [CA3316]1281
Failure Code [CA3317]1282
Failure Code [CA3318]1283
Failure Code [CA3319]1285
Failure Code [CA3321]1286
Failure Code [CA3322]1288
Failure Code [CA3419]1290
Failure Code [CA3421]1292
Failure Code [CA3497]1294
Failure Code [CA3498]1295
Failure Code [CA3543]1296
Failure Code [CA3545]1303
Failure Code [CA3547]1305
Failure Code [CA3558]1306
Failure Code [CA3559]1308
Failure Code [CA3562]1310
Failure Code [CA3563]1312
Failure Code [CA3567]1315
Failure Code [CA3568]1318
Failure Code [CA3571]1322
Failure Code [CA3572]1324
Failure Code [CA3574]1326
Failure Code [CA3575]1328
Failure Code [CA3577]1329
Failure Code [CA3578]1331
Failure Code [CA3582]1333
Failure Code [CA3583]1339
Failure Code [CA3596]1341
Failure Code [CA3649]1343
Failure Code [CA3681]1345
Failure Code [CA3682]1350
Failure Code [CA3713]1355
Failure Code [CA3717]1358
Failure Code [CA3718]1359
Failure Code [CA3725]1360
Failure Code [CA3741]1363
Failure Code [CA3748]1364
Failure Code [CA3751]1366
Failure Code [CA3755]1368
Failure Code [CA3866]1370
Failure Code [CA3867]1374
Failure Code [CA3868]1377
Failure Code [CA3899]1381
Failure Code [CA3911]1383
Failure Code [CA3912]1387
Failure Code [CA3932]1389
Failure Code [CA3933]1391
Failure Code [CA3934]1393
Failure Code [CA3935]1396
Failure Code [CA3936]1398
Failure Code [CA4151]1400
Failure Code [CA4152]1404
Failure Code [CA4155]1408
Failure Code [CA4156]1411
Failure Code [CA4157]1414
Failure Code [CA4158]1416
Failure Code [CA4159]1417
Failure Code [CA4161]1418
Failure Code [CA4162]1421
Failure Code [CA4163]1424
Failure Code [CA4164]1425
Failure Code [CA4165]1427
Failure Code [CA4166]1429
Failure Code [CA4168]1430
Failure Code [CA4169]1433
Failure Code [CA4171]1435
Failure Code [CA4249]1438
Failure Code [CA4251]1440
Failure Code [CA4259]1442
Failure Code [CA4261]1445
Failure Code [CA4277]1448
Failure Code [CA4281]1452
Failure Code [CA4459]1455
Failure Code [CA4461]1458
Failure Code [CA4658]1461
Failure Code [CA4731]1465
Failure Code [CA4732]1466
Failure Code [CA4739]1467
Failure Code [CA4768]1468
Failure Code [CA4769]1470
Failure Code [CA4842]1473
Failure Code [CA4952]1477
Failure Code [CA5115]1479
Failure Code [CA5179]1482
Failure Code [CA5181]1484
Failure Code [CA5383]1486
Failure Code [D110KB]1488
Failure Code [D19JKZ]1490
Failure Code [D811MC]1493
Failure Code [D862KA]1494
Failure Code [D8ALKA]1495
Failure Code [D8ALKB]1497
Failure Code [D8AQKR]1499
Failure Code [DA20MC]1501
Failure Code [DA22KK]1502
Failure Code [DA25KP]1505
Failure Code [DA26KP]1508
Failure Code [DA29KQ]1510
Failure Code [DA2LKA]1512
Failure Code [DA2LKB]1514
Failure Code [DA2QKR]1516
Failure Code [DA2RKR]1519
Failure Code [DAF0KM]1520
Failure Code [DAF0MB]1521
Failure Code [DAF0MC]1522
Failure Code [DAF8KB]1523
Failure Code [DAF9KQ]1527
Failure Code [DAFGMC]1528
Failure Code [DAFLKA]1529
Failure Code [DAFLKB]1531
Failure Code [DAFQKR]1533
Failure Code [DAZ9KQ]1534
Failure Code [DAZQKR]1535
Failure Code [DB2QKR]1540
Failure Code [DB2RKR]1545
Failure Code [DBP0KM]1550
Failure Code [DBP0KT]1551
Failure Code [DBP5KB]1552
Failure Code [DBP5KY]1555
Failure Code [DBPQKR]1557
Failure Code [DDNRKA]1562
Failure Code [DDNRKY]1564
Failure Code [DDNS00]1566
Failure Code [DGH2KA]1568
Failure Code [DGH2KB]1570
Failure Code [DHA4KA]1572
Failure Code [DHAAMA]1574
Failure Code [DHACMA]1576
Failure Code [DHPAMA]1578
Failure Code [DHPBMA]1581
Failure Code [DHS3MA]1584
Failure Code [DHS4MA]1587
Failure Code [DHS8MA]1590
Failure Code [DHS9MA]1593
Failure Code [DHSAMA]1596
Failure Code [DHSBMA]1599
Failure Code [DHSCMA]1602
Failure Code [DHSDMA]1605
Failure Code [DHSFMA]1608
Failure Code [DHSGMA]1611
Failure Code [DHSHMA]1614
Failure Code [DHSJMA]1617
Failure Code [DHZAMA]1620
Failure Code [DHZCL8]1624
Failure Code [DKR0MA]1625
Failure Code [DKR1MA]1628
Failure Code [DKULKA]1631
Failure Code [DKULKB]1633
Failure Code [DKULKY]1635
Failure Code [DR10KA]1637
Failure Code [DR12KA]1640
Failure Code [DR20KA]1642
Failure Code [DR21KX]1644
Failure Code [DR30KA]1646
Failure Code [DR31KX]1648
Failure Code [DR40KA]1650
Failure Code [DUMBKA]1652
Failure Code [DUMBKB]1654
Failure Code [DV20KB]1656
Failure Code [DW43KA]1658
Failure Code [DW43KB]1660
Failure Code [DW43KY]1662
Failure Code [DW45KA]1664
Failure Code [DW45KB]1667
Failure Code [DW45KY]1670
Failure Code [DW4CKY]1672
Failure Code [DW91KA]1674
Failure Code [DW91KB]1676
Failure Code [DW91KY]1678
Failure Code [DWA2KA]1680
Failure Code [DWA2KB]1682
Failure Code [DWA2KY]1684
Failure Code [DWK0KA]1686
Failure Code [DWK0KB]1688
Failure Code [DWK0KY]1690
Failure Code [DWK2KA]1692
Failure Code [DWK2KB]1694
Failure Code [DWK2KY]1696
Failure Code [DWK8KA]1698
Failure Code [DWK8KB]1700
Failure Code [DWK8KY]1702
Failure Code [DXA8KA]1704
Failure Code [DXA8KB]1706
Failure Code [DXA9KA]1708
Failure Code [DXA9KB]1710
Failure Code [DXE0KA]1712
Failure Code [DXE0KB]1714
Failure Code [DXE4KA]1716
Failure Code [DXE4KB]1718
Failure Code [DXE4KY]1720
Failure Code [DXE5KA]1722
Failure Code [DXE5KB]1724
Failure Code [DXE6KA]1726
Failure Code [DXE6KB]1728
Failure Code [DXE7KA]1730
Failure Code [DXE7KB]1732
Failure Code [DXE7KY]1734
Failure Code [DXE8KA]1736
Failure Code [DXE8KB]1738
Failure Code [DXE8KY]1740
Failure Code [DXE9KA]1742
Failure Code [DXE9KB]1744
Failure Code [DXE9KY]1746
Failure Code [DXEAKA]1748
Failure Code [DXEAKB]1750
Failure Code [DXEAKY]1752
Failure Code [DXEKKA]1754
Failure Code [DXEKKB]1756
Failure Code [DXEKKY]1758
Failure Code [DXELKA]1760
Failure Code [DXELKB]1762
Failure Code [DXELKY]1764
Failure Code [DY20KA]1766
Failure Code [DY20MA]1768
Failure Code [DY2CKB]1770
Failure Code [DY2DKB]1773
Failure Code [DY2EKB]1775
Troubleshooting of Electrical System (E-Mode)1777
E-1 Engine Does Not Start (Engine Does Not Crank)1777
E-2 Manual Preheating System Does Not Operate1783
E-3 Automatic Preheating System Does Not Operate1786
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On1788
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1790
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow1793
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow1794
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation1795
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs1796
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs1797
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation1798
E-12 Fuel Level Monitor Comes On in Red While Engine Runs1799
E-13 Water Separator Monitor Comes On in Red While Engine Runs1800
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1801
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation1802
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation1803
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum1804
E-18 Display of Fuel Gauge is Different from Actual Fuel Level1806
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum1807
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature1808
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum1809
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature1811
E-23 Some Areas of Machine Monitor Screen are Not Shown1812
E-24 Function Switch Does Not Operate1813
E-25 Automatic Warm-up System Does Not Work (in Cold Weather)1814
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out1815
E-27 Auto-Decelerator is Not Operated or Canceled with Lever1816
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown1817
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed1818
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change1819
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change1820
E-32 Alarm Buzzer Cannot be Canceled1822
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position1823
E-34 Service Mode Cannot be Selected1824
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move1825
E-36 All Work Equipment, Swing and Travel Do Not Lock1828
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing1830
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate1833
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show1835
E-40 One-Touch Power Maximizing Function is Not Cancelled1838
E-41 Alarm Does Not Sound During Travel1839
E-42 Alarm Does Not Stop When Machine Stops1841
E-43 Horn Does Not Sound1842
E-44 Horn Does Not Stop1845
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out1847
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate1848
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated1850
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function1851
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function1852
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function1853
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function1854
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function1855
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function1856
E-54 “Swing” is Not Shown Correctly with Monitoring Function1857
E-55 “Travel” is Not Shown Correctly with Monitoring Function1858
E-56 Service is Not Shown Correctly with Monitoring Function1859
E-57 Attachment Hydraulic Circuit Cannot be Changed1861
E-58 KOMTRAX System Does Not Operate Correctly1862
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1863
Information Shown in Troubleshooting Table (H-Mode)1863
System Chart of Hydraulic and Mechanical Systems1864
Failure Mode and Cause Table1866
H-1 All Work Equipment, Swing and Travel Do Not Work1875
H-2 All Work Equipment, Swing and Travel Lack Speed and Power1876
H-3 Fine Control Performance or Response is Unsatisfactory1879
H-4 Unusual Noise is Heard from Around Hydraulic Pump1880
H-5 Engine Speed Drops Largely or Engine Stops1881
H-6 Speed or Power of Boom is Low1883
H-7 Arm Speed or Power is Low1887
H-8 Bucket Speed or Power is Low1892
H-9 Work Equipment Does Not Move in Single Operation1895
H-10 Hydraulic Drift of Boom is Large1896
H-11 Hydraulic Drift of Arm is Large1898
H-12 Hydraulic Drift of Bucket is Large1900
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves1901
H-14 Time Lag of Work Equipment is Large1902
H-15 One-Touch Power Maximizing Function Does Not Operate1903
H-16 Attachment Circuit Cannot be Changed1904
H-17 Oil Flow in Attachment Circuit Cannot be Changed1905
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower1906
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely1907
H-20 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low1908
H-21 Machine Does Not Travel Straight1909
H-22 Machine is Not Steered Correctly or Steering Power is Low1911
H-23 Travel Speed is Low1914
H-24 One of Tracks Does Not Run1916
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast1917
H-26 Upper Structure Does Not Swing to Right and Left1918
H-27 Upper Structure Swings Only to Right or Left1919
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions1920
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction1921
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)1922
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)1923
H-32 Shock is Large When Upper Structure Stops Swing Operation1924
H-33 There is Large Unusual Noise When It Stops Swing Operation1925
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)1926
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)1927
Troubleshooting of Engine (S-Mode)1928
Information Shown in Troubleshooting Table (S-Mode)1928
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position1929
S-2 Engine Cranks but No Exhaust Smoke Comes Out1930
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)1931
S-4 Engine Startability is Unsatisfactory1933
S-5 Engine Does Not Pick Up Smoothly1935
S-6 Engine Stops During Operation1937
S-7 Engine Runs Rough or is Not Stable1939
S-8 Engine Lacks Power1940
S-9 KDPF Becomes Clogged in a Short Time1942
S-10 Engine Oil Consumption is Excessive1944
S-11 Oil Becomes Dirty Quickly1945
S-12 Fuel Consumption is Excessive1946
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant1947
S-14 Oil Pressure Drops1948
S-15 Fuel Mixes Into Engine Oil1950
S-16 Water Mixes Into Engine Oil (Milky)1951
S-17 Coolant Temperature Increases Too High (Overheating)1952
S-18 Unusual Noise is Heard1953
S-19 Vibration is Excessive1954
S-20 Air Cannot be Bled from Fuel Circuit1955
S-21 Active Regeneration is Done Frequently1956
S-22 Active Regeneration Continues Long1958
S-23 White Smoke is Exhausted During Active Regeneration1959
S-24 DEF Consumption is Excessive1960
S-25 There is Unusual Smell (Irritating Odor)1962
S-26 Foreign Materials Enter DEF (DEF Increases)1963
50 Disassembly and Assembly1965
Table of Contents1966
Precautions Before Work1971
Related Information on Disassembly and Assembly1972
How to Read This Manual1972
Coating Materials List1973
Special Tool List1978
Sketches of Special Tools1990
Engine and Cooling System1995
Remove and Install Supply Pump Assembly1995
How to Remove Supply Pump Assembly1995
How to Install Supply Pump Assembly1998
Remove and Install Injector Assembly2002
How to Remove Injector Assembly2002
How to Install Injector Assembly2007
Remove and Install Cylinder Head Assembly2015
How to Remove Cylinder Head Assembly2015
How to Install Cylinder Head Assembly2024
Remove and Install EGR Valve Assembly2040
How to Remove EGR Valve Assembly2040
How to Install EGR Valve Assembly2041
Remove and Install EGR Cooler Assembly2044
How to Remove EGR Cooler Assembly2044
How to Install EGR Cooler Assembly2047
Remove and Install Starter Assembly2052
How to Remove Starting Motor Assembly2052
How to Install Starting Motor Assembly2054
Remove and Install Alternator Belt2056
How to Remove Alternator Belt2056
How to Install Alternator Belt2058
Remove and Install Radiator Assembly2060
How to Remove Radiator Assembly2060
How to Install Radiator Assembly2062
Remove and Install Hydraulic Oil Cooler Assembly2064
How to Remove Hydraulic Oil Cooler Assembly2064
How to Install Hydraulic Oil Cooler Assembly2067
Remove and Install Aftercooler Assembly2070
How to Remove Aftercooler Assembly2070
How to Install Aftercooler Assembly2071
Remove and Install Engine and Main Pump Assembly2073
How to Remove Engine and Main Pump Assembly2074
How to Install Engine and Main Pump Assembly2082
Remove and Install Engine Front Oil Seal2093
How to Remove Engine Front Oil Seal2093
How to Install Engine Front Oil Seal2096
Remove and Install Engine Rear Oil Seal2100
How to Remove Engine Rear Oil Seal2100
How to Install Engine Rear Oil Seal2101
Remove and Install Fuel Cooler Assembly2104
How to Remove Fuel Cooler Assembly2104
How to Install Fuel Cooler Assembly2105
Remove and Install Engine Hood Assembly2106
How to Remove Engine Hood Assembly2106
How to Install Engine Hood Assembly2108
Remove and Install Fuel Tank Assembly2114
How to Remove Fuel Tank Assembly2114
How to Install Fuel Tank Assembly2118
Remove and Install DEF Tank Assembly2124
How to Remove DEF Tank Assembly2124
How to Install DEF Tank Assembly2129
Remove and Install DEF Tank Sensor Flange Assembly2135
How to Remove DEF Tank Sensor Flange Assembly2135
How to Install DEF Tank Sensor Flange Assembly2140
Remove and Install DEF Tank Sensor2146
How to Remove DEF Tank Sensor2146
How to Install DEF Tank Sensor2146
Remove and Install DEF Tank Strainer2153
How to Remove DEF Tank Strainer2153
How to Install DEF Tank Strainer2153
Remove and Install DEF Tank Filler Port Filter2154
How to Remove DEF Tank Filler Port Filter2154
How to Install DEF Tank Filler Port Filter2156
Remove and Install KDPF Assembly2159
How to Remove KDPF Assembly2159
How to Install KDPF Assembly2161
Disassemble and Assemble KDPF Assembly2163
How to Disassemble KDPF Assembly2164
How to Assemble KDPF Assembly2167
Remove and Install SCR Assembly2172
How to Remove SCR Assembly2172
How to Install SCR Assembly2174
Remove and Install KDPF and SCR Assembly2176
How to Remove KDPF and SCR Assembly2176
How to Install KDPF and SCR Assembly2182
Remove and Install KDPF and SCR Assembly Bracket2188
How to Remove KDPF and SCR Assembly Bracket2188
How to Install KDPF and SCR Assembly Bracket2195
Remove and Install Bellows Pipe Assembly2203
How to Remove Bellows Pipe Assembly2203
How to Install Bellows Pipe Assembly2205
Remove and Install KCCV Assembly2209
How to Remove KCCV Assembly2209
How to Install KCCV Assembly2211
Remove and Install DEF Mixing Tube2216
How to Remove DEF Mixing Tube2216
How to Install DEF Mixing Tube2221
Remove and Install DEF Injector2226
How to Remove DEF Injector2226
How to Install DEF Injector2228
Remove and Install DEF Pump2230
How to Remove DEF Pump2230
How to Install DEF Pump2232
Remove and Install DEF Hose2235
How to Remove DEF Hose2235
How to Install DEF Hose2243
Remove and Install Air Cleaner Assembly2249
How to Remove Air Cleaner Assembly2249
How to Install Air Cleaner Assembly2250
Remove and Install Air Conditioner Compressor Assembly2252
How to Remove Air Conditioner Compressor Assembly2252
How to Install Air Conditioner Compressor Assembly2254
Remove and Install Air Conditioner Condenser Assembly2257
How to Remove Air Conditioner Condenser Assembly2257
How to Install Air Conditioner Condenser Assembly2258
Power Train2259
Remove and Install Travel Motor and Final Drive Assembly2259
How to Remove Travel Motor and Final Drive Assembly2259
How to Install Travel Motor and Final Drive Assembly2260
Disassemble and Assemble Final Drive Assembly2261
How to Disassemble Final Drive Assembly2261
How to Assemble Final Drive Assembly2265
Remove and Install Swing Motor and Swing Machinery Assembly2274
How to Remove Swing Motor and Swing Machinery Assembly2274
How to Install Swing Motor and Swing Machinery Assembly2276
Disassemble and Assemble Swing Machinery Assembly2280
How to Disassemble Swing Machinery Assembly2280
How to Assemble Swing Machinery Assembly2284
Remove and Install Swing Circle Assembly2291
How to Remove Swing Circle Assembly2291
How to Install Swing Circle Assembly2291
Undercarriage and Frame2293
Separate and Connect Track Assembly2293
How to Separate Track Assembly2293
How to Install Track Assembly2295
Remove and Install Sprocket2298
How to Remove Sprocket2298
How to Install Sprocket2298
Remove and Install Idler and Idler Cushion Assembly2300
How to Remove Idler and Idler Cushion Assembly2300
How to Install Idler and Idler Cushion Assembly2301
Disassemble and Assemble Idler Assembly2302
How to Disassemble Idler Assembly2302
How to Assemble Idler Assembly2303
Disassemble and Assemble Idler Cushion Assembly2307
How to Disassemble Idler Cushion Assembly2308
How to Assemble Idler Cushion Assembly2309
Disassemble and Assemble Track Roller Assembly2310
How to Disassemble Track Roller Assembly2311
How to Assemble Track Roller Assembly2312
Disassemble and Assemble Carrier Roller Assembly2314
How to Disassemble Carrier Roller Assembly2314
How to Assemble Carrier Roller Assembly2315
Remove and Install Revolving Frame Assembly2318
How to Remove Revolving Frame Assembly2318
How to Install Revolving Frame Assembly2320
Remove and Install Counterweight Assembly2322
How to Remove Counterweight Assembly2322
How to Install Counterweight Assembly2325
Hydraulic System2329
Remove and Install Center Swivel Joint Assembly2329
How to Remove Center Swivel Joint Assembly2329
How to Install Center Swivel Joint Assembly2331
Disassemble and Assemble Center Swivel Joint Assembly2334
How to Disassemble Center Swivel Joint Assembly2335
How to Assemble Center Swivel Joint Assembly2336
Remove and Install Hydraulic Tank Assembly2337
How to Remove Hydraulic Tank Assembly2337
How to Install Hydraulic Tank Assembly2340
Remove and Install Main Pump Assembly2344
How to Remove Main Pump Assembly2344
How to Install Main Pump Assembly2347
Remove and Install Control Valve Assembly2351
How to Remove Control Valve Assembly2351
How to Install Control Valve Assembly2356
Disassemble and Assemble Control Valve Assembly2363
How to Replace Pressure Compensation Valve Seal Ring2363
How to Assemble Control Valve Assembly2365
Disassemble and Assemble Work Equipment PPC Valve Assembly2369
How to Disassemble Work Equipment PPC Valve Assembly2369
How to Assemble Work Equipment PPC Valve Assembly2369
Disassemble and Assemble Travel PPC Valve Assembly2371
How to Disassemble Travel PPC Valve Assembly2371
How to Assemble Travel PPC Valve Assembly2372
Work Equipment2374
Remove and Install Work Equipment Assembly2374
How to Remove Work Equipment Assembly2374
How to Install Work Equipment Assembly2378
Remove and Install Boom Anti-drop Valve Assembly2384
How to Remove Boom Anti-drop Valve Assembly2384
How to Install Boom Anti-drop Valve Assembly2386
Remove and Install Arm Anti-Drop Valve Assembly2387
How to Remove Arm Anti-Drop Valve Assembly2387
How to Install Arm Anti-Drop Valve Assembly2389
Disassemble and Assemble Anti-Drop Valve Assembly2390
How to Disassemble Anti-Drop Valve Assembly2390
How to Assemble Anti-Drop Valve Assembly2390
Disassemble and Assemble Work Equipment Cylinder Assembly2391
How to Disassemble Work Equipment Cylinder Assembly2391
How to Assemble Work Equipment Cylinder Assembly2394
CAB Related Parts2400
Remove and Install Operator Cab Assembly2400
How to Remove Operator Cab Assembly2400
How to Install Operator Cab Assembly2406
Remove and Install Operator Cab Glass (Adhered Glass)2413
How to Remove Operator Cab Glass (Adhered Glass)2415
How to Install Operator Cab Glass (Adhered Glass)2415
Remove and Install Front Window Assembly2425
How to Remove Front Window Assembly2425
How to Install Front Window Assembly2428
Remove and Install Floor Frame Assembly2434
How to Remove Floor Frame Assembly2434
How to Install Floor Frame Assembly2441
Remove and Install Air Conditioner Unit Assembly2448
How to Remove Air Conditioner Unit Assembly2448
How to Install Air Conditioner Unit Assembly2454
Remove and Install Operator Seat2461
How to Remove Operator Seat2461
How to Install Operator Seat2463
How to Remove and Install Seat Belt2466
How to Remove Seat Belt2466
How to Install Seatbelt2467
Remove and Install Work Equipment Control Lever Assembly2468
How to Remove Work Equipment Control Lever Assembly2468
How to Install Work Equipment Control Lever Assembly2474
Remove and Install Front Wiper Assembly2483
How to Remove Front Wiper Assembly2483
How to Install Front Wiper Assembly2488
Electrical System2497
Remove and Install Engine Controller Assembly2497
How to Remove Engine Controller Assembly2497
How to Install Engine Controller Assembly2499
Remove and Install Pump Controller Assembly2500
How to Remove Pump Controller Assembly2500
How to Install Pump Controller Assembly2504
Remove and Install KomVision Controller Assembly2509
How to Remove KomVision Controller Assembly2509
How to Install KomVision Controller Assembly2510
Remove and Install Machine Monitor Assembly2512
How to Remove Machine Monitor Assembly2512
How to Install Machine Monitor Assembly2515
Remove and Install Pump Swash Plate Sensor2519
How to Remove Pump Swash Plate Sensor2519
How to Install Pump Swash Plate Sensor2520
Remove and Install Mass Air Flow and Temperature Sensor2521
How to Remove Mass Air Flow and Temperature Sensor2521
How to Install Mass Air Flow and Temperature Sensor2521
Remove and Install KCCV Crankcase Pressure Sensor2523
How to Remove KCCV Crankcase Pressure Sensor2523
How to Install KCCV Crankcase Pressure Sensor2524
Remove and Install SCR Temperature Sensor2526
How to Remove SCR Temperature Sensor2526
How to Install SCR Temperature Sensor2528
Remove and Install KomVision Camera2531
How to Remove KomVision Camera2531
How to Install KomVision Camera2534
Remove and Install KOMTRAX Terminal Assembly2537
How to Remove KOMTRAX Terminal Assembly2537
How to Install KOMTRAX Terminal Assembly2540
60 Maintenance Standard2543
Table of Contents2544
Engine and Cooling System2545
Maintenance Standard for Engine Mount2545
Maintenance Standard for Cooling System2546
Power Train2547
Maintenance Standard for Swing Circle2547
Maintenance Standard for Swing Machinery2548
Maintenance Standard for Final Drive2550
Maintenance Standard for Sprocket2552
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing2553
Undercarriage and Frame2554
Maintenance Standard for Track Frame and Idler Cushion2554
Maintenance Standard for Idler2556
Maintenance Standard for Track Roller2558
Maintenance Standard for Carrier Roller2560
Maintenance Standard for Track Shoes2561
Maintenance Standard for Triple Shoes2564
Hydraulic System2565
Maintenance Standard for Hydraulic Tank2565
Maintenance Standard for Main Pump2566
Maintenance Standard for LS-EPC Valve2567
Maintenance Standard for PC-EPC Valve2568
Maintenance Standard for Swing Motor2569
Maintenance Standard for Travel Motor2572
Maintenance Standard for Control Valve2575
Maintenance Standard for Boom Anti-Drop Valve2585
Maintenance Standard for Arm Anti-Drop Valve2587
Maintenance Standard for Work Equipment and Swing PPC Valve2589
Maintenance Standard for Travel PPC Valve2592
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)2595
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve2596
Maintenance Standard for 2nd-Line Attachment PPC Valve2598
Maintenance Standard for Solenoid Valve2600
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure)2601
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)2602
Maintenance Standard for Center Swivel Joint2603
Work Equipment2604
Maintenance Standard for Work Equipment Linkage2604
Dimensions of Arm2609
Dimensions of Bucket2611
Maintenance Standard for Boom Cylinder2613
Maintenance Standard for Arm Cylinder2614
Maintenance Standard for Bucket Cylinder2615
80 Appendix2617
Table of Contents2618
Precautions Before Work2620
Air Conditioner System2621
Precautions for Refrigerant2621
Air Conditioner Component2622
Specifications of Air Conditioner2624
Structure and Function of Refrigeration Cycle2625
Outline of Refrigeration Cycle2626
Component Parts of Air Conditioner System2628
Air Conditioner Unit2628
Configuration Diagram of Air Conditioner Unit2628
Function of Air Conditioner Unit2630
Component Parts of Air Conditioner Unit2632
Function of Evaporator as Air Conditioner Unit Component2633
Function of Heater Core as Air Conditioner Unit Component2633
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2633
Function of Servo Motor as Air Conditioner Unit Component2633
Structure of Expansion Valve as Air Conditioner Unit Component2634
Function of Expansion Valve as Air Conditioner Unit Component2634
Operate Expansion Valve as Air Conditioner Unit Component2634
Function of Dual Pressure Switch2635
Air Conditioner Controller2636
Structure of Air Conditioner Controller2636
Compressor2637
Structure of Compressor2637
Specifications of Compressor2637
Function of Compressor2637
Condenser2638
Structure of Condenser2638
Specifications of Condenser2638
Function of Condenser2638
Air Conditioner Related Sensors2640
Structure of Sunlight Sensor2640
Function of Sunlight Sensor2640
Structure of Outside Temperature Sensor2640
Function of Outside Air Temperature Sensor2640
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2642
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2644
System Diagram of Air Conditioner2646
Input and Output Signals of Air Conditioner Controller2647
Function of Air Conditioner Controller2648
Locations of Air Conditioner Parts and Layout of Connectors2649
Examine Air Leakage (Duct)2653
How to Examine Air Leakage (Duct)2653
Examine Air Conditioner with Self-Diagnosis Function2655
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2656
Examine Vent (Mode) Changeover2657
How to Examine Vent (Mode) Changeover2657
Examine Fresh/Recirc Air Changeover2659
How to Examine Fresh/Recirc Air Changeover2659
Examine Sunlight Sensor2660
How to Examine Sunlight Sensor2660
Examine Refrigerant (Dual) Pressure Switch2661
How to Examine Refrigerant (Dual) Pressure Switch2661
Examine Relay2662
How to Examine Relay2662
Air Conditioner Troubleshooting Chart 12663
Air Conditioner Troubleshooting Chart 22664
Information Shown in Troubleshooting Table2667
Failure Code [879AKA]2668
Failure Code [879AKB]2669
Failure Code [879BKA]2670
Failure Code [879BKB]2672
Failure Code [879CKA]2674
Failure Code [879CKB]2675
Failure Code [879DKZ]2676
Failure Code [879EMC]2678
Failure Code [879FMC]2679
Failure Code [879GKX]2680
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2682
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2684
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2687
A-4 Troubleshooting for Fresh/Recirc Air Changeover2689
Troubleshooting by Gauge Pressure2691
Connect Service Tool2694
How to Connect Service Tool2694
Precautions for Disconnection and Connection of Air Conditioner Piping2696
Handle Compressor Oil2698
How to Replace Desiccant2700
90 Circuit Diagrams2703
Table of Contents2704
Hydraulic Circuit Diagram2705
Symbols Used in Hydraulic Circuit Diagram2705
Hydraulic Circuit Diagram (1/2)2709
Hydraulic Circuit Diagram (2/2)2711
Electrical Circuit Diagram2713
Symbols Used in Electric Circuit Diagram2713
Electrical Circuit Diagram (1/9)2717
Electrical Circuit Diagram (2/9)2719
Electrical Circuit Diagram (3/9)2721
Electrical Circuit Diagram (4/9)2723
Electrical Circuit Diagram (5/9)2725
Electrical Circuit Diagram (6/9)2727
Electrical Circuit Diagram (7/9)2729
Electrical Circuit Diagram (8/9)2731
Electrical Circuit Diagram (9/9)2733
Index2735

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24