Komatsu HYDRAULIC EXCAVATOR PC360LC-1 1 Shop Manual SEN06699-09 – PDF

Description

Komatsu HYDRAULIC EXCAVATOR PC360LC-1 1 Shop Manual SEN06699-09 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HYDRAULIC EXCAVATOR PC360LC-1 1 Shop Manual SEN06699-09 – PDF DOWNLOAD

Language : English
Pages :2766
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC360LC-1 1 Shop Manual SEN06699-09 – PDF DOWNLOAD

SERIAL NUMBERS 90001 and up

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC360LC-1 1 Shop Manual SEN06699-09 – PDF DOWNLOAD

SERIAL NUMBERS 90001 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 20
Foreword, Safety, Basic Information 23
How to Read the Shop Manual 23
Safety Notice for Operation 25
Precautions to Prevent Fire 33
Procedures If Fire Occurs 35
Precautions for Disposing of Waste Materials 36
Procedures for Exhaust Gas Regulations 37
Precautions for DEF 38
General Character and Precautions for Handling 38
Precautions for Adding 38
Precautions for Storage 38
Precautions for Fire Hazard and Leakage 38
Other Precautions 38
Store DEF 39
Precautions When You Handle Hydraulic Equipment 40
Precautions When You Disconnect and Connect Pipings 43
Precautions When You Handle Electrical Equipment 50
Precautions When You Handle Fuel System Equipment 52
Precautions When You Handle Intake System Equipment 53
Practical Use of KOMTRAX 54
Disconnect and Connect Push-Pull Type Coupler 55
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 55
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 57
Precautions for Disconnection and Connection of Connectors 59
How to Disconnect and Connect Deutsch Connector 63
How to Disconnect and Connect Slide Lock Type Connector 64
How to Disconnect and Connect Connector with Lock to Pull 66
How to Disconnect and Connect Connector with Lock to Push 67
How to Disconnect and Connect Connector with Housing to Rotate 69
How to Read the Codes for Electric Cable 70
Explanation of Terms for Maintenance Standard 74
Standard Tightening Torque Table 77
Conversion Table 84
01 Specifications 89
Table of Contents 90
Specifications 91
Specification Drawing 91
Specification Drawing: PC360LC-11 91
Working Range Drawings 93
Working Range: PC360LC-11 93
Specifications 94
Specifications: PC360LC-11 94
Weight Table 97
Weight Table: PC360LC-11 97
Table of Fuel, Coolant, and Lubricants 99
10 Structure and Function 101
Table of Contents 102
Urea SCR System 105
Layout Drawing of Urea SCR System 105
Urea SCR System Diagram 109
Function of Urea SCR System 110
Function of DEF System 110
Inducement Strategy 112
Component Parts of Urea SCR System 126
DEF Mixing Tube 126
SCR Assembly 126
DEF Tank 129
DEF Pump 131
DEF Injector 132
DEF Hose 133
DEF Tank Heating Valve 134
Boot-up System 135
Layout Drawing of Boot-up System 135
System Operating Lamp System 137
System Diagram of System Operating Lamp System 137
Function of Operation Lamp System 137
Battery Isolator 139
Function of Battery Isolator 139
Engine System 140
Layout Drawing of Engine System 140
Specifications of Engine System 141
Function of Engine System 141
Engine Control System 142
System Diagram of Engine Control 142
Function of Engine Control System 143
Auto-Deceleration System 146
System Diagram of Auto-Deceleration System 146
Function of Auto-Deceleration System 146
Operation of Auto-Deceleration System 147
Engine Automatic Warm-up System 148
System Diagram of Engine Automatic Warm-up System 148
Function of Engine Automatic Warm-up System 149
Overheat Prevention System 150
Overheat Prevention System Diagram 150
Function of Overheat Prevention System 151
Turbocharger Protection System 152
System Diagram of Turbocharger Protection System 152
Function of Turbocharger Protection System 153
Automatic Idle Stop System 154
System Diagram of Automatic Idle Stop System 154
Function of Automatic Idle Stop System 154
Component Parts of Engine System 157
VGT 157
EGR System 160
EGR Valve 162
EGR Cooler 164
KCCV System 165
KCCV Ventilator 167
KDPF 168
Cooling System 173
Layout Drawing of Cooling System 173
Specifications of Cooling System 174
Control System 175
Layout Drawing of Control System 175
Machine Monitor System 178
System Diagram of Machine Monitor System 178
Function of Machine Monitor System 178
KomVision System 180
Layout Drawing of KomVision System 180
System Diagram of KomVision System 182
Function of KomVision System 182
KOMTRAX System 184
System Diagram of KOMTRAX System 184
Function of KOMTRAX System 184
Component Parts of Control System 185
Machine Monitor 185
KomVision Controller 198
KomVision Camera 202
KOMTRAX Terminal 203
Pump Controller 206
Resistor for PC-EPC Valve 210
CAN Terminating Resistor 210
Engine Controller 212
Fuel Control Dial 218
Hydraulic System 220
Layout Drawing of Hydraulic System 220
CLSS 223
Structure of CLSS 223
Operation of Unload Valve and LS Pressure 225
Pump Swash Plate Angle (Oil Flow) Control 226
Pressure Compensation Control 242
Engine and Pump Combined Control System 246
Engine and Pump Combined Control System Diagram 246
Function of Engine and Pump Combined Control System 247
Pump and Valve Control System 252
Pump and Valve Control System Diagram 252
Function of Pump and Valve Control System 253
Component Parts of Hydraulic System 255
Hydraulic Tank 255
Main Pump 258
Control Valve 284
Work Equipment System 344
Layout Drawing of Work Equipment System 344
Structure of Valve Control 350
One-Touch Power Maximizing System 352
System Diagram of One-Touch Power Maximizing System 352
Function of One-Touch Power Maximizing System 353
Machine Push-up System 354
Machine Push-up System Diagram 354
Function of Machine Push-up System 355
PPC Lock System 356
System Diagram of PPC Lock 356
Function of PPC Lock System 356
Work Equipment and Travel Automatic Lock System 357
System Diagram of Lock Lever Automatic Lock System 357
Function of Work Equipment and Travel Automatic Lock System 357
Operation of Lock Lever Automatic Lock System 358
Attachment Oil Flow Adjuster System 359
Attachment Oil Flow Adjuster System Diagram 359
Function of Attachment Oil Flow Adjuster System 360
Component Parts of Work Equipment System 361
Work Equipment and Swing PPC Valve 361
1st-Line Attachment PPC Valve (with EPC Valve) 367
2nd-Line Attachment PPC Valve 371
Solenoid Valve 373
Boom Anti-drop Valve 376
Arm Anti-Drop Valve 380
Attachment Circuit Selector Valve 385
Pilot Circuit Accumulator 387
Swing System 388
Layout Drawing of Swing System 388
Swing Control System Diagram 391
Function of Swing Control System 391
Component Parts of Swing System 395
Swing Motor 395
Swing Machinery 406
Swing Circle 408
Travel System 409
Layout Drawing of Travel System 409
System Diagram of Travel Control System 413
Function of Travel Control System 413
Component Parts of Travel System 415
Travel Motor 415
Final Drive 427
Travel PPC Valve 428
Center Swivel Joint 433
Undercarriage and Frame 435
Layout Drawing of Undercarriage 435
Specifications of Undercarriage 435
Work Equipment 437
Structure of Work Equipment 437
Function of Work Equipment 438
Work Equipment Clearance Adjustment Shim 439
Function of Work Equipment Clearance Adjustment Shim 439
Bucket Clearance Adjustment Shim 440
Function of Bucket Clearance Adjustment Shim 440
CAB Related Parts 441
ROPS CAB 441
Structure of ROPS CAB 441
Function of ROPS CAB 441
CAB Mount 442
Structure of CAB Mount 442
Function of CAB Mount 442
CAB Tipping Stopper 443
Structure of CAB Tipping Stopper 443
Function of CAB Tipping Stopper 443
20 Standard Value Table 445
Table of Contents 446
Standard Value Table for Engine 447
Standard Value Table for Engine: PC360LC-11 447
Standard Value Table for Machine 452
Standard Value Table for Machine: PC360LC-11 452
Machine Posture and Procedures to Measure Performance 467
Standard Value Table for Electricity 471
Standard Value Table for Electricity 471
30 Testing and Adjusting 481
Table of Contents 482
Precautions Before Work 485
Related Information on Testing and Adjusting 486
Tools for Testing and Adjusting 486
Sketch of Tools for Testing and Adjusting 493
Engine and Cooling System 495
Examine Engine Speed 495
How to Examine Engine Speed 495
Examine Boost Pressure 499
How to Examine Boost Pressure on Machine Monitor 499
How to Examine Boost Pressure by Testing Tool 500
Examine Exhaust Gas Color 501
How to Examine Exhaust Gas Color with the Handy Smoke Checker 501
How to Examine Exhaust Gas Color with Smoke Meter 502
Examine Mass Air Flow and Temperature Sensor 503
How to Examine Mass Air Flow and Temperature Sensor 503
Examine and Adjust Valve Clearance 505
How to Examine Valve Clearance 505
How to Adjust Valve Clearance 507
Examine Compression Pressure 508
How to Examine Compression Pressure 508
Examine Blowby Pressure 511
How to Examine Blowby Pressure 511
Examine Engine Oil Pressure 513
How to Examine Engine Oil Pressure 513
Examine EGR Valve and VGT Oil Pressure 515
How to Examine EGR Valve and VGT Oil Pressure 515
Examine Fuel Pressure 517
How to Examine Fuel Pressure 518
Examine Fuel Discharge, Return and Leakage 524
How to Examine Fuel Discharge, Return, and Leakage 525
Bleed Air from Fuel System 531
How to Bleed Air from Fuel System 531
Examine Fuel Circuit for Leakage 532
How to Examine Fuel System for Leakage 532
Handle Cylinder Cut-out Mode Operation 534
Handle No-Injection Cranking Operation 535
Examine and Adjust Air Conditioner Compressor Belt Tension 536
How to Examine Air Conditioner Compressor Belt Tension 536
How to Adjust Air Conditioner Compressor Belt Tension 536
How to Adjust Air Conditioner Compressor Belt 537
Examine Alternator Belt 538
How to Examine Alternator Belt 538
Examine Automatic Tensioner 539
How to Examine Automatic Tensioner 539
Write Correction for Ash in Soot Accumulation to Engine Controller 540
How to Write Correction for Ash in Soot Accumulation to Engine Controller 540
Examine SCR Related Functions 541
Examine DEF Pump Raised Pressure 544
Examine Injection Volume from DEF Injector 547
Examine DEF Line Heater Relay 1 550
Examine DEF Line Heater Relay 2 553
Examine DEF Pump Heater Relay 556
Examine DEF Tank Heater Valve 559
Examine SCR Denitration Efficiency 562
Clean DEF Tank 566
How to Clean DEF Tank 566
Clean DEF Pump 570
How to Clean DEF Pump 570
Power Train 576
Examine Swing Circle Bearing Clearance 576
How to Examine Swing Circle Bearing Clearance 576
Undercarriage and Frame 577
Examine and Adjust Track Tension 577
How to Examine Track Tension 577
How to Adjust Track Tension 577
Hydraulic System 579
Release Remained Pressure in Hydraulic Circuit 579
How to Release Remained Pressure from Hydraulic Tank 579
How to Release Remained Pressure in Hydraulic Cylinder Circuit 579
How to Release Remained Pressure from Swing Motor Circuit 583
How to Release Remained Pressure from Travel Motor Circuit 583
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 584
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 585
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 593
Examine Oil Pressure of Control Circuit 596
How to Examine Oil Pressure in Control Circuit 596
Examine and adjust oil pressure in pump PC control circuit 598
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 598
Examine PC-EPC Valve Outlet Pressure 599
How to Adjust Oil Pressure in Pump PC Control Circuit 600
Examine and Adjust Oil Pressure in Pump LS Control Circuit 601
How to Examine LS Differential Pressure with Machine Monitor 601
How to Examine LS Differential Pressure by Testing Tool 602
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 604
How to Examine LS-EPC Valve Outlet Pressure 604
How to Adjust LS Valve 605
Examine Outlet Pressure of Solenoid Valve 606
How to Examine Outlet Pressure of Solenoid Valve 606
Operating Condition of Solenoid Valve 607
Examine PPC Valve Outlet Pressure 609
How to Examine Outlet Pressure in PPC Valve 609
Adjust Play of Work Equipment and Swing PPC Valves 611
How to Adjust Play of Work Equipment and Swing PPC Valves 611
Examine Pump Swash Plate Sensor 612
How to Examine pump swash plate sensor 612
Examine Parts Which Cause Hydraulic Drift of Work Equipment 613
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 613
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 613
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 614
Examine Oil Leakage 615
How to Examine Oil Leakage from Boom Cylinder 615
How to Examine Oil Leakage from Arm Cylinder 615
How to Examine Oil Leakage from Bucket Cylinder 616
How to Examine Oil Leakage from Swing Motor 616
How to Examine Oil Leakage from Travel Motor 617
Bleed Air from Hydraulic System 618
How to Bleed Air from Hydraulic System 620
CAB Related Parts 623
Examine CAB Tipping Stopper 623
How to Examine Cab Tipping Stopper 623
How to Adjust Mirrors 624
Procedure to Adjust Machine Left Front Mirror (A) 624
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 625
Procedure to Adjust Machine Right Front Mirror (B) 626
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 627
Procedure to Adjust Machine Right Side Mirror (C) 628
Electrical System 630
Set and Operate Machine Monitor 630
Operator Mode 633
Function to Show Technician Identification Status Screen 634
Function to Show Operator Identification Input Screen 634
Examine Function by LCD (Liquid Crystal Display) 635
Examine Function of Service Meter 635
Usage Limitation and Maintenance Password Change Function 635
Service Mode 638
How to Operate Service Mode 638
How to See Pre-defined Monitoring Information 640
How to Examine Self-Define Monitor Information 647
Abnormality Record Menu 657
How to See Maintenance Record 662
Maintenance Mode Setting 663
How to Set Phone Number Entry 667
Default Menu 668
Diagnostic Tests Menu 676
Adjustment Menu 685
No-Injection Cranking Operation 702
KOMTRAX Settings Menu 703
How to Show Service Message 705
How to Start Up KOMTRAX Terminal 707
Adjust Rearview Camera Angle 712
How to Adjust Rearview Camera Angle 712
Adjust KomVision Camera Angle 715
How to Adjust KomVision Camera Angle 716
Adjust KomVision Related Function 720
Setting of KomVision (Main Setting) 720
Setting of KomVision (Camera Setting) 722
Setting of KomVision (Camera Calibration) 724
KomVision screen – Check 12 m visibility 737
Set Region of Bluetooth(R) Compatible Radio 740
How to Set Region of Bluetooth(R) Compatible Radio 740
Handle Voltage Circuit of Engine Controller 742
Handle Battery Isolator Switch 743
Examine Diodes 744
How to Examine Diodes by Digital Tester 744
How to Examine Diodes by Analog Tester 744
Pm Clinic 745
Pm Clinic Service 745
Pm Clinic Check Sheet 746
40 Troubleshooting 763
Table of Contents 764
Precautions Before Work 774
Related Information to Troubleshooting 775
General Troubleshooting Points 775
Troubleshooting Points for Urea SCR System 776
Sequence of Events in Troubleshooting 790
Checks Before Troubleshooting 792
Inspection Procedure Before Troubleshooting 794
Walk-Around Check 794
Test in Accordance with Testing Procedure 796
Examine Fuel Level and Type 796
Examine for Impure Ingredient in Fuel 796
Examine Fuel Prefilter 797
Examine Water Separator, Drain Water and Sediment 797
How to Replace Fuel Prefilter Cartridge 798
Examine Fuel Main Filter 799
Examine Engine Oil Level (Oil Quantity in Oil Pan) 801
Examine Coolant Level (Reservoir Tank) 802
Examine Air Cleaner Clogging 803
Clean Outer Element 803
Replace Element 805
Examine Hydraulic Oil Level 806
Examine Hydraulic Oil Strainer 807
Examine Hydraulic Oil Filter 808
Examine Oil Level in Swing Machinery Case 809
Examine Oil Level in Damper Case 809
Examine Oil Level in Final Drive Case 810
Bleed Air from Fuel System 810
Bleed Air from Hydraulic System 810
How to Examine Electric Equipment 811
Preparation for Troubleshooting of Electrical System 816
Procedure for Troubleshooting 826
Symptom and Troubleshooting Numbers 829
Information Shown in Troubleshooting Table 833
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 835
Connector List and Layout 838
Connector Contact Connection Table 851
T-Branch Box and T-Branch Adapter Table 891
Fuse Location Table 897
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 900
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 904
Failure Code Table 906
Troubleshooting by Failure Code (Display of Code) 923
Failure Code [6AZ0ZG] 923
Failure Code [879AKA] 925
Failure Code [879AKB] 926
Failure Code [879BKA] 927
Failure Code [879BKB] 929
Failure Code [879CKA] 931
Failure Code [879CKB] 932
Failure Code [879DKZ] 933
Failure Code [879EMC] 935
Failure Code [879FMC] 936
Failure Code [879GKX] 937
Failure Code [989L00] 939
Failure Code [989M00] 940
Failure Code [989N00] 941
Failure Code [A1U0N3] 942
Failure Code [A1U0N4] 944
Failure Code [A900FR] 946
Failure Code [A900N6] 947
Failure Code [A900NY] 948
Failure Code [AA10NX] 949
Failure Code [AB00KE] 951
Failure Code [AQ10N3] 954
Failure Code [AS00N3] 956
Failure Code [AS00R2] 958
Failure Code [AS00R3] 959
Failure Code [AS00R4] 960
Failure Code [AS00R5] 961
Failure Code [AS00R6] 962
Failure Code [AS00ZK] 963
Failure Code [AS10KM] 964
Failure Code [AS10NR] 965
Failure Code [AS10NT] 966
Failure Code [B@BAZG] 967
Failure Code [B@BAZK] 968
Failure Code [B@BCNS] 970
Failure Code [B@BCQA] 971
Failure Code [B@BCZK] 973
Failure Code [B@HANS] 975
Failure Code [CA115] 976
Failure Code [CA122] 977
Failure Code [CA123] 979
Failure Code [CA131] 981
Failure Code [CA132] 983
Failure Code [CA144] 985
Failure Code [CA145] 987
Failure Code [CA153] 989
Failure Code [CA154] 992
Failure Code [CA187] 995
Failure Code [CA221] 997
Failure Code [CA222] 999
Failure Code [CA227]1001
Failure Code [CA234]1002
Failure Code [CA238]1003
Failure Code [CA239]1005
Failure Code [CA249]1007
Failure Code [CA256]1009
Failure Code [CA271]1011
Failure Code [CA272]1013
Failure Code [CA281]1015
Failure Code [CA322]1016
Failure Code [CA323]1018
Failure Code [CA324]1020
Failure Code [CA325]1022
Failure Code [CA331]1024
Failure Code [CA332]1026
Failure Code [CA343]1028
Failure Code [CA351]1029
Failure Code [CA352]1030
Failure Code [CA356]1033
Failure Code [CA357]1035
Failure Code [CA386]1037
Failure Code [CA428]1038
Failure Code [CA429]1040
Failure Code [CA435]1042
Failure Code [CA441]1044
Failure Code [CA442]1047
Failure Code [CA449]1048
Failure Code [CA451]1052
Failure Code [CA452]1055
Failure Code [CA488]1057
Failure Code [CA515]1058
Failure Code [CA516]1060
Failure Code [CA553]1062
Failure Code [CA555]1063
Failure Code [CA556]1064
Failure Code [CA559]1065
Failure Code [CA595]1069
Failure Code [CA687]1070
Failure Code [CA689]1072
Failure Code [CA691]1077
Failure Code [CA692]1079
Failure Code [CA697]1081
Failure Code [CA698]1082
Failure Code [CA731]1083
Failure Code [CA778]1085
Failure Code [CA1117]1090
Failure Code [CA1664]1091
Failure Code [CA1669]1093
Failure Code [CA1673]1094
Failure Code [CA1677]1095
Failure Code [CA1678]1096
Failure Code [CA1682]1097
Failure Code [CA1683]1099
Failure Code [CA1684]1101
Failure Code [CA1686]1103
Failure Code [CA1691]1104
Failure Code [CA1694]1107
Failure Code [CA1695]1110
Failure Code [CA1696]1111
Failure Code [CA1712]1113
Failure Code [CA1713]1116
Failure Code [CA1714]1118
Failure Code [CA1715]1119
Failure Code [CA1776]1120
Failure Code [CA1777]1123
Failure Code [CA1843]1126
Failure Code [CA1844]1128
Failure Code [CA1879]1131
Failure Code [CA1881]1134
Failure Code [CA1883]1136
Failure Code [CA1885]1139
Failure Code [CA1887]1141
Failure Code [CA1921]1143
Failure Code [CA1922]1146
Failure Code [CA1942]1151
Failure Code [CA1993]1152
Failure Code [CA2185]1155
Failure Code [CA2186]1157
Failure Code [CA2249]1159
Failure Code [CA2265]1160
Failure Code [CA2266]1162
Failure Code [CA2271]1164
Failure Code [CA2272]1167
Failure Code [CA2288]1170
Failure Code [CA2311]1171
Failure Code [CA2349]1172
Failure Code [CA2353]1175
Failure Code [CA2357]1177
Failure Code [CA2381]1178
Failure Code [CA2382]1181
Failure Code [CA2383]1184
Failure Code [CA2386]1187
Failure Code [CA2387]1189
Troubleshooting Flowchart1193
Failure Code [CA2555]1194
Failure Code [CA2556]1197
Failure Code [CA2637]1200
Failure Code [CA2639]1202
Failure Code [CA2771]1205
Failure Code [CA2777]1211
Failure Code [CA2976]1214
Failure Code [CA3133]1216
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]1330
Failure Code [CA3578]1332
Failure Code [CA3582]1334
Failure Code [CA3583]1340
Failure Code [CA3596]1342
Failure Code [CA3649]1344
Failure Code [CA3681]1346
Failure Code [CA3682]1351
Failure Code [CA3713]1356
Failure Code [CA3717]1359
Failure Code [CA3718]1360
Failure Code [CA3725]1361
Failure Code [CA3741]1364
Failure Code [CA3748]1365
Failure Code [CA3751]1367
Failure Code [CA3755]1369
Failure Code [CA3866]1371
Failure Code [CA3867]1375
Failure Code [CA3868]1378
Failure Code [CA3899]1382
Failure Code [CA3911]1384
Failure Code [CA3912]1388
Failure Code [CA3932]1390
Failure Code [CA3933]1392
Failure Code [CA3934]1394
Failure Code [CA3935]1397
Failure Code [CA3936]1399
Failure Code [CA4151]1401
Failure Code [CA4152]1405
Failure Code [CA4155]1409
Failure Code [CA4156]1412
Failure Code [CA4157]1415
Failure Code [CA4158]1417
Failure Code [CA4159]1418
Failure Code [CA4161]1419
Failure Code [CA4162]1422
Failure Code [CA4163]1425
Failure Code [CA4164]1427
Failure Code [CA4165]1429
Failure Code [CA4166]1431
Failure Code [CA4168]1433
Failure Code [CA4169]1436
Failure Code [CA4171]1438
Failure Code [CA4249]1441
Failure Code [CA4251]1443
Failure Code [CA4259]1445
Failure Code [CA4261]1448
Failure Code [CA4277]1451
Failure Code [CA4281]1455
Failure Code [CA4459]1458
Failure Code [CA4461]1461
Failure Code [CA4658]1464
Failure Code [CA4731]1468
Failure Code [CA4732]1469
Failure Code [CA4739]1470
Failure Code [CA4768]1471
Failure Code [CA4769]1473
Failure Code [CA4842]1476
Failure Code [CA4952]1480
Failure Code [CA5115]1482
Failure Code [CA5179]1485
Failure Code [CA5181]1487
Failure Code [CA5383]1489
Failure Code [D110KB]1491
Failure Code [D19JKZ]1493
Failure Code [D811MC]1496
Failure Code [D862KA]1497
Failure Code [D8ALKA]1498
Failure Code [D8ALKB]1500
Failure Code [D8AQKR]1502
Failure Code [DA20MC]1504
Failure Code [DA22KK]1505
Failure Code [DA25KP]1508
Failure Code [DA29KQ]1511
Failure Code [DA2LKA]1513
Failure Code [DA2LKB]1515
Failure Code [DA2QKR]1517
Failure Code [DA2RKR]1520
Failure Code [DAF0KM]1521
Failure Code [DAF0MB]1522
Failure Code [DAF0MC]1523
Failure Code [DAF8KB]1524
Failure Code [DAF9KQ]1526
Failure Code [DAFGMC]1527
Failure Code [DAFLKA]1528
Failure Code [DAFLKB]1530
Failure Code [DAFQKR]1532
Failure Code [DAZ9KQ]1533
Failure Code [DAZQKR]1534
Failure Code [DB2QKR]1539
Failure Code [DB2RKR]1544
Failure Code [DBP0KM]1549
Failure Code [DBP0KT]1550
Failure Code [DBP5KB]1551
Failure Code [DBP5KY]1554
Failure Code [DBPQKR]1557
Failure Code [DDNRKA]1562
Failure Code [DDNRKY]1564
Failure Code [DDNS00]1566
Failure Code [DGH2KB]1568
Failure Code [DHA4KA]1570
Failure Code [DHAAMA]1572
Failure Code [DHACMA]1574
Failure Code [DHPAMA]1576
Failure Code [DHPBMA]1579
Failure Code [DHS3MA]1582
Failure Code [DHS4MA]1585
Failure Code [DHS8MA]1588
Failure Code [DHS9MA]1591
Failure Code [DHSAMA]1594
Failure Code [DHSBMA]1597
Failure Code [DHSCMA]1600
Failure Code [DHSDMA]1603
Failure Code [DHSFMA]1606
Failure Code [DHSGMA]1609
Failure Code [DHSHMA]1612
Failure Code [DHSJMA]1615
Failure Code [DKR0MA]1618
Failure Code [DKR1MA]1621
Failure Code [DKULKA]1624
Failure Code [DKULKB]1626
Failure Code [DKULKY]1628
Failure Code [DR10KA]1630
Failure Code [DR12KA]1633
Failure Code [DR20KA]1635
Failure Code [DR21KX]1637
Failure Code [DR30KA]1639
Failure Code [DR31KX]1641
Failure Code [DR40KA]1643
Failure Code [DUMBKA]1645
Failure Code [DUMBKB]1647
Failure Code [DV20KB]1649
Failure Code [DW43KA]1651
Failure Code [DW43KB]1653
Failure Code [DW43KY]1655
Failure Code [DW45KA]1657
Failure Code [DW45KB]1660
Failure Code [DW45KY]1663
Failure Code [DW4CKY]1665
Failure Code [DW91KA]1666
Failure Code [DW91KB]1668
Failure Code [DW91KY]1670
Failure Code [DWA2KA]1672
Failure Code [DWA2KB]1674
Failure Code [DWA2KY]1676
Failure Code [DWK0KA]1678
Failure Code [DWK0KB]1680
Failure Code [DWK0KY]1682
Failure Code [DWK2KA]1684
Failure Code [DWK2KB]1686
Failure Code [DWK2KY]1688
Failure Code [DWK8KA]1690
Failure Code [DWK8KB]1692
Failure Code [DWK8KY]1694
Failure Code [DXA8KA]1696
Failure Code [DXA8KB]1699
Failure Code [DXA9KA]1701
Failure Code [DXA9KB]1704
Failure Code [DXE0KA]1706
Failure Code [DXE0KB]1708
Failure Code [DXE4KA]1710
Failure Code [DXE4KB]1712
Failure Code [DXE4KY]1714
Failure Code [DXE5KA]1715
Failure Code [DXE5KB]1717
Failure Code [DXE6KA]1719
Failure Code [DXE6KB]1721
Failure Code [DXE7KA]1723
Failure Code [DXE7KB]1725
Failure Code [DXE7KY]1727
Failure Code [DXE8KA]1729
Failure Code [DXE8KB]1731
Failure Code [DXE8KY]1733
Failure Code [DXE9KA]1735
Failure Code [DXE9KB]1737
Failure Code [DXE9KY]1739
Failure Code [DXEAKA]1741
Failure Code [DXEAKB]1743
Failure Code [DXEAKY]1745
Failure Code [DY20KA]1747
Failure Code [DY20MA]1750
Failure Code [DY2CKB]1752
Failure Code [DY2DKB]1755
Failure Code [DY2EKB]1757
Troubleshooting of Electrical System (E-Mode)1759
E-1 Engine Does Not Start (Engine Does Not Crank)1759
E-2 Manual Preheating System Does Not Operate1765
E-3 Automatic Preheating System Does Not Operate1768
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On1770
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1772
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow1775
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow1776
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation1777
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs1778
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs1779
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation1780
E-12 Fuel Level Monitor Comes On in Red While Engine Runs1781
E-13 Water Separator Monitor Comes On in Red While Engine Runs1782
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1783
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation1784
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation1785
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum1786
E-18 Display of Fuel Gauge is Different from Actual Fuel Level1788
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum1789
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature1790
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum1791
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature1793
E-23 Some Areas of Machine Monitor Screen are Not Shown1794
E-24 Function Switch Does Not Operate1795
E-25 Automatic Warm-up System Does Not Work (in Cold Weather)1796
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out1797
E-27 Auto-Decelerator is Not Operated or Canceled with Lever1798
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown1799
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed1800
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change1801
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change1802
E-32 Alarm Buzzer Cannot be Canceled1804
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position1805
E-34 Service Mode Cannot be Selected1806
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move1807
E-36 All Work Equipment, Swing and Travel Do Not Lock1809
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing1810
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate1813
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show1815
E-40 One-Touch Power Maximizing Function is Not Cancelled1817
E-41 Alarm Does Not Sound During Travel1818
E-42 Alarm Does Not Stop When Machine Stops1820
E-43 Horn Does Not Sound1821
E-44 Horn Does Not Stop1825
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out1827
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate1828
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated1830
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function1831
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function1832
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function1833
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function1834
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function1835
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function1836
E-54 “Swing” is Not Shown Correctly with Monitoring Function1837
E-55 “Travel” is Not Shown Correctly with Monitoring Function1838
E-56 Service is Not Shown Correctly with Monitoring Function1839
E-57 Attachment Hydraulic Circuit Cannot be Changed1841
E-58 KOMTRAX System Does Not Operate Correctly1842
E-59 Machine Push-Up Function is Not Canceled1843
E-60 Machine Push-Up Function Does Not Operate1845
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1846
Information Shown in Troubleshooting Table (H-Mode)1846
System Chart of Hydraulic and Mechanical Systems1847
Failure Mode and Cause Table1849
H-1 All Work Equipment, Swing and Travel Do Not Work1860
H-2 All Work Equipment, Swing and Travel Lack Speed and Power1861
H-3 Fine Control Performance or Response is Unsatisfactory1864
H-4 Unusual Noise is Heard from Around Hydraulic Pump1865
H-5 Engine Speed Drops Largely or Engine Stops1866
H-6 Speed or Power of Boom is Low1868
H-7 Arm Speed or Power is Low1874
H-8 Bucket Speed or Power is Low1879
H-9 Work Equipment Does Not Move in Single Operation1883
H-10 Hydraulic Drift of Boom is Large1884
H-11 Hydraulic Drift of Arm is Large1886
H-12 Hydraulic Drift of Bucket is Large1888
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves1889
H-14 Time Lag of Work Equipment is Large1890
H-15 One-Touch Power Maximizing Function Does Not Operate1891
H-16 Machine Push-Up Function Does Not Operate1892
H-17 Attachment Circuit Cannot be Changed1893
H-18 Oil Flow in Attachment Circuit Cannot be Changed1894
H-19 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower1895
H-20 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely1896
H-21 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low1897
H-22 Machine Does Not Travel Straight1898
H-23 Machine is Not Steered Correctly or Steering Power is Low1900
H-24 Travel Speed is Low1903
H-25 One of Tracks Does Not Run1905
H-26 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast1907
H-27 Machine Does Not Swing to Right or Left1908
H-28 Upper Structure Swings Only to Right or Left1909
H-29 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left1910
H-30 Swing Acceleration or Swing Speed is Low in Only One Direction1911
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)1912
H-32 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)1913
H-33 Shock is Large When Upper Structure Stops Swing Operation1914
H-34 There is Large Unusual Noise When It Stops Swing Operation1915
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)1916
H-36 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)1917
Troubleshooting of Engine (S-Mode)1918
Information Shown in Troubleshooting Table (S-Mode)1918
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position1919
S-2 Engine Cranks but No Exhaust Smoke Comes Out1920
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)1921
S-4 Engine Startability is Unsatisfactory1923
S-5 Engine Does Not Pick Up Smoothly1925
S-6 Engine Stops During Operation1927
S-7 Engine Runs Rough or is Not Stable1929
S-8 Engine Lacks Power1930
S-9 KDPF Becomes Clogged in a Short Time1932
S-10 Engine Oil Consumption is Excessive1934
S-11 Oil Becomes Dirty Quickly1935
S-12 Fuel Consumption is Excessive1936
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant1937
S-14 Oil Pressure Drops1938
S-15 Fuel Mixes Into Engine Oil1940
S-16 Water Mixes Into Engine Oil (Milky)1941
S-17 Coolant Temperature Increases Too High (Overheating)1942
S-18 Unusual Noise is Heard1943
S-19 Vibration is Excessive1944
S-20 Air Cannot be Bled from Fuel Circuit1945
S-21 Active Regeneration is Done Frequently1946
S-22 Active Regeneration Continues Long1948
S-23 White Smoke is Exhausted During Active Regeneration1949
S-24 DEF Consumption is Excessive1950
S-25 There is Unusual Smell (Irritating Odor)1952
S-26 Foreign Materials Enter DEF (DEF Increases)1953
50 Disassembly and Assembly1955
Table of Contents1956
Precautions Before Work1961
Related Information on Disassembly and Assembly1962
How to Read This Manual1962
Coating Materials List1963
Special Tool List1968
Sketches of Special Tools1983
Engine and Cooling System1991
Remove and Install Supply Pump Assembly1991
How to Remove Supply Pump Assembly1991
How to Install Supply Pump Assembly1996
Remove and Install Injector Assembly2004
How to Remove Injector Assembly2004
How to Install Injector Assembly2011
Remove and Install Cylinder Head Assembly2023
How to Remove Cylinder Head Assembly2024
How to Install Cylinder Head Assembly2033
Remove and Install EGR Valve Assembly2051
How to Remove EGR Valve Assembly2051
How to Install EGR Valve Assembly2052
Remove and Install EGR Cooler Assembly2054
How to Remove EGR Cooler Assembly2054
How to Install EGR Cooler Assembly2055
Remove and Install Starter Assembly2058
How to Remove Starting Motor Assembly2058
How to Install Starting Motor Assembly2059
Remove and Install Alternator Belt2060
How to Remove Alternator Belt2060
How to Install Alternator Belt2063
Remove and Install Radiator Assembly2066
How to Remove Radiator Assembly2066
How to Install Radiator Assembly2068
Remove and Install Hydraulic Oil Cooler Assembly2070
How to Remove Hydraulic Oil Cooler Assembly2070
How to Install Hydraulic Oil Cooler Assembly2072
Remove and Install Aftercooler Assembly2075
How to Remove Aftercooler Assembly2075
How to Install Aftercooler Assembly2076
Remove and Install Engine and Main Pump Assembly2078
How to Remove Engine and Main Pump Assembly2079
How to Install Engine and Main Pump Assembly2091
Remove and Install Engine Front Oil Seal2106
How to Remove Engine Front Oil Seal2106
How to Install Engine Front Oil Seal2110
Remove and Install Engine Rear Oil Seal2114
How to Remove Engine Rear Oil Seal2115
How to Install Engine Rear Oil Seal2116
Remove and Install Engine Hood Assembly2123
How to Remove Engine Hood Assembly2123
How to Install Engine Hood Assembly2124
Remove and Install Fuel Tank Assembly2127
How to Remove Fuel Tank Assembly2127
How to Install Fuel Tank Assembly2130
Remove and Install DEF Tank Assembly2133
How to Remove DEF Tank Assembly2133
How to Install DEF Tank Assembly2139
Remove and Install DEF Tank Sensor Flange Assembly2144
How to Remove DEF Tank Sensor Flange Assembly2144
How to Install DEF Tank Sensor Flange Assembly2151
Remove and Install DEF Tank Sensor2156
How to Remove DEF Tank Sensor2156
How to Install DEF Tank Sensor2156
Remove and Install DEF Tank Strainer2163
How to Remove DEF Tank Strainer2163
How to Install DEF Tank Strainer2163
Remove and Install DEF Tank Filler Port Filter2164
How to Remove DEF Tank Filler Port Filter2164
How to Install DEF Tank Filler Port Filter2166
Remove and Install KDPF Assembly2169
How to Remove KDPF Assembly2169
How to Install KDPF Assembly2172
Disassemble and Assemble KDPF Assembly2177
How to Disassemble KDPF Assembly2178
How to Assemble KDPF Assembly2181
Remove and Install SCR Assembly2186
How to Remove SCR Assembly2186
How to Install SCR Assembly2189
Remove and Install KDPF and SCR Assembly2192
How to Remove KDPF and SCR Assembly2193
How to Install KDPF and SCR Assembly2200
Remove and Install KDPF and SCR Assembly Bracket2207
How to Remove KDPF and SCR Assembly Bracket2207
How to Install KDPF and SCR Assembly Bracket2210
Remove and Install Bellows Pipe Assembly2215
How to Remove Bellows Pipe Assembly2215
How to Install Bellows Pipe Assembly2218
Remove and Install KCCV Assembly2222
How to Remove KCCV Assembly2222
How to Install KCCV Assembly2223
Remove and Install DEF Mixing Tube2225
How to Remove DEF Mixing Tube2226
How to Install DEF Mixing Tube2229
Remove and Install DEF Injector2233
How to Remove DEF Injector2233
How to Install DEF Injector2236
Remove and Install DEF Pump2240
How to Remove DEF Pump2240
How to Install DEF Pump2243
Remove and Install DEF Hose2246
How to Remove DEF Hose2247
How to Install DEF Hose2253
Remove and Install Air Cleaner Assembly2261
How to Remove Air Cleaner Assembly2261
How to Install Air Cleaner Assembly2263
Remove and Install Air Conditioner Compressor Assembly2265
How to Remove Air Conditioner Compressor Assembly2265
How to Install Air Conditioner Compressor Assembly2266
Remove and Install Air Conditioner Condenser Assembly2268
How to Remove Air Conditioner Condenser Assembly2268
How to Install Air Conditioner Condenser Assembly2269
Power Train2270
Remove and Install Travel Motor and Final Drive Assembly2270
How to Remove Travel Motor and Final Drive Assembly2270
How to Install Travel Motor and Final Drive Assembly2271
Disassemble and Assemble Final Drive Assembly2273
How to Disassemble Final Drive Assembly2274
How to Assemble Final Drive Assembly2278
Remove and Install Swing Motor and Swing Machinery Assembly2286
How to Remove Swing Motor and Swing Machinery Assembly2286
How to Install Swing Motor and Swing Machinery Assembly2287
Disassemble and Assemble Swing Machinery Assembly2289
How to Disassemble Swing Machinery Assembly2289
How to Assemble Swing Machinery Assembly2292
Remove and Install Swing Circle Assembly2300
How to Remove Swing Circle Assembly2300
How to Install Swing Circle Assembly2300
Undercarriage and Frame2302
Separate and Connect Track Assembly2302
How to Separate Track Assembly2302
How to Install Track Assembly2304
Remove and Install Sprocket2307
How to Remove Sprocket2307
How to Install Sprocket2307
Remove and Install Idler and Idler Cushion Assembly2309
How to Remove Idler and Idler Cushion Assembly2309
How to Install Idler and Idler Cushion Assembly2310
Disassemble and Assemble Idler Assembly2311
How to Disassemble Idler Assembly2311
How to Assemble Idler Assembly2312
Disassemble and Assemble Idler Cushion Assembly2316
How to Disassemble Idler Cushion Assembly2317
How to Assemble Idler Cushion Assembly2317
Disassemble and Assemble Track Roller Assembly2319
How to Disassemble Track Roller Assembly2320
How to Assemble Track Roller Assembly2321
Disassemble and Assemble Carrier Roller Assembly2323
How to Disassemble Carrier Roller Assembly2323
How to Assemble Carrier Roller Assembly2324
Remove and Install Revolving Frame Assembly2327
How to Remove Revolving Frame Assembly2327
How to Install Revolving Frame Assembly2329
Remove and Install Counterweight Assembly2332
How to Remove Counterweight Assembly2332
How to Install Counterweight Assembly2333
Hydraulic System2336
Remove and Install Center Swivel Joint Assembly2336
How to Remove Center Swivel Joint Assembly2336
How to Install Center Swivel Joint Assembly2337
Disassemble and Assemble Center Swivel Joint Assembly2340
How to Disassemble Center Swivel Joint Assembly2341
How to Assemble Center Swivel Joint Assembly2342
Remove and Install Hydraulic Tank Assembly2343
How to Remove Hydraulic Tank Assembly2343
How to Install Hydraulic Tank Assembly2347
Remove and Install Main Pump Assembly2351
How to Remove Main Pump Assembly2351
How to Install Main Pump Assembly2354
Remove and Install Control Valve Assembly2357
How to Remove Control Valve Assembly2357
How to Install Control Valve Assembly2364
Disassemble and Assemble Control Valve Assembly2371
How to Replace Pressure Compensation Valve Seal Ring2372
How to Assemble Control Valve Assembly2373
Disassemble and Assemble Work Equipment PPC Valve Assembly2378
How to Disassemble Work Equipment PPC Valve Assembly2378
How to Assemble Work Equipment PPC Valve Assembly2379
Disassemble and Assemble Travel PPC Valve Assembly2381
How to Disassemble Travel PPC Valve Assembly2381
How to Assemble Travel PPC Valve Assembly2382
Work Equipment2384
Remove and Install Bucket Assembly2384
How to Remove Bucket Assembly2384
How to Install Bucket Assembly2384
Remove and Install Arm Assembly2386
How to Remove Arm Assembly2386
How to Install Arm Assembly2387
Remove and Install Work Equipment Assembly2389
How to Remove Work Equipment Assembly2389
How to Install Work Equipment Assembly2392
Remove and Install Boom Anti-drop Valve Assembly2395
How to Remove Boom Anti-drop Valve Assembly2395
How to Install Boom Anti-drop Valve Assembly2397
Remove and Install Arm Anti-Drop Valve Assembly2398
How to Remove Arm Anti-Drop Valve Assembly2398
How to Install Arm Anti-Drop Valve Assembly2400
Disassemble and Assemble Anti-Drop Valve Assembly2401
How to Disassemble Anti-Drop Valve Assembly2401
How to Assemble Anti-Drop Valve Assembly2401
Disassemble and Assemble Work Equipment Cylinder Assembly2402
How to Disassemble Work Equipment Cylinder Assembly2402
How to Assemble Work Equipment Cylinder Assembly2405
CAB Related Parts2412
Remove and Install Operator Cab Assembly2412
How to Remove Operator Cab Assembly2412
How to Install Operator Cab Assembly2420
Remove and Install Operator Cab Glass (Adhered Glass)2427
How to Remove Operator Cab Glass (Adhered Glass)2429
How to Install Operator Cab Glass (Adhered Glass)2429
Remove and Install Front Window Assembly2439
How to Remove Front Window Assembly2439
How to Install Front Window Assembly2442
Remove and Install Floor Frame Assembly2448
How to Remove Floor Frame Assembly2449
How to Install Floor Frame Assembly2455
Remove and Install Air Conditioner Unit Assembly2463
How to Remove Air Conditioner Unit Assembly2463
How to Install Air Conditioner Unit Assembly2469
Remove and Install Operator Seat2475
How to Remove Operator Seat2475
How to Install Operator Seat2477
How to Remove and Install Seat Belt2480
How to Remove Seat Belt2480
How to Install Seatbelt2481
Remove and Install Work Equipment Control Lever Assembly2482
How to Remove Work Equipment Control Lever Assembly2482
How to Install Work Equipment Control Lever Assembly2488
Remove and Install Front Wiper Assembly2497
How to Remove Front Wiper Assembly2497
How to Install Front Wiper Assembly2502
Electrical System2511
Remove and Install Engine Controller Assembly2511
How to Remove Engine Controller Assembly2511
How to Install Engine Controller Assembly2513
Remove and Install Pump Controller Assembly2517
How to Remove Pump Controller Assembly2517
How to Install Pump Controller Assembly2520
Remove and Install KomVision Controller Assembly2524
How to Remove KomVision Controller Assembly2524
How to Install KomVision Controller Assembly2525
Remove and Install Machine Monitor Assembly2526
How to Remove Machine Monitor Assembly2526
How to Install Machine Monitor Assembly2529
Remove and Install Pump Swash Plate Sensor2533
How to Remove Pump Swash Plate Sensor2533
How to Install Pump Swash Plate Sensor2533
Remove and Install Mass Air Flow and Temperature Sensor2535
How to Remove Mass Air Flow and Temperature Sensor2535
How to Install Mass Air Flow and Temperature Sensor2536
Remove and Install KCCV Crankcase Pressure Sensor2537
How to Remove KCCV Crankcase Pressure Sensor2537
How to Install KCCV Crankcase Pressure Sensor2538
Remove and Install SCR Temperature Sensor2539
How to Remove SCR Temperature Sensor2539
How to Install SCR Temperature Sensor2540
Remove and Install Rearview Camera2542
How to Remove Rearview Camera2542
How to Install Rearview Camera2543
Remove and Install KomVision Camera2545
How to Remove KomVision Camera2545
How to Install KomVision Camera2546
Remove and Install KOMTRAX Terminal Assembly2548
How to Remove KOMTRAX Terminal Assembly2548
How to Install KOMTRAX Terminal Assembly2551
60 Maintenance Standard2555
Table of Contents2556
Engine and Cooling System2557
Maintenance Standard for Engine Mount2557
Maintenance Standard for Cooling System2559
Power Train2561
Maintenance Standard for Swing Circle2561
Maintenance Standard for Swing Machinery2562
Maintenance Standard for Final Drive2564
Maintenance Standard for Sprocket2566
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing2567
Undercarriage and Frame2568
Maintenance Standard for Track Frame and Idler Cushion2568
Maintenance Standard for Idler2570
Maintenance Standard for Track Roller2572
Maintenance Standard for Carrier Roller2574
Maintenance Standard for Track Shoes2575
Maintenance Standard for Triple Shoes2578
Hydraulic System2579
Maintenance Standard for Hydraulic Tank2579
Maintenance Standard for Main Pump2580
Maintenance Standard for Swing Motor2582
Maintenance Standard for Travel Motor2585
Maintenance Standard for Control Valve2588
Maintenance Standard for Boom Anti-Drop Valve2598
Maintenance Standard for Arm Anti-Drop Valve2600
Maintenance Standard for Work Equipment and Swing PPC Valve2602
Maintenance Standard for Travel PPC Valve2605
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)2608
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve2609
Maintenance Standard for 2nd-Line Attachment PPC Valve2611
Maintenance Standard for Solenoid Valve2613
Maintenance Standard for Attachment Circuit Selector Valve2614
Maintenance Standard for Center Swivel Joint2615
Work Equipment2616
Maintenance Standard for Work Equipment Linkage2616
Dimensions of Arm2621
Dimensions of Bucket2623
Maintenance Standard for Boom Cylinder2625
Maintenance Standard for Arm Cylinder2626
Maintenance Standard for Bucket Cylinder2627
80 Appendix2629
Table of Contents2630
Precautions Before Work2632
Air Conditioner System2633
Precautions for Refrigerant2633
Air Conditioner Component2634
Specifications of Air Conditioner2636
Structure and Function of Refrigeration Cycle2637
Outline of Refrigeration Cycle2638
Component Parts of Air Conditioner System2640
Air Conditioner Unit2640
Configuration Diagram of Air Conditioner Unit2640
Function of Air Conditioner Unit2642
Component Parts of Air Conditioner Unit2644
Function of Evaporator as Air Conditioner Unit Component2645
Function of Heater Core as Air Conditioner Unit Component2645
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2645
Function of Servo Motor as Air Conditioner Unit Component2645
Structure of Expansion Valve as Air Conditioner Unit Component2646
Function of Expansion Valve as Air Conditioner Unit Component2646
Operate Expansion Valve as Air Conditioner Unit Component2646
Function of Dual Pressure Switch2647
Air Conditioner Controller2648
Structure of Air Conditioner Controller2648
Compressor2649
Structure of Compressor2649
Specifications of Compressor2649
Function of Compressor2649
Condenser2650
Structure of Condenser2650
Specifications of Condenser2650
Function of Condenser2650
Receiver Drier2651
Structure of Receiver Dryer2651
Specifications of Receiver Dryer2651
Function of Receiver Dryer2651
Air Conditioner Related Sensors2652
Structure of Sunlight Sensor2652
Function of Sunlight Sensor2652
Structure of Outside Temperature Sensor2652
Function of Outside Air Temperature Sensor2652
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2654
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2656
System Diagram of Air Conditioner2658
Input and Output Signals of Air Conditioner Controller2659
Function of Air Conditioner Controller2660
Locations of Air Conditioner Parts and Layout of Connectors2661
Examine Air Leakage (Duct)2665
How to Examine Air Leakage (Duct)2665
Examine Air Conditioner with Self-Diagnosis Function2667
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2668
Examine Vent (Mode) Changeover2669
How to Examine Vent (Mode) Changeover2669
Examine Fresh/Recirc Air Changeover2671
How to Examine Fresh/Recirc Air Changeover2671
Examine Sunlight Sensor2672
How to Examine Sunlight Sensor2672
Examine Refrigerant (Dual) Pressure Switch2673
How to Examine Refrigerant (Dual) Pressure Switch2673
Examine Relay2674
How to Examine Relay2674
Air Conditioner Troubleshooting Chart 12675
Air Conditioner Troubleshooting Chart 22676
Information Shown in Troubleshooting Table2679
Failure Code [879AKA]2680
Failure Code [879AKB]2681
Failure Code [879BKA]2682
Failure Code [879BKB]2684
Failure Code [879CKA]2686
Failure Code [879CKB]2687
Failure Code [879DKZ]2688
Failure Code [879EMC]2690
Failure Code [879FMC]2691
Failure Code [879GKX]2692
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2694
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2696
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2699
A-4 Troubleshooting for Fresh/Recirc Air Changeover2701
Troubleshooting by Gauge Pressure2703
Connect Service Tool2706
How to Connect Service Tool2706
Precautions for Disconnection and Connection of Air Conditioner Piping2708
Handle Compressor Oil2710
90 Circuit Diagrams2713
Table of Contents2714
Hydraulic Circuit Diagram2715
Symbols Used in Hydraulic Circuit Diagram2715
Hydraulic Circuit Diagram2719
Electrical Circuit Diagram2721
Symbols Used in Electric Circuit Diagram2721
Electrical Circuit Diagram (1/11)2725
Electrical Circuit Diagram (2/11)2727
Electrical Circuit Diagram (3/11)2729
Electrical Circuit Diagram (4/11)2731
Electrical Circuit Diagram (5/11)2733
Electrical Circuit Diagram (6/11)2735
Electrical Circuit Diagram (7/11)2737
Electrical Circuit Diagram (8/11)2739
Electrical Circuit Diagram (9/11)2741
Electrical Circuit Diagram (10/11)2743
Electrical Circuit Diagram (11/11)2745
Index2747

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24