Komatsu HYDRAULIC EXCAVATOR PC360LC-11 Shop Manual SEN06513-19 PDF

Description

Komatsu HYDRAULIC EXCAVATOR PC360LC-11 Shop Manual SEN06513-19 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HYDRAULIC EXCAVATOR PC360LC-11 Shop Manual SEN06513-19 – PDF DOWNLOAD

Language : English
Pages :2816
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC360LC-11 Shop Manual SEN06513-19 – PDF DOWNLOAD

SERIAL NUMBERS 90001 and up

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC360LC-11 Shop Manual SEN06513-19 – PDF DOWNLOAD

SERIAL NUMBERS 90001 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: PC360LC-11 93
Working Range Drawings 95
Working Range: PC360LC-11 95
Specifications 96
Specifications: PC360LC-11 96
Weight Table 99
Weight Table: PC360LC-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 107
Urea SCR System Diagram 111
Function of Urea SCR System 112
Function of DEF System 112
Inducement Strategy 114
Component Parts of Urea SCR System 128
DEF Mixing Tube 128
SCR Assembly 128
DEF Tank 131
DEF Pump 133
DEF Injector 134
DEF Hose 135
DEF Tank Heating Valve 136
Boot-up System 137
Layout Drawing of Boot-up System 137
System Operating Lamp System 139
System Diagram of System Operating Lamp System 139
Function of Operation Lamp System 139
Battery Disconnect Switch 141
Function of Battery Disconnect Switch 141
Engine System 142
Layout Drawing of Engine System 142
Specifications of Engine System 143
Function of Engine System 143
Engine Control System 144
System Diagram of Engine Control 144
Function of Engine Control System 145
Auto-Deceleration System 147
System Diagram of Auto-Deceleration System 147
Function of Auto-Deceleration System 147
Operation of Auto-Deceleration System 148
Engine Automatic Warm-up System 149
System Diagram of Engine Automatic Warm-up System 149
Function of Engine Automatic Warm-up System 150
Overheat Prevention System 151
Overheat Prevention System Diagram 151
Function of Overheat Prevention System 152
Turbocharger Protection System 153
System Diagram of Turbocharger Protection System 153
Function of Turbocharger Protection System 154
Automatic Idle Stop System 155
System Diagram of Automatic Idle Stop System 155
Function of Automatic Idle Stop System 155
Component Parts of Engine System 158
VGT 158
EGR System 161
EGR Valve 163
EGR Cooler 165
KCCV System 166
KCCV Ventilator 168
KDPF 169
Cooling System 174
Layout Drawing of Cooling System 174
Specifications of Cooling System 175
Control System 176
Layout Drawing of Control System 176
Machine Monitor System 179
System Diagram of Machine Monitor System 179
Function of Machine Monitor System 179
KomVision System 181
Layout Drawing of KomVision System 181
System Diagram of KomVision System 183
Function of KomVision System 183
KOMTRAX System 185
System Diagram of KOMTRAX System 185
Function of KOMTRAX System 185
Component Parts of Control System 186
Machine Monitor 186
KomVision Controller 200
KomVision Camera 204
KOMTRAX Terminal 204
Pump Controller 207
Resistor for PC-EPC Valve 211
CAN Terminating Resistor 211
Engine Controller 213
Fuel Control Dial 219
Hydraulic System 221
Layout Drawing of Hydraulic System 221
CLSS 224
Structure of CLSS 224
Operation of Unload Valve and LS Pressure 226
Pump Swash Plate Angle (Oil Flow) Control 227
Pressure Compensation Control 243
Engine and Pump Combined Control System 247
Engine and Pump Combined Control System Diagram 247
Function of Engine and Pump Combined Control System 248
Pump and Valve Control System 253
Pump and Valve Control System Diagram 253
Function of Pump and Valve Control System 254
Component Parts of Hydraulic System 256
Hydraulic Tank 256
Main Pump 259
Control Valve 285
Work Equipment System 345
Layout Drawing of Work Equipment System 345
Structure of Valve Control 351
One-Touch Power Maximizing System 353
System Diagram of One-Touch Power Maximizing System 353
Function of One-Touch Power Maximizing System 354
Machine Push-up System 355
Machine Push-up System Diagram 355
Function of Machine Push-up System 356
PPC Lock System 357
System Diagram of PPC Lock 357
Function of PPC Lock System 357
Work Equipment and Travel Automatic Lock System 358
System Diagram of Lock Lever Automatic Lock System 358
Function of Work Equipment and Travel Automatic Lock System 358
Operation of Lock Lever Automatic Lock System 359
Attachment Oil Flow Adjuster System 360
Attachment Oil Flow Adjuster System Diagram 360
Function of Attachment Oil Flow Adjuster System 361
Tool Control System 362
Tool Control System Diagram 362
Function of Tool Control System 363
Component Parts of Work Equipment System 364
Work Equipment and Swing PPC Valve 364
1st-Line Attachment PPC Valve (with EPC Valve) 370
2nd-Line Attachment PPC Valve 374
Solenoid Valve 376
Boom Anti-drop Valve 379
Arm Anti-Drop Valve 383
Attachment Circuit Selector Valve (For High Pressure) 387
Attachment Circuit Selector Valve (For Low Pressure) 389
1st-Line Attachment Variable Relief Valve 392
Attachment Bypass Solenoid Valve 395
Pilot Circuit Accumulator 396
Swing System 397
Layout Drawing of Swing System 397
Swing Control System Diagram 400
Function of Swing Control System 400
Component Parts of Swing System 404
Swing Motor 404
Swing Machinery 415
Swing Circle 417
Travel System 418
Layout Drawing of Travel System 418
System Diagram of Travel Control System 422
Function of Travel Control System 422
Component Parts of Travel System 424
Travel Motor 424
Final Drive 436
Travel PPC Valve 437
Center Swivel Joint 442
Undercarriage and Frame 444
Layout Drawing of Undercarriage 444
Specifications of Undercarriage 444
Work Equipment 446
Structure of Work Equipment 446
Function of Work Equipment 447
Work Equipment Clearance Adjustment Shim 448
Function of Work Equipment Clearance Adjustment Shim 448
Bucket Clearance Adjustment Shim 449
Function of Bucket Clearance Adjustment Shim 449
CAB Related Parts 450
ROPS CAB 450
Structure of ROPS CAB 450
Function of ROPS CAB 450
CAB Mount 451
Structure of CAB Mount 451
Function of CAB Mount 451
CAB Tipping Stopper 452
Structure of CAB Tipping Stopper 452
Function of CAB Tipping Stopper 452
20 Standard Value Table 453
Table of Contents 454
Standard Value Table for Engine 455
Standard Value Table for Engine: PC360LC-11 455
Standard Value Table for Machine 460
Standard Value Table for Machine: PC360LC-11 460
Machine Posture and Procedures to Measure Performance 475
Standard Value Table for Electricity 479
Standard Value Table for Electricity 479
30 Testing and Adjusting 489
Table of Contents 490
Precautions Before Work 493
Related Information on Testing and Adjusting 494
Tools for Testing and Adjusting 494
Sketch of Tools for Testing and Adjusting 501
Engine and Cooling System 503
Examine Engine Speed 503
How to Examine Engine Speed 503
Examine Boost Pressure 507
How to Examine Boost Pressure on Machine Monitor 507
How to Examine Boost Pressure by Testing Tool 508
Examine Exhaust Gas Color 509
How to Examine Exhaust Gas Color with the Handy Smoke Checker 509
How to Examine Exhaust Gas Color with Smoke Meter 510
Examine Mass Air Flow and Temperature Sensor 511
How to Examine Mass Air Flow and Temperature Sensor 511
Examine and Adjust Valve Clearance 513
How to Examine Valve Clearance 513
How to Adjust Valve Clearance 515
Examine Compression Pressure 516
How to Examine Compression Pressure 516
Examine Blowby Pressure 519
How to Examine Blowby Pressure 519
Examine Engine Oil Pressure 521
How to Examine Engine Oil Pressure 521
Examine EGR Valve and VGT Oil Pressure 523
How to Examine EGR Valve and VGT Oil Pressure 523
Examine Fuel Pressure 525
How to Examine Fuel Pressure 526
Examine Fuel Discharge, Return and Leakage 532
How to Examine Fuel Discharge, Return, and Leakage 533
Bleed Air from Fuel System 539
How to Bleed Air from Fuel System 539
Examine Fuel Circuit for Leakage 540
How to Examine Fuel System for Leakage 540
Handle Cylinder Cut-out Mode Operation 542
Handle No-Injection Cranking Operation 543
Examine and Adjust Air Conditioner Compressor Belt Tension 544
How to Examine Air Conditioner Compressor Belt Tension 544
How to Adjust Air Conditioner Compressor Belt Tension 544
How to Adjust Air Conditioner Compressor Belt 545
Examine Alternator Belt 546
How to Examine Alternator Belt 546
Examine Automatic Tensioner 547
How to Examine Automatic Tensioner 547
Write Correction for Ash in Soot Accumulation to Engine Controller 548
How to Write Correction for Ash in Soot Accumulation to Engine Controller 548
Examine SCR Related Functions 549
Examine DEF Pump Raised Pressure 553
Examine Injection Volume from DEF Injector 556
Examine DEF Line Heater Relay 1 561
Examine DEF Line Heater Relay 2 564
Examine DEF Pump Heater Relay 567
Examine DEF Tank Heater Valve 570
Examine SCR Denitration Efficiency 573
Clean DEF Tank 577
How to Clean DEF Tank 577
Clean DEF Pump 581
How to Clean DEF Pump 581
Power Train 587
Examine Swing Circle Bearing Clearance 587
How to Examine Swing Circle Bearing Clearance 587
Undercarriage and Frame 588
Examine and Adjust Track Tension 588
How to Examine Track Tension 588
How to Adjust Track Tension 588
Hydraulic System 590
Release Remained Pressure in Hydraulic Circuit 590
How to Release Remained Pressure from Hydraulic Tank 590
How to Release Remained Pressure in Hydraulic Cylinder Circuit 590
How to Release Remained Pressure from Swing Motor Circuit 594
How to Release Remained Pressure from Travel Motor Circuit 594
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 595
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 596
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 604
Examine Oil Pressure of Control Circuit 607
How to Examine Oil Pressure in Control Circuit 607
Examine and adjust oil pressure in pump PC control circuit 609
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 609
Examine PC-EPC Valve Outlet Pressure 610
How to Adjust Oil Pressure in Pump PC Control Circuit 611
Examine and Adjust Oil Pressure in Pump LS Control Circuit 612
How to Examine LS Differential Pressure with Machine Monitor 612
How to Examine LS Differential Pressure by Testing Tool 613
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 615
How to Examine LS-EPC Valve Outlet Pressure 615
How to Adjust LS Valve 616
Examine Outlet Pressure of Solenoid Valve 617
How to Examine Outlet Pressure of Solenoid Valve 617
Operating Condition of Solenoid Valve 618
Examine PPC Valve Outlet Pressure 620
How to Examine Outlet Pressure in PPC Valve 620
Adjust Play of Work Equipment and Swing PPC Valves 622
How to Adjust Play of Work Equipment and Swing PPC Valves 622
Examine Pump Swash Plate Sensor 623
How to Examine pump swash plate sensor 623
Examine Parts Which Cause Hydraulic Drift of Work Equipment 624
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 624
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 624
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 625
Examine Oil Leakage 626
How to Examine Oil Leakage from Boom Cylinder 626
How to Examine Oil Leakage from Arm Cylinder 626
How to Examine Oil Leakage from Bucket Cylinder 627
How to Examine Oil Leakage from Swing Motor 627
How to Examine Oil Leakage from Travel Motor 628
Bleed Air from Hydraulic System 629
How to Bleed Air from Hydraulic System 631
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 634
How to Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 634
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 638
How to Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 638
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 642
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping 642
CAB Related Parts 649
Examine CAB Tipping Stopper 649
How to Examine Cab Tipping Stopper 649
How to Adjust Mirrors 650
Procedure to Adjust Machine Left Front Mirror (A) 650
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 651
Procedure to Adjust Machine Right Front Mirror (B) 652
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 653
Procedure to Adjust Machine Right Side Mirror (C) 654
Electrical System 656
Set and Operate Machine Monitor 656
Operator Mode 660
Function to Show Technician Identification Status Screen 660
Function to Show Operator Identification Input Screen 660
Examine Function by LCD (Liquid Crystal Display) 661
Examine Function of Service Meter 661
Usage Limitation and Maintenance Password Change Function 661
Service Mode 664
How to Operate Service Mode 664
How to See Pre-defined Monitoring Information 666
How to Examine Self-Define Monitor Information 673
Abnormality Record Menu 684
How to See Maintenance Record 688
Maintenance Mode Setting 689
How to Set Phone Number Entry 693
Default Menu 695
Diagnostic Tests Menu 707
Adjustment Menu 716
No-Injection Cranking Operation 733
KOMTRAX Settings Menu 735
How to Show Service Message 737
How to Start Up KOMTRAX Terminal 739
Adjust Rearview Camera Angle 744
How to Adjust Rearview Camera Angle 744
Adjust KomVision Camera Angle 747
How to Adjust KomVision Camera Angle 748
Adjust KomVision Related Function 752
Setting of KomVision (Main Setting) 752
Setting of KomVision (Camera Setting) 754
Setting of KomVision (Camera Calibration) 756
KomVision screen – Check 12 m visibility 769
Set Region of Bluetooth(R) Compatible Radio 772
How to Set Region of Bluetooth(R) Compatible Radio 772
Handle Voltage Circuit of Engine Controller 774
Handle Battery Disconnect Switch 775
Examine Diodes 776
How to Examine Diodes by Digital Tester 776
How to Examine Diodes by Analog Tester 776
Pm Clinic 777
Pm Clinic Service 777
Pm Clinic Check Sheet 779
40 Troubleshooting 795
Table of Contents 796
Precautions Before Work 806
Related Information to Troubleshooting 807
General Troubleshooting Points 807
Troubleshooting Points for Urea SCR System 808
Sequence of Events in Troubleshooting 822
Checks Before Troubleshooting 824
Inspection Procedure Before Troubleshooting 826
Walk-Around Check 826
Test in Accordance with Testing Procedure 828
Examine Fuel Level and Type 828
Examine for Impure Ingredient in Fuel 828
Examine Fuel Prefilter 829
Examine Water Separator, Drain Water and Sediment 829
How to Replace Fuel Prefilter Cartridge 830
Examine Fuel Main Filter 831
Examine Engine Oil Level (Oil Quantity in Oil Pan) 833
Examine Coolant Level (Reservoir Tank) 834
Examine Air Cleaner Clogging 835
Clean Outer Element 835
Replace Element 837
Examine Hydraulic Oil Level 838
Examine Hydraulic Oil Strainer 839
Examine Hydraulic Oil Filter 840
Examine Oil Level in Swing Machinery Case 841
Examine Oil Level in Damper Case 841
Examine Oil Level in Final Drive Case 842
Bleed Air from Fuel System 842
Bleed Air from Hydraulic System 842
How to Examine Electric Equipment 843
Preparation for Troubleshooting of Electrical System 848
Procedure for Troubleshooting 858
Symptom and Troubleshooting Numbers 861
Information Shown in Troubleshooting Table 865
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 867
Connector List and Layout 870
Connector Contact Connection Table 883
T-Branch Box and T-Branch Adapter Table 923
Fuse Location Table 929
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 932
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 936
Failure Code Table 938
Troubleshooting by Failure Code (Display of Code) 956
Failure Code [879AKA] 956
Failure Code [879AKB] 957
Failure Code [879BKA] 958
Failure Code [879BKB] 960
Failure Code [879CKA] 962
Failure Code [879CKB] 963
Failure Code [879DKZ] 964
Failure Code [879EMC] 966
Failure Code [879FMC] 967
Failure Code [879GKX] 968
Failure Code [989L00] 970
Failure Code [989M00] 971
Failure Code [989N00] 972
Failure Code [A1U0N3] 973
Failure Code [A1U0N4] 975
Failure Code [A900FR] 977
Failure Code [A900N6] 978
Failure Code [A900NY] 979
Failure Code [AA10NX] 980
Failure Code [AB00KE] 982
Failure Code [AQ10N3] 985
Failure Code [AS00N3] 987
Failure Code [AS00R2] 989
Failure Code [AS00R3] 990
Failure Code [AS00R4] 991
Failure Code [AS00R5] 992
Failure Code [AS00R6] 993
Failure Code [AS00ZK] 994
Failure Code [AS10KM] 995
Failure Code [AS10NR] 996
Failure Code [AS10NT] 997
Failure Code [B@BAZG] 998
Failure Code [B@BAZK] 999
Failure Code [B@BCNS]1001
Failure Code [B@BCQA]1002
Failure Code [B@BCZK]1004
Failure Code [B@HANS]1006
Failure Code [CA115]1007
Failure Code [CA122]1008
Failure Code [CA123]1010
Failure Code [CA131]1012
Failure Code [CA132]1014
Failure Code [CA144]1016
Failure Code [CA145]1018
Failure Code [CA153]1020
Failure Code [CA154]1023
Failure Code [CA187]1026
Failure Code [CA221]1028
Failure Code [CA222]1030
Failure Code [CA227]1032
Failure Code [CA234]1033
Failure Code [CA238]1034
Failure Code [CA239]1036
Failure Code [CA249]1038
Failure Code [CA256]1040
Failure Code [CA271]1042
Failure Code [CA272]1044
Failure Code [CA281]1046
Failure Code [CA322]1047
Failure Code [CA323]1049
Failure Code [CA324]1051
Failure Code [CA325]1053
Failure Code [CA331]1055
Failure Code [CA332]1057
Failure Code [CA343]1059
Failure Code [CA351]1060
Failure Code [CA352]1061
Failure Code [CA356]1064
Failure Code [CA357]1066
Failure Code [CA386]1068
Failure Code [CA428]1069
Failure Code [CA429]1071
Failure Code [CA435]1073
Failure Code [CA441]1075
Failure Code [CA442]1077
Failure Code [CA449]1078
Failure Code [CA451]1082
Failure Code [CA452]1085
Failure Code [CA488]1087
Failure Code [CA515]1088
Failure Code [CA516]1090
Failure Code [CA553]1092
Failure Code [CA555]1093
Failure Code [CA556]1094
Failure Code [CA559]1095
Failure Code [CA595]1099
Failure Code [CA687]1100
Failure Code [CA689]1102
Failure Code [CA691]1107
Failure Code [CA692]1109
Failure Code [CA697]1111
Failure Code [CA698]1112
Failure Code [CA731]1113
Failure Code [CA778]1115
Failure Code [CA1117]1120
Failure Code [CA1664]1121
Failure Code [CA1669]1123
Failure Code [CA1673]1124
Failure Code [CA1677]1125
Failure Code [CA1678]1126
Failure Code [CA1682]1127
Failure Code [CA1683]1129
Failure Code [CA1684]1131
Failure Code [CA1686]1133
Failure Code [CA1691]1134
Failure Code [CA1694]1137
Failure Code [CA1695]1140
Failure Code [CA1696]1141
Failure Code [CA1712]1143
Failure Code [CA1713]1146
Failure Code [CA1714]1148
Failure Code [CA1715]1149
Failure Code [CA1776]1150
Failure Code [CA1777]1153
Failure Code [CA1843]1156
Failure Code [CA1844]1158
Failure Code [CA1879]1161
Failure Code [CA1881]1164
Failure Code [CA1883]1166
Failure Code [CA1885]1169
Failure Code [CA1887]1171
Failure Code [CA1921]1173
Failure Code [CA1922]1176
Failure Code [CA1942]1181
Failure Code [CA1993]1182
Failure Code [CA2185]1185
Failure Code [CA2186]1187
Failure Code [CA2249]1189
Failure Code [CA2265]1190
Failure Code [CA2266]1192
Failure Code [CA2271]1194
Failure Code [CA2272]1197
Failure Code [CA2288]1200
Failure Code [CA2311]1201
Failure Code [CA2349]1202
Failure Code [CA2353]1205
Failure Code [CA2357]1207
Failure Code [CA2381]1208
Failure Code [CA2382]1211
Failure Code [CA2383]1214
Failure Code [CA2386]1217
Failure Code [CA2387]1219
Troubleshooting Flowchart1223
Failure Code [CA2555]1224
Failure Code [CA2556]1227
Failure Code [CA2637]1230
Failure Code [CA2639]1232
Failure Code [CA2771]1235
Failure Code [CA2777]1241
Failure Code [CA2976]1244
Failure Code [CA3133]1246
Failure Code [CA3134]1248
Failure Code [CA3135]1250
Failure Code [CA3142]1253
Failure Code [CA3143]1254
Failure Code [CA3144]1255
Failure Code [CA3146]1257
Failure Code [CA3147]1258
Failure Code [CA3148]1259
Failure Code [CA3151]1261
Failure Code [CA3165]1267
Failure Code [CA3229]1269
Failure Code [CA3231]1271
Failure Code [CA3232]1273
Failure Code [CA3235]1277
Failure Code [CA3239]1279
Failure Code [CA3241]1282
Failure Code [CA3242]1285
Failure Code [CA3251]1288
Failure Code [CA3253]1290
Failure Code [CA3254]1293
Failure Code [CA3255]1296
Failure Code [CA3256]1300
Failure Code [CA3311]1302
Failure Code [CA3312]1304
Failure Code [CA3313]1307
Failure Code [CA3314]1308
Failure Code [CA3315]1309
Failure Code [CA3316]1311
Failure Code [CA3317]1312
Failure Code [CA3318]1313
Failure Code [CA3319]1315
Failure Code [CA3321]1316
Failure Code [CA3322]1318
Failure Code [CA3419]1320
Failure Code [CA3421]1322
Failure Code [CA3497]1324
Failure Code [CA3498]1325
Failure Code [CA3543]1326
Failure Code [CA3545]1333
Failure Code [CA3547]1335
Failure Code [CA3558]1336
Failure Code [CA3559]1338
Failure Code [CA3562]1340
Failure Code [CA3563]1342
Failure Code [CA3567]1345
Failure Code [CA3568]1348
Failure Code [CA3571]1352
Failure Code [CA3572]1354
Failure Code [CA3574]1356
Failure Code [CA3575]1358
Failure Code [CA3577]1360
Failure Code [CA3578]1362
Failure Code [CA3582]1364
Failure Code [CA3583]1370
Failure Code [CA3596]1372
Failure Code [CA3649]1374
Failure Code [CA3681]1376
Failure Code [CA3682]1381
Failure Code [CA3713]1387
Failure Code [CA3717]1390
Failure Code [CA3718]1391
Failure Code [CA3725]1392
Failure Code [CA3741]1395
Failure Code [CA3748]1396
Failure Code [CA3751]1398
Failure Code [CA3755]1400
Failure Code [CA3866]1402
Failure Code [CA3867]1406
Failure Code [CA3868]1409
Failure Code [CA3899]1413
Failure Code [CA3911]1415
Failure Code [CA3912]1419
Failure Code [CA3932]1421
Failure Code [CA3933]1423
Failure Code [CA3934]1425
Failure Code [CA3935]1428
Failure Code [CA3936]1430
Failure Code [CA4151]1432
Failure Code [CA4152]1436
Failure Code [CA4155]1440
Failure Code [CA4156]1442
Failure Code [CA4157]1445
Failure Code [CA4158]1447
Failure Code [CA4159]1448
Failure Code [CA4161]1449
Failure Code [CA4162]1452
Failure Code [CA4163]1455
Failure Code [CA4164]1457
Failure Code [CA4165]1459
Failure Code [CA4166]1461
Failure Code [CA4168]1463
Failure Code [CA4169]1466
Failure Code [CA4171]1468
Failure Code [CA4249]1471
Failure Code [CA4251]1473
Failure Code [CA4259]1475
Failure Code [CA4261]1478
Failure Code [CA4277]1481
Failure Code [CA4281]1485
Failure Code [CA4459]1488
Failure Code [CA4461]1490
Failure Code [CA4658]1493
Failure Code [CA4731]1497
Failure Code [CA4732]1498
Failure Code [CA4739]1499
Failure Code [CA4768]1500
Failure Code [CA4769]1502
Failure Code [CA4842]1505
Failure Code [CA4952]1509
Failure Code [CA5115]1511
Failure Code [CA5179]1514
Failure Code [CA5181]1516
Failure Code [CA5383]1518
Failure Code [D110KB]1520
Failure Code [D19JKZ]1522
Failure Code [D811MC]1525
Failure Code [D862KA]1526
Failure Code [D8ALKA]1527
Failure Code [D8ALKB]1529
Failure Code [D8AQKR]1531
Failure Code [DA20MC]1533
Failure Code [DA22KK]1534
Failure Code [DA25KP]1537
Failure Code [DA29KQ]1540
Failure Code [DA2LKA]1542
Failure Code [DA2LKB]1544
Failure Code [DA2QKR]1546
Failure Code [DA2RKR]1549
Failure Code [DAF0KM]1550
Failure Code [DAF0MB]1551
Failure Code [DAF0MC]1552
Failure Code [DAF8KB]1553
Failure Code [DAF9KQ]1555
Failure Code [DAFGMC]1556
Failure Code [DAFLKA]1557
Failure Code [DAFLKB]1559
Failure Code [DAFQKR]1561
Failure Code [DAZ9KQ]1562
Failure Code [DAZQKR]1563
Failure Code [DB2QKR]1568
Failure Code [DB2RKR]1573
Failure Code [DBP0KT]1578
Failure Code [DBP0KM]1579
Failure Code [DBP5KB]1580
Failure Code [DBP5KY]1583
Failure Code [DBPQKR]1586
Failure Code [DDNRKA]1591
Failure Code [DDNRKY]1593
Failure Code [DDNS00]1595
Failure Code [DGH2KB]1597
Failure Code [DHA4KA]1599
Failure Code [DHAAMA]1601
Failure Code [DHACMA]1603
Failure Code [DHPAMA]1605
Failure Code [DHPBMA]1608
Failure Code [DHS3MA]1611
Failure Code [DHS4MA]1614
Failure Code [DHS8MA]1617
Failure Code [DHS9MA]1620
Failure Code [DHSAMA]1623
Failure Code [DHSBMA]1626
Failure Code [DHSCMA]1629
Failure Code [DHSDMA]1632
Failure Code [DHSFMA]1635
Failure Code [DHSGMA]1638
Failure Code [DHSHMA]1641
Failure Code [DHSJMA]1644
Failure Code [DHZAMA]1647
Failure Code [DHZCL8]1651
Failure Code [DKR0MA]1652
Failure Code [DKR1MA]1655
Failure Code [DKULKA]1658
Failure Code [DKULKB]1660
Failure Code [DKULKY]1662
Failure Code [DR10KA]1664
Failure Code [DR12KA]1667
Failure Code [DR20KA]1669
Failure Code [DR21KX]1671
Failure Code [DR30KA]1673
Failure Code [DR31KX]1675
Failure Code [DR40KA]1677
Failure Code [DUMBKA]1679
Failure Code [DUMBKB]1681
Failure Code [DV20KB]1683
Failure Code [DW43KA]1685
Failure Code [DW43KB]1687
Failure Code [DW43KY]1689
Failure Code [DW45KA]1691
Failure Code [DW45KB]1694
Failure Code [DW45KY]1697
Failure Code [DW4CKY]1699
Failure Code [DW91KA]1700
Failure Code [DW91KB]1702
Failure Code [DW91KY]1704
Failure Code [DWA2KA]1706
Failure Code [DWA2KB]1708
Failure Code [DWA2KY]1710
Failure Code [DWK0KA]1712
Failure Code [DWK0KB]1714
Failure Code [DWK0KY]1716
Failure Code [DWK2KA]1718
Failure Code [DWK2KB]1720
Failure Code [DWK2KY]1722
Failure Code [DWK8KA]1724
Failure Code [DWK8KB]1726
Failure Code [DWK8KY]1728
Failure Code [DWPUKA]1730
Failure Code [DWPUKB]1732
Failure Code [DWPUKY]1734
Failure Code [DXA8KA]1736
Failure Code [DXA8KB]1739
Failure Code [DXA9KA]1741
Failure Code [DXA9KB]1744
Failure Code [DXE0KA]1746
Failure Code [DXE0KB]1748
Failure Code [DXE4KA]1750
Failure Code [DXE4KB]1752
Failure Code [DXE4KY]1754
Failure Code [DXE5KA]1755
Failure Code [DXE5KB]1757
Failure Code [DXE6KA]1759
Failure Code [DXE6KB]1761
Failure Code [DXE7KA]1763
Failure Code [DXE7KB]1765
Failure Code [DXE7KY]1767
Failure Code [DXE8KA]1769
Failure Code [DXE8KB]1771
Failure Code [DXE8KY]1773
Failure Code [DXE9KA]1775
Failure Code [DXE9KB]1777
Failure Code [DXE9KY]1779
Failure Code [DXEAKA]1781
Failure Code [DXEAKB]1783
Failure Code [DXEAKY]1785
Failure Code [DXEKKA]1787
Failure Code [DXEKKB]1789
Failure Code [DXEKKY]1791
Failure Code [DXELKA]1793
Failure Code [DXELKB]1795
Failure Code [DXELKY]1797
Failure Code [DY20KA]1799
Failure Code [DY20MA]1802
Failure Code [DY2CKB]1804
Failure Code [DY2DKB]1807
Failure Code [DY2EKB]1809
Troubleshooting of Electrical System (E-Mode)1811
E-1 Engine Does Not Start (Engine Does Not Crank)1811
E-2 Manual Preheating System Does Not Operate1817
E-3 Automatic Preheating System Does Not Operate1820
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On1822
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1824
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow1827
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow1828
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation1829
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs1830
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs1831
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation1832
E-12 Fuel Level Monitor Comes On in Red While Engine Runs1833
E-13 Water Separator Monitor Comes On in Red While Engine Runs1834
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1835
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation1836
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation1837
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum1838
E-18 Display of Fuel Gauge is Different from Actual Fuel Level1840
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum1841
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature1842
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum1843
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature1845
E-23 Some Areas of Machine Monitor Screen are Not Shown1846
E-24 Function Switch Does Not Operate1847
E-25 Automatic Warm-up System Does Not Work (in Cold Weather)1848
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out1849
E-27 Auto-Decelerator is Not Operated or Canceled with Lever1850
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown1851
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed1852
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change1853
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change1854
E-32 Alarm Buzzer Cannot be Canceled1856
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position1857
E-34 Service Mode Cannot be Selected1858
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move1859
E-36 All Work Equipment, Swing and Travel Do Not Lock1861
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing1862
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate1865
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show1867
E-40 One-Touch Power Maximizing Function is Not Cancelled1869
E-41 Alarm Does Not Sound During Travel1870
E-42 Alarm Does Not Stop When Machine Stops1872
E-43 Horn Does Not Sound1873
E-44 Horn Does Not Stop1877
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out1879
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate1880
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated1882
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function1883
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function1884
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function1885
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function1886
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function1887
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function1888
E-54 “Swing” is Not Shown Correctly with Monitoring Function1889
E-55 “Travel” is Not Shown Correctly with Monitoring Function1890
E-56 Service is Not Shown Correctly with Monitoring Function1891
E-57 Attachment Hydraulic Circuit Cannot be Changed1893
E-58 KOMTRAX System Does Not Operate Correctly1894
R-55 Machine Push-Up Function is Not Canceled1895
E-60 Machine Push-Up Function Does Not Operate1897
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1898
Information Shown in Troubleshooting Table (H-Mode)1898
System Chart of Hydraulic and Mechanical Systems1899
Failure Mode and Cause Table1901
H-1 All Work Equipment, Swing and Travel Do Not Work1912
H-2 All Work Equipment, Swing and Travel Lack Speed and Power1913
H-3 Fine Control Performance or Response is Unsatisfactory1916
H-4 Unusual Noise is Heard from Around Hydraulic Pump1917
H-5 Engine Speed Drops Largely or Engine Stops1918
H-6 Speed or Power of Boom is Low1920
H-7 Arm Speed or Power is Low1926
H-8 Bucket Speed or Power is Low1931
H-9 Work Equipment Does Not Move in Single Operation1935
H-10 Hydraulic Drift of Boom is Large1936
H-11 Hydraulic Drift of Arm is Large1938
H-12 Hydraulic Drift of Bucket is Large1940
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves1941
H-14 Time Lag of Work Equipment is Large1942
H-15 One-Touch Power Maximizing Function Does Not Operate1943
H-16 Machine Push-Up Function Does Not Operate1944
H-17 Attachment Circuit Cannot be Changed1945
H-18 Oil Flow in Attachment Circuit Cannot be Changed1946
H-19 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower1947
H-20 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely1948
H-21 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low1949
H-22 Machine Does Not Travel Straight1950
H-23 Machine is Not Steered Correctly or Steering Power is Low1952
H-24 Travel Speed is Low1955
H-25 One of Tracks Does Not Run1957
H-26 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast1959
H-27 Machine Does Not Swing to Right or Left1960
H-28 Upper Structure Swings Only to Right or Left1961
H-29 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left1962
H-30 Swing Acceleration or Swing Speed is Low in Only One Direction1963
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)1964
H-32 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)1965
H-33 Shock is Large When Upper Structure Stops Swing Operation1966
H-34 There is Large Unusual Noise When It Stops Swing Operation1967
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)1968
H-36 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)1969
Troubleshooting of Engine (S-Mode)1970
Information Shown in Troubleshooting Table (S-Mode)1970
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position1971
S-2 Engine Cranks but No Exhaust Smoke Comes Out1972
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)1973
S-4 Engine Startability is Unsatisfactory1975
S-5 Engine Does Not Pick Up Smoothly1977
S-6 Engine Stops During Operation1979
S-7 Engine Runs Rough or is Not Stable1981
S-8 Engine Lacks Power1982
S-9 KDPF Becomes Clogged in a Short Time1984
S-10 Engine Oil Consumption is Excessive1986
S-11 Oil Becomes Dirty Quickly1987
S-12 Fuel Consumption is Excessive1988
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant1989
S-14 Oil Pressure Drops1990
S-15 Fuel Mixes Into Engine Oil1992
S-16 Water Mixes Into Engine Oil (Milky)1993
S-17 Coolant Temperature Increases Too High (Overheating)1994
S-18 Unusual Noise is Heard1995
S-19 Vibration is Excessive1996
S-20 Air Cannot be Bled from Fuel Circuit1997
S-21 Active Regeneration is Done Frequently1998
S-22 Active Regeneration Continues Long2000
S-23 White Smoke is Exhausted During Active Regeneration2001
S-24 DEF Consumption is Excessive2002
S-25 There is Unusual Smell (Irritating Odor)2004
S-26 Foreign Materials Enter DEF (DEF Increases)2005
50 Disassembly and Assembly2007
Table of Contents2008
Precautions Before Work2013
Related Information on Disassembly and Assembly2014
How to Read This Manual2014
Coating Materials List2015
Special Tool List2020
Sketches of Special Tools2035
Engine and Cooling System2043
Remove and Install Supply Pump Assembly2043
How to Remove Supply Pump Assembly2043
How to Install Supply Pump Assembly2048
Remove and Install Injector Assembly2056
How to Remove Injector Assembly2056
How to Install Injector Assembly2063
Remove and Install Cylinder Head Assembly2075
How to Remove Cylinder Head Assembly2076
How to Install Cylinder Head Assembly2085
Remove and Install EGR Valve Assembly2103
How to Remove EGR Valve Assembly2103
How to Install EGR Valve Assembly2104
Remove and Install EGR Cooler Assembly2106
How to Remove EGR Cooler Assembly2106
How to Install EGR Cooler Assembly2107
Remove and Install Starter Assembly2110
How to Remove Starting Motor Assembly2110
How to Install Starting Motor Assembly2111
Remove and Install Alternator Belt2112
How to Remove Alternator Belt2112
How to Install Alternator Belt2115
Remove and Install Radiator Assembly2118
How to Remove Radiator Assembly2118
How to Install Radiator Assembly2120
Remove and Install Hydraulic Oil Cooler Assembly2122
How to Remove Hydraulic Oil Cooler Assembly2122
How to Install Hydraulic Oil Cooler Assembly2124
Remove and Install Aftercooler Assembly2127
How to Remove Aftercooler Assembly2127
How to Install Aftercooler Assembly2128
Remove and Install Engine and Main Pump Assembly2130
How to Remove Engine and Main Pump Assembly2131
How to Install Engine and Main Pump Assembly2143
Remove and Install Engine Front Oil Seal2158
How to Remove Engine Front Oil Seal2158
How to Install Engine Front Oil Seal2162
Remove and Install Engine Rear Oil Seal2166
How to Remove Engine Rear Oil Seal2167
How to Install Engine Rear Oil Seal2168
Remove and Install Engine Hood Assembly2175
How to Remove Engine Hood Assembly2175
How to Install Engine Hood Assembly2176
Remove and Install Fuel Tank Assembly2179
How to Remove Fuel Tank Assembly2179
How to Install Fuel Tank Assembly2182
Remove and Install DEF Tank Assembly2185
How to Remove DEF Tank Assembly2185
How to Install DEF Tank Assembly2191
Remove and Install DEF Tank Sensor Flange Assembly2196
How to Remove DEF Tank Sensor Flange Assembly2196
How to Install DEF Tank Sensor Flange Assembly2203
Remove and Install DEF Tank Sensor2208
How to Remove DEF Tank Sensor2208
How to Install DEF Tank Sensor2208
Remove and Install DEF Tank Strainer2215
How to Remove DEF Tank Strainer2215
How to Install DEF Tank Strainer2215
Remove and Install DEF Tank Filler Port Filter2216
How to Remove DEF Tank Filler Port Filter2216
How to Install DEF Tank Filler Port Filter2218
Remove and Install KDPF Assembly2221
How to Remove KDPF Assembly2221
How to Install KDPF Assembly2224
Disassemble and Assemble KDPF Assembly2229
How to Disassemble KDPF Assembly2230
How to Assemble KDPF Assembly2233
Remove and Install SCR Assembly2238
How to Remove SCR Assembly2238
How to Install SCR Assembly2241
Remove and Install KDPF and SCR Assembly2244
How to Remove KDPF and SCR Assembly2245
How to Install KDPF and SCR Assembly2252
Remove and Install KDPF and SCR Assembly Bracket2259
How to Remove KDPF and SCR Assembly Bracket2259
How to Install KDPF and SCR Assembly Bracket2262
Remove and Install Bellows Pipe Assembly2267
How to Remove Bellows Pipe Assembly2267
How to Install Bellows Pipe Assembly2270
Remove and Install KCCV Assembly2274
How to Remove KCCV Assembly2274
How to Install KCCV Assembly2275
Remove and Install DEF Mixing Tube2277
How to Remove DEF Mixing Tube2278
How to Install DEF Mixing Tube2281
Remove and Install DEF Injector2285
How to Remove DEF Injector2285
How to Install DEF Injector2288
Remove and Install DEF Pump2292
How to Remove DEF Pump2292
How to Install DEF Pump2295
Remove and Install DEF Hose2298
How to Remove DEF Hose2299
How to Install DEF Hose2305
Remove and Install Air Cleaner Assembly2313
How to Remove Air Cleaner Assembly2313
How to Install Air Cleaner Assembly2315
Remove and Install Air Conditioner Compressor Assembly2317
How to Remove Air Conditioner Compressor Assembly2317
How to Install Air Conditioner Compressor Assembly2318
Remove and Install Air Conditioner Condenser Assembly2320
How to Remove Air Conditioner Condenser Assembly2320
How to Install Air Conditioner Condenser Assembly2321
Power Train2322
Remove and Install Travel Motor and Final Drive Assembly2322
How to Remove Travel Motor and Final Drive Assembly2322
How to Install Travel Motor and Final Drive Assembly2323
Disassemble and Assemble Final Drive Assembly2325
How to Disassemble Final Drive Assembly2326
How to Assemble Final Drive Assembly2330
Remove and Install Swing Motor and Swing Machinery Assembly2338
How to Remove Swing Motor and Swing Machinery Assembly2338
How to Install Swing Motor and Swing Machinery Assembly2339
Disassemble and Assemble Swing Machinery Assembly2341
How to Disassemble Swing Machinery Assembly2341
How to Assemble Swing Machinery Assembly2344
Remove and Install Swing Circle Assembly2352
How to Remove Swing Circle Assembly2352
How to Install Swing Circle Assembly2352
Undercarriage and Frame2354
Separate and Connect Track Assembly2354
How to Separate Track Assembly2354
How to Install Track Assembly2356
Remove and Install Sprocket2359
How to Remove Sprocket2359
How to Install Sprocket2359
Remove and Install Idler and Idler Cushion Assembly2361
How to Remove Idler and Idler Cushion Assembly2361
How to Install Idler and Idler Cushion Assembly2362
Disassemble and Assemble Idler Assembly2363
How to Disassemble Idler Assembly2363
How to Assemble Idler Assembly2364
Disassemble and Assemble Idler Cushion Assembly2368
How to Disassemble Idler Cushion Assembly2369
How to Assemble Idler Cushion Assembly2369
Disassemble and Assemble Track Roller Assembly2371
How to Disassemble Track Roller Assembly2372
How to Assemble Track Roller Assembly2373
Disassemble and Assemble Carrier Roller Assembly2375
How to Disassemble Carrier Roller Assembly2375
How to Assemble Carrier Roller Assembly2376
Remove and Install Revolving Frame Assembly2379
How to Remove Revolving Frame Assembly2379
How to Install Revolving Frame Assembly2381
Remove and Install Counterweight Assembly2384
How to Remove Counterweight Assembly2384
How to Install Counterweight Assembly2385
Hydraulic System2388
Remove and Install Center Swivel Joint Assembly2388
How to Remove Center Swivel Joint Assembly2388
How to Install Center Swivel Joint Assembly2389
Disassemble and Assemble Center Swivel Joint Assembly2392
How to Disassemble Center Swivel Joint Assembly2393
How to Assemble Center Swivel Joint Assembly2394
Remove and Install Hydraulic Tank Assembly2395
How to Remove Hydraulic Tank Assembly2395
How to Install Hydraulic Tank Assembly2399
Remove and Install Main Pump Assembly2403
How to Remove Main Pump Assembly2403
How to Install Main Pump Assembly2406
Remove and Install Control Valve Assembly2409
How to Remove Control Valve Assembly2409
How to Install Control Valve Assembly2416
Disassemble and Assemble Control Valve Assembly2423
How to Replace Pressure Compensation Valve Seal Ring2424
How to Assemble Control Valve Assembly2425
Remove and Install ATT Bypass Solenoid2430
How to Remove ATT Bypass Solenoid2430
How to Install ATT Bypass Solenoid2433
Disassemble and Assemble Work Equipment PPC Valve Assembly2435
How to Disassemble Work Equipment PPC Valve Assembly2435
How to Assemble Work Equipment PPC Valve Assembly2436
Disassemble and Assemble Travel PPC Valve Assembly2438
How to Disassemble Travel PPC Valve Assembly2438
How to Assemble Travel PPC Valve Assembly2439
Work Equipment2441
Remove and Install Bucket Assembly2441
How to Remove Bucket Assembly2441
How to Install Bucket Assembly2441
Remove and Install Arm Assembly2443
How to Remove Arm Assembly2443
How to Install Arm Assembly2444
Remove and Install Work Equipment Assembly2446
How to Remove Work Equipment Assembly2446
How to Install Work Equipment Assembly2449
Remove and Install Boom Anti-drop Valve Assembly2452
How to Remove Boom Anti-drop Valve Assembly2452
How to Install Boom Anti-drop Valve Assembly2454
Remove and Install Arm Anti-Drop Valve Assembly2455
How to Remove Arm Anti-Drop Valve Assembly2455
How to Install Arm Anti-Drop Valve Assembly2457
Disassemble and Assemble Anti-Drop Valve Assembly2458
How to Disassemble Anti-Drop Valve Assembly2458
How to Assemble Anti-Drop Valve Assembly2458
Disassemble and Assemble Work Equipment Cylinder Assembly2459
How to Disassemble Work Equipment Cylinder Assembly2459
How to Assemble Work Equipment Cylinder Assembly2462
CAB Related Parts2469
Remove and Install Operator Cab Assembly2469
How to Remove Operator Cab Assembly2469
How to Install Operator Cab Assembly2477
Remove and Install Operator Cab Glass (Adhered Glass)2484
How to Remove Operator Cab Glass (Adhered Glass)2486
How to Install Operator Cab Glass (Adhered Glass)2486
Remove and Install Front Window Assembly2496
How to Remove Front Window Assembly2496
How to Install Front Window Assembly2499
Remove and Install Floor Frame Assembly2505
How to Remove Floor Frame Assembly2506
How to Install Floor Frame Assembly2512
Remove and Install Air Conditioner Unit Assembly2520
How to Remove Air Conditioner Unit Assembly2520
How to Install Air Conditioner Unit Assembly2526
Remove and Install Operator Seat2532
How to Remove Operator Seat2532
How to Install Operator Seat2534
How to Remove and Install Seat Belt2537
How to Remove Seat Belt2537
How to Install Seatbelt2538
Remove and Install Work Equipment Control Lever Assembly2539
How to Remove Work Equipment Control Lever Assembly2539
How to Install Work Equipment Control Lever Assembly2545
Remove and Install Front Wiper Assembly2554
How to Remove Front Wiper Assembly2554
How to Install Front Wiper Assembly2559
Electrical System2568
Remove and Install Engine Controller Assembly2568
How to Remove Engine Controller Assembly2568
How to Install Engine Controller Assembly2570
Remove and Install Pump Controller Assembly2574
How to Remove Pump Controller Assembly2574
How to Install Pump Controller Assembly2577
Remove and Install KomVision Controller Assembly2581
How to Remove KomVision Controller Assembly2581
How to Install KomVision Controller Assembly2582
Remove and Install Machine Monitor Assembly2583
How to Remove Machine Monitor Assembly2583
How to Install Machine Monitor Assembly2586
Remove and Install Pump Swash Plate Sensor2590
How to Remove Pump Swash Plate Sensor2590
How to Install Pump Swash Plate Sensor2590
Remove and Install Mass Air Flow and Temperature Sensor2592
How to Remove Mass Air Flow and Temperature Sensor2592
How to Install Mass Air Flow and Temperature Sensor2593
Remove and Install KCCV Crankcase Pressure Sensor2594
How to Remove KCCV Crankcase Pressure Sensor2594
How to Install KCCV Crankcase Pressure Sensor2595
Remove and Install SCR Temperature Sensor2596
How to Remove SCR Temperature Sensor2596
How to Install SCR Temperature Sensor2597
Remove and Install Rearview Camera2599
How to Remove Rearview Camera2599
How to Install Rearview Camera2600
Remove and Install KomVision Camera2602
How to Remove KomVision Camera2602
How to Install KomVision Camera2603
Remove and Install KOMTRAX Terminal Assembly2605
How to Remove KOMTRAX Terminal Assembly2605
How to Install KOMTRAX Terminal Assembly2608
60 Maintenance Standard2611
Table of Contents2612
Engine and Cooling System2613
Maintenance Standard for Engine Mount2613
Maintenance Standard for Cooling System2615
Power Train2617
Maintenance Standard for Swing Circle2617
Maintenance Standard for Swing Machinery2618
Maintenance Standard for Final Drive2620
Maintenance Standard for Sprocket2622
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing2623
Undercarriage and Frame2624
Maintenance Standard for Track Frame and Idler Cushion2624
Maintenance Standard for Idler2626
Maintenance Standard for Track Roller2628
Maintenance Standard for Carrier Roller2630
Maintenance Standard for Track Shoes2631
Maintenance Standard for Triple Shoes2634
Hydraulic System2635
Maintenance Standard for Hydraulic Tank2635
Maintenance Standard for Main Pump2636
Maintenance Standard for Swing Motor2638
Maintenance Standard for Travel Motor2641
Maintenance Standard for Control Valve2644
Maintenance Standard for Boom Anti-Drop Valve2654
Maintenance Standard for Arm Anti-Drop Valve2656
Maintenance Standard for Work Equipment and Swing PPC Valve2658
Maintenance Standard for Travel PPC Valve2661
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)2664
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve2665
Maintenance Standard for 2nd-Line Attachment PPC Valve2667
Maintenance Standard for Solenoid Valve2669
Maintenance Standard for Attachment Circuit Selector Valve2670
Maintenance Standard for Center Swivel Joint2671
Work Equipment2672
Maintenance Standard for Work Equipment Linkage2672
Dimensions of Arm2677
Dimensions of Bucket2679
Maintenance Standard for Boom Cylinder2681
Maintenance Standard for Arm Cylinder2682
Maintenance Standard for Bucket Cylinder2683
80 Appendix2685
Table of Contents2686
Precautions Before Work2688
Air Conditioner System2689
Precautions for Refrigerant2689
Air Conditioner Component2690
Specifications of Air Conditioner2692
Structure and Function of Refrigeration Cycle2693
Outline of Refrigeration Cycle2694
Component Parts of Air Conditioner System2696
Air Conditioner Unit2696
Configuration Diagram of Air Conditioner Unit2696
Function of Air Conditioner Unit2698
Component Parts of Air Conditioner Unit2700
Function of Evaporator as Air Conditioner Unit Component2701
Function of Heater Core as Air Conditioner Unit Component2701
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2701
Function of Servo Motor as Air Conditioner Unit Component2701
Structure of Expansion Valve as Air Conditioner Unit Component2702
Function of Expansion Valve as Air Conditioner Unit Component2702
Operate Expansion Valve as Air Conditioner Unit Component2702
Function of Dual Pressure Switch2703
Air Conditioner Controller2704
Structure of Air Conditioner Controller2704
Compressor2705
Structure of Compressor2705
Specifications of Compressor2705
Function of Compressor2705
Condenser2706
Structure of Condenser2706
Specifications of Condenser2706
Function of Condenser2706
Receiver Drier2707
Structure of Receiver Dryer2707
Specifications of Receiver Dryer2707
Function of Receiver Dryer2707
Air Conditioner Related Sensors2708
Structure of Sunlight Sensor2708
Function of Sunlight Sensor2708
Structure of Outside Temperature Sensor2708
Function of Outside Air Temperature Sensor2708
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2710
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2712
System Diagram of Air Conditioner2714
Input and Output Signals of Air Conditioner Controller2715
Function of Air Conditioner Controller2716
Locations of Air Conditioner Parts and Layout of Connectors2717
Examine Air Leakage (Duct)2721
How to Examine Air Leakage (Duct)2721
Examine Air Conditioner with Self-Diagnosis Function2723
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2724
Examine Vent (Mode) Changeover2725
How to Examine Vent (Mode) Changeover2725
Examine Fresh/Recirc Air Changeover2727
How to Examine Fresh/Recirc Air Changeover2727
Examine Sunlight Sensor2728
How to Examine Sunlight Sensor2728
Examine Refrigerant (Dual) Pressure Switch2729
How to Examine Refrigerant (Dual) Pressure Switch2729
Examine Relay2730
How to Examine Relay2730
Air Conditioner Troubleshooting Chart 12731
Air Conditioner Troubleshooting Chart 22732
Information Shown in Troubleshooting Table2735
Failure Code [879AKA]2736
Failure Code [879AKB]2737
Failure Code [879BKA]2738
Failure Code [879BKB]2740
Failure Code [879CKA]2742
Failure Code [879CKB]2743
Failure Code [879DKZ]2744
Failure Code [879EMC]2746
Failure Code [879FMC]2747
Failure Code [879GKX]2748
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2750
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2752
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2755
A-4 Troubleshooting for Fresh/Recirc Air Changeover2757
Troubleshooting by Gauge Pressure2759
Connect Service Tool2762
How to Connect Service Tool2762
Precautions for Disconnection and Connection of Air Conditioner Piping2764
Handle Compressor Oil2766
90 Circuit Diagrams2769
Table of Contents2770
Hydraulic Circuit Diagram2771
Symbols Used in Hydraulic Circuit Diagram2771
Hydraulic Circuit Diagram2775
Electrical Circuit Diagram2777
Symbols Used in Electric Circuit Diagram2777
Electrical Circuit Diagram (1/8)2781
Electrical Circuit Diagram (2/8)2783
Electrical Circuit Diagram (3/8)2785
Electrical Circuit Diagram (4/8)2787
Electrical Circuit Diagram (5/8)2789
Electrical Circuit Diagram (6/8)2791
Electrical Circuit Diagram (7/8)2793
Electrical Circuit Diagram (8/8)2795
Index2797

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24